Lecture 3: Introduction to Engineering Design

Lecture 3: Introduction to
Engineering Design
EEE2032: 공학입문설계
서강대학교 전자공학과 2013학년도 1학기
Engineering design process
• Looking at what constitutes the design process.
1.
Recognizing the need for a product or a service,
2.
Defining and understanding the problem (the need)
completely,
3.
Doing preliminary research and preparation,
4.
Conceptualizing ideas for possible solutions,
5.
Synthesizing the findings,
6.
Evaluating good ideas in more detail,
7.
Optimizing solutions to arrive at the best possible solution,
and
8.
Presenting the final solution.
2
Engineering design process
• Step 1: Recognizing the need for a product or a
service
– Some of existing products are constantly being modified to
take advantage of new technologies.
– In addition, new products are being developed every day for
the purpose of making our lives more comfortable, more
reliable, and less laborious.
– “Every time someone complains about a situation, or about a
task, or curses a product, right there, there is an opportunity
for a product or a service.”
• What one has to do is to identify them.
3
Engineering design process
• Step 2: Defining and understanding the problem
– One of the first thing to do as a design engineer is to fully
understand the problem.
• The most important step in any design process.
• By many questions:
– How much money are you willing to spend on this project?
– Are there restrictions on the size or the type of materials that can be used?
– Engineers generally work in a team environment where they
consult each other to solve complex problems.
• Good interpersonal and communication skills are increasingly important
now because of the global market.
4
Engineering design process
• Step 3: Preliminary research and preparation
– To collect useful information
• By searching to determine if a product already exists that closely meets
the need of your client.
• This is the step the engineers spend lots of time not only with the client
but also with other engineers and technicians.
• To review and organize the information in a suitable manner.
5
Engineering design process
• Step 4: Conceptualizing ideas for possible solutions
– To generate some ideas or concepts that could offer
reasonable solutions to the problem
• Without performing any detailed analysis, to come up with some possible
ways of solving the problem
• Without looking at details of each possible solution yet, but performing
enough analysis to see whether the concepts have merit.
– The step includes creating milestone chart detailing the time
plan for completing the project.
6
Engineering design process
• Step 5: Synthesizing the results
– To begin to consider details
• To perform calculation, run computer models, narrow down the type of
materials to be used, size the components of the system, and answer
questions about how the product is going to be fabricated.
• To consult pertinent codes and standards and make sure that the design
will be compliance with these codes and standards.
7
Engineering design process
• Step 6: Evaluating good ideas in more detail
– Analyze the problem in more detail
• To identify critical design parameters and consider their influence in the
final design
• To make sure all calculations are performed correctly
• To perform experimental investigation if there are some uncertainties in
the analysis.
• The best solution must be identified from alternations in this stage.
8
Engineering design process
• Step 7: Optimizing solutions to arrive at the best
possible solution
– Minimization or maximization
– Two broad types of design:
• functional design
• One that meets all of the preestablished design requirements but allows
for improvement to be made in certain areas
• optimized design
• Based on some particular criterion, such as cost, strength, size, weight,
reliability, noise, or performance.
– Optimizing individual components of a system does not
necessarily lead to an optimized system
9
Engineering design process
• Step 7: Optimizing solutions to
arrive at the best possible solution
10
Engineering design process
• Step 8: Presenting the final solution
– To communicate the solution (design) to the client (boss,
another group in the company, or an outside customer).
– An oral presentation and/or a written report
– Engineers are required to give oral and written progress
reports on a regular time basis to various groups.
11
Engineering economics
• Economic factors always play important roles in
engineering design decision making.
– If a product is too expensive to manufacture, it can not be
sold at a price that consumers can afford and still be
profitable to the company.
– Chapter 20 deals with the basics of engineering economics.
12
Material selection
• Questions coming up when selecting material for
products
– How strong will the material be when subjected to an expected
load?
– Would it fail, and if not, how safely would the material carry
the load?
– How would the material behave if its temperature were
changed?
– …
• Material properties and material cost are important
design factors
– Electrical, mechanical, and thermal
– The manufacturers’ material property values should be
considered in the design. (Electrical resistivity, density…)
13
Consumer Product Engineering
• Acknowledgement:
Boise State University and the William and Flora
Hewlett Foundation
Engineers Improve Our World
Engineers apply the principles of science and
mathematics to develop economical solutions
to technical problems.
(US Dept. of Labor, Bureau of Labor Statistics, Occupational Outlook Handbook,
http://www.bls.gov/oco/ocos027.htm )
“Science can amuse and fascinate us all, but
it is engineering that changes the world.”
Isaac Asimov (1920 – 1992)
Russian-American biochemist & author
15
Consumer Products Engineering
• Engineers developing consumer products
– They solve customer problems AND
– Make money for their company
What Constitutes a Consumer Product?
• Tend to be high volume and mass produced (not
“one-off” or limited run)
• Cost-effective solution based on market demands
(quality vs. price tradeoff)
• Often low cost of manufacture is chosen over repairability by manufacturer
Developing a consumer product…
• Numerous engineering tasks required
–
–
–
–
–
Design products
Manufacture products
Test products
Distribute products
Support products
The best design is useless if it can’t be manufactured,
distributed and purchased in a cost effective manner!
Engineering Design Process
• 1. Define the problem or need
Mice often carry
hantavirus. Design a
mousetrap to allow a
person to trap and
dispose of a mouse
without exposure to
viruses carried by the
mouse.
Engineering Design Process
• 1. Define the problem or need
• 2. Gather information
–
–
–
–
Shortcomings of existing solutions
Competitive Analysis
Environment for use
Economic factors
• 3. Brainstorm multiple solutions
• 4. Select one solution
• 5. Prototype and test the solution
Product Design Engineers*
• Start with an idea or problem to solve
– Most successful when the customer needs are well
understood
– Develop a set of product specifications
• Develop a solution
–
–
–
–
–
Iterative process
Invention - Intellectual Property
Intuitive and Ergonomic Use - Human Factors Engineers
Material selection & development– Material Science Engineers
Component sourcing – Procurement Engineers
*Also known as:
Research & Development (R&D) Engineers
Product Design Engineering Examples
Product
Cell Phones
Electrical /
Computer
Engineers
Configuration modes
Communication
Miniaturization
Personal Computers
Design mother board &
I/O boards
Performance
Automobiles
Instrumentation
Power Systems
Accessories – GPS,
sound system, etc.
Mechanical
Engineers
Design case /
packaging
Durability
Design enclosures
Thermal management
Serviceability
Design engine, drive
train, chassis, etc.
Passenger safety
Product Development Models
• Internal Development
• Original Equipment Manufacture (OEM)
– Sub-assemblies are sourced from another vendor
• Personal computers - disk drives, fans, motherboards
• Outsourced development
– Subassemblies or entire product developed by a 3rd party
per “customers” specifications
• LaserJet printer engines developed by Canon with design
input from HP
• Re-branding 3rd party products
– Near identical products sold as different options
• Automotive industry – Oldsmobile vs. Buick, Ford vs. Mercury
Engineering tasks
become
progressively more
project
management
oriented!
Accessory Product Engineering
• Companies share interface specifications with 3rd
parties to allow them to develop accessory products
• Why?
– Provide greater capabilities for the “base product” = more
sales
– Allows company to focus on “core competencies”
Accessory Products - iPOD
• “the market for iPod accessories is so huge that our
offices can barely handle the periodic influx of new
products ...”
• Broad Range of Choices…”transform the iPod into a
fully functional stereo or just want to wrap it in a cool,
scratch-resistant casing…”
http://reviews.cnet.com/4520-6450_7-1025145-1.html
Just a few examples… iPOD
Apple iPod Hi-Fi
Rain Design iWoofer for iPod
•
•
•
•
•
•
•
•
•
•
•
•
•
Belkin TuneStage
Bose SoundDock
CMO America ZipKord iPod USB Synch
& Charge
Creative i-Trigue i3350
DLO HomeDock for iPod
FireJuice 4 (for iPod w/ Dock
Connector)
FireJuice 6 (for iPod w/ Dock
Connector)
Harmon JBL Creature
iCleaner iPod Scratch Remover Pro
iPodSoft Pod Player 1.4.0
Kensington Entertainment Dock 500
Kensington StereoDock for iPod
Klipsch iFi
DLO HomeDock Deluxe
Klipsch iGroove
Logic 3 i-Station8 (white)
Logitech Wireless Music System for
iPod
Logitech mm50 Portable Speakers for
iPod (white)
Monitor Audio i-Deck
Onkyo DS-A1
Oregon Scientific iBall
Radian iBlast (black)
SDI iHome iH5
Sonance iPort
Soundcast iCast
Targus RemoteTunes digital player
accessory kit
Tivoli Audio iSongBook
Manufacturing Engineering
• Manufacturing Process
– Process design
– Process support & maintenance
– Continuous process improvement
• Product
– Testing & quality control
The next unit will provide
you with first-hand
experience!
Product Test Engineering
• Incoming raw materials to finished product
• Design appropriate tests
– Meet product specification
– Robust to survive use environment
– Meet regulatory requirements
• Conduct testing & analyze results
– During design phase
– Monitor finished product quality
Product Distribution
• Supply-chain management & improvements
– Opportunities for inventory management from production to
purchase
– Requires significant Information Technology collaboration
• Technology improves efficiency
– Barcodes
– Radio Frequency ID (RFID) mircochips
Sales Engineering
• Used mainly for complex system sales
• Specify system for customer environment
• Technology - Customer Relationship Manager (CRM) institutionalize customer knowledge to provide better
customer service
These are people-oriented jobs
requiring excellent
communication skills & often
frequent travel.
Product Support Engineering
• Problem solvers
• Assist customer when problems arise
• Determine “class” problems to be fixed with next
revision
• Must balance customer satisfaction while controlling
warranty costs
Product Cost Contributors…
Raw Materials
Material
Processing &
Manufacturing
Margin
Final Purchase
Price
Packaging
Can you create a
Marketing
viable business where
the purchase price =
Overhead
$0.00?
Razors and Blades Business Model
• Pioneered by the King C. Gillette who used model to
see razors and blades
• Base product sold at a substantial discount (or given
away)
• Essential consumable or disposable parts are sold at a
high profit margin
Examples – “Razors and Blades” businesses
•
•
•
•
•
Electric toothbrushes and their brush heads
Computer printers and their ink cartridges
Game consoles and the games & peripherals
Cell phones and air time costs
Satellite television dishes/installation and subscription
costs
• Blood glucose meters and costly single-use test strips
References
US Dept. of Labor, Bureau of Labor Statistics, Occupational Outlook
Handbook, http://www.bls.gov/oco/ocos027.htm
The Engineering Student Survival Guide, Third edition, Krista Donaldson.
McGraw-Hill’s Basic Engineering Series and Tools
http://en.wikipedia.org/wiki/Razor_and_blades_business_model
http://reviews.cnet.com/4520-6450_7-1025145-1.html CNET Reviews –
Ultimate iPOD Accessories
“The World is Flat, A Brief History of the Twenty-first Century” by Thomas L.
Friedman.
http://www.cio.com/research/crm/edit/crmabc.html Customer Relationship
Management Research Center, The ABCs of CRM
“Engineers Toolkit, A First Course in Engineering”, Addison-Wesley
Publishing Company, Inc.
Teamwork
• A design team:
– a group of individuals with complementary expertise, problem
solving skills, and talent who are working together to solve a
problem or achieve a common goal.
• Communication is an essential part of successful
teamwork.
– the individuals making up the team need to clearly understand
the role of each member and how each task fits together.
36
Common traits of good teams
• Employers are looking for individuals who not only
have a good grasp of engineering fundamentals but
who can work well with others in a team environment.
1.
2.
3.
4.
5.
The project that is assigned to a team must have clear and
realistic goals.
The team should be made up of individuals with
complementary expertise, problem solving skills,
background, and talent.
The team must have a good leader.
The team leadership and the environment in which
discussions take place should promote openness, respect,
and honesty.
Team needs and goals should come before individual needs
and goals
37
Common traits of good teams
• A team with members who represent the following
secondary roles tends to be very successful.
–
Organizer
•
•
•
•
–
Experienced and confident
Trusted by members of the team
Serves as a coordinator
Good at Clarifying goals and advancing decision making
Creator
• Good at coming up with new ideas, sharing them with other team
members, letting the team develop the dieas further, and solving difficult
problems
• May have problems with following certain protocols
38
Common traits of good teams
• A team with members who represent the following
secondary roles tends to be very successful.
– Gatherer
• Enthusiastic and good at obtaining things, looking for possibilities, and
developing contacts
– Motivator
• Energetic, confident, and outgoing
• Good at finding ways around obstacles and making objective decisions
– Evaluator
• Intelligent and capable of understanding the complete scope of the
project
• Good at judging outcomes correctly
Common traits of good teams
• A team with members who represent the following
secondary roles tends to be very successful.
– Team worker
• Tries to get everyone to come together
• Does not like friction or problems among team members
– Solver
• Reliable and decisive
• Turn concepts into practical solutions
– Finishers
• Counted on to finish his or her assigned task on time
• Detail orientated
• May worry about the beam’s progress toward finishing the assignment
Conflict Resolution
• Conflict could be the result of miscommunication,
personality differences, or the way events and actions
are interpreted by a member of a team.
– Managing conflicts is an important part of a team dynamic.
• Good communication is an integral part of any conflict
resolution.
– One of the most important rules in communication is to make
sure that the message sent is the message received – without
misunderstanding.
– Team members must listen to each other.
41
Brain Storming
Brain Storming
• What is brainstorming
• Why and when use it
• How to organise and lead a successful brainstorming
session
• What mistakes are to be avoided
• Additional creative problem solving methods
What is brainstorming
„The best way how to have a good idea is to have many
ideas“
– Alex F. Osborne, 1939
• method of thinking up solutions, concepts, ideas in problem solving
• using the brain to storm new ideas in groups
• „It is easier to tone down a wild idea than to think up a new one.“
Why and When Use It
• the creative process is not always easy (problems of
fear, criticism, no existing solutions yet)
• one person has a limited capacity
• people tend to judge new ideas immediately (a change is
difficult for a human being)
Creative thinking require appropriate tools !
How does it work
•
•
•
•
in a group of people
free associations to the topic given
relaxed and friendly atmosphere
deferred judgements – release the human mind, lateral
thinking
As many ideas as possible, no
matter how crazy they are
The key rules
1.
2.
3.
4.
5.
6.
relaxed atmosphere - completely free
no criticism or judgements
quantity matters
all ideas legitimate
all ideas put on the sheet of paper
evaluation only after the session
BENEFITS of brainstorming
Why and When Use It
Specific questions:
-
How can we promote our products?
What can our company do in 5 years hence?
What can we do to solve the problem XY?
How can we improve co-operation of A and B?
- What do our customers really want?
- What opportunities do we have this year?
- How can we have more fun at work?
BRAINSTORMING CONSTRAINTS
•
•
•
•
does not rank the ideas
cannot help you select the important ones
does not suggest the best solutions
must be amended by other methods
Organising a session?
1. PREPARATION PHASE
3. EVALUATION
2. CONDUCT THE SESSION
1. PREPARATION PHASE
Specify the problem
What do we really want?
Invite people
Select the right people
make sure they
have time
Decide when and where
place and time matters
„U“ layout of the room
up to 10 – 12
different positions
2. CONDUCT THE SESSION
1. Specify the objectives – make sure that everybody is happy with
the central question.
2. Decide the roles: - leader, recorder, panel.
3. Explain the rules (or make sure that everybody knows them.
Eventually – a warm-up exercise for fun). You can let people to jot
down a few ideas before starting.
4. Begin by going around, after some rounds, open the floor.
5. Record the ideas exactly, clarify only in the end.
6. Suspend judgements !
7. Encourage the ideas, even the most radical and far-fetched. Allow
the late coming ideas, do not hurry.
8. At the end – eliminate duplicates, clarify, thank the participants.
3. EVALUATION PHASE
Put the evaluation off / next day
Add newly born ideas to the list
Group similar ideas together
Select the best or most interesting su
ggestions
Create teams which will work on them
further
Inform people about the results
Mistakes to be avoided
•
•
•
•
•
•
people are negative in advance (it will not work anyway)
too many brainstormings in the company
bad atmosphere in the beginning
bad experience with the method
judgements occur during the session
any criticism and personal attacks
SUMMARY
• creativity is not born by itself
• creative methods must be consciously introduced and
developed in organisations
• people must be encouraged to use them, with no fear to
make mistakes, prized for new ideas
• support from top management needed
• good preparation and patience
Have fun and all the best !
Team Project
• Design the best smartphone applications for the 1st year
college student
• 3/18
– Team organization
– 7 students
• 3/20, 3/25
– Brainstorming and team meeting (Ricci Hall 7th Floor)
• 3/25 by 6 pm
– Submit the ppt slide
• 3/27, 4/01
– Team presentation