![Functional
Requirement
s
Design
Paramete
rs Analysis
Reference
s Risk
Counter
Measures
Attractive
Appearance
make it
appealing
to kids -
glow in the
dark; neat
shapes…
Surveys and
customer
profiling
Research
different
types of
yoyo
designs
Mold
becomes
more
complicated;
harder to
machine
Make the design
as simple as
possible; try
various colors
Function Well
Must
perform in
a typical
manner;
Simple,
standard
design
a = g / (I/mr2
+ 1)
w = [2gx /
(I/m+r2
)]1/2
t = (2L/g)1/2
(1+I/mr2
)1/2
v = [2gx /
(1+I/mr2
)]1/2
Experiment
al
Investigatio
n of Yoyo
Design by
Alma
Bardon;
Physics and
Dynamics
books
improper
application
of equations;
unbalanced
design
Study
references;
Design a good
symmetrical
design; Bench-
level
experiments
EXAMPLE – FRDPARRC Sheet (incomplete)](https://image.slidesharecdn.com/designprocesstemp-231009092152-01ffa795/85/DesignProcess-temp-ppt-85-320.jpg)
DesignProcess temp.ppt
- 1. Design Process Overview (Material developed by Project Lead the Way)
- 2. What is Design? The word “design” is often used as a generic term that refers to anything that was made by a conscious human effort. Design is also a process that is used to systematically solve problems.
- 3. A design process is a systematic problem-solving strategy, with criteria and constraints, used to develop many possible solutions to solve or satisfy human needs or wants and to narrow down the possible solutions to one final choice. – ITEA Standards for Technological Literacy What is a Design Process?
- 4. There are several design processes used in the different technical fields. The following are examples. Design Process
- 5. 1. Identifying problems and opportunities 2. Framing a design brief 3. Investigation and research 4. Generating alternative solutions 5. Choosing a solution 6. Developmental work 7. Modeling and prototyping 8. Testing and evaluating 9. Redesigning and improving – Design and Problem Solving in Technology Example Design Process
- 6. 1. Identify the need 2. Define the criteria 3. Explore/research/investigate 4. Generate alternate solutions 5. Choose a solution 6. Develop the solution 7. Model/prototype 8. Test and evaluate 9. Redesign and improve – Engineering Drawing and Design (3rd edition) Example Design Process
- 7. The following is the design process used for this course. The Adopted Design Process for PLTW courses
- 8. 1. Define a Problem 2. Brainstorm 3. Research and Generate Ideas 4. Identify Criteria and Specify Constraints 5. Explore Possibilities 6. Select an Approach 7. Develop a Design Proposal 8. Make a Model or Prototype 9. Test and Evaluate the Design using Specifications 10. Refine the Design 11. Create or Make Solution 12. Communicate Processes and Results Example Design Process – ITEA Standards for Technological Literacy
- 9. 1. Define a Problem • Receive a problem to solve from the client. • Gather information. • Be inspired through media exposure of a current problem and take action.
- 10. 2. Brainstorm • A group problem-solving process in which each person in the group presents ideas in an open forum. • Generate and record ideas. • Keep the mind alert through rapidly paced sessions. • Develop preliminary ideas.
- 11. 3. Research and Generate Ideas • Conduct interviews with those affected by the problem. • Research solutions that may already exist; identify shortcomings and reasons why they aren’t appropriate to a given situation. • Compile ideas and report findings to the team.
- 12. 4. Identify Criteria and Specify Constraints • Identify what the solution should do and the degree to which the solution will be pursued. • Identify constraints (i.e., budget and time are typical considerations). • Draft the Design Brief.
- 13. 5. Explore Possibilities • Consider further development of brainstorming ideas with constraints and tradeoffs. • Explore alternative ideas based on further knowledge and technologies.
- 14. 6. Select an Approach • Review brainstormed information and answer any lingering questions. • Narrow ideas down through a voting process, or by use of a decision matrix. • Decide on final idea, usually through group consensus.
- 15. 7. Develop a Design Proposal • Explore the idea in greater detail with annotated sketches. • Make critical decisions such as material types and manufacturing methods. • Generate through computer models detailed sketches to further refine the idea. • Produce working drawings so the idea can be built.
- 16. 8. Make a Model or Prototype • Make models to help communicate the idea, and study aspects such as shape, form, fit, or texture. • Construct a prototype from the working drawings, so the solution can be tested.
- 17. 9. Test and Evaluate the Design using Specifications • Design experiments and test the prototype in controlled and working environments. • Gather performance data; analyze and check results against established criteria. • Conduct a formal critique to flesh out areas of concerns, identify shortcomings, and establish any need for redesign work.
- 18. 10. Refine the Design • Make design changes; modify or rebuild the prototype. • Make refinements until accuracy and repeatability of the prototype’s performance results are consistent. • Update documentation to reflect changes. • Receive user’s critique to provide outside perspective to help determine if established criteria have been met.
- 19. 11. Create or Make Solution • Determine custom/mass production. • Consider packaging.
- 20. 12. Communicate Processes and Results • Communicate the designer’s final solution through media such as PowerPoint, poster session, technical report. • Market the Product. • Distribute.
- 21. Design Process Design process is a collection of procedures and habits that help teams design better products
- 22. The Process of Design • Designing is the process of making many decisions that converts an abstract concept into a hardware reality. Concept Product
- 23. 7-Step Design Process 1. Problem definition (PDS) 2. External Search (Research) 3. Internal Search (Brainstorming) 4. Evaluation and Selection 5. Detail Design (Engineering) 6. Prototyping 7. Documentation
- 24. What Product? ToyTown Top Executives Nail Driver Rope Climber
- 25. Product Design Specifications Customer Needs • Climbs fast • Affordable as a birthday present • Fully assembled • Uses batteries for power • It is safe • Looks good • Plays music as it climbs • Glows in the dark • Last a long time
- 26. Product Design Specifications Engineering Specs • Climbs at 1 ft/s or faster • Retail cost is to be less than $30 • Uses 2 AA batteries (not included) • Has no removable small parts • Music loudness between 20-30 db • Luminosity is to be more than 5 W • Works for more than 3 hours on 2 AA
- 27. External Search • Level-I –Rope climbing toys / machines –Rope climbers (sports or circus) –Nature (spiders, bats, etc) • Level-II (Team uses friction wheels) • Hoists • Trolleys • Ski Lifts
- 28. Internal Search & Evaluation • Brainstorming –Generate many ideas –Evaluate against PDS –Select one to engineer
- 29. Lift and Drag Coefficients (as effected by ground promimity) 0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0 0.05 0.1 0.15 h/L Coefficient Drag Coefficient Lift Coefficient Detail Design (Engineering) More Abstract Engineering Less Abstract
- 30. Design Process • Top-level problem definition is called PDS (Product Design Specifications) • Problem definitions at lower levels derive from PDS: – Sub-system design specifications. – Component design specifications. – Feature design specifications.
- 31. Product Development Process Market Research Product Design Specifications & QFD Design Brief (Mission Statement) Product Planning
- 32. Product Development Process Concept Synthesis PDS Concept Evaluation Candidate Design Detail Design Candidate Design Release for Production Prototyping
- 33. Detail Design Parameter Design Candidate Design Release for Production System-Level Design Prototype Testing Components No Numbers Numbers
- 34. Customers • People who are affected by the product Team Company (Internal) Globe (External)
- 35. External Customers EXTERNAL End Users Maintenance Society Retailer Buyers Government & Standards
- 37. What Do They Want? • End Users – Performance & Functionality – Affordability – Ease of use including ergonomics – Reliability and Long life – Versatility – Safety – Low maintenance and easy assembly – Esthetics
- 38. External Customers • Buying managers – Low Cost/Performance – Safety – Ruggedness (abuse resistance) – Ergonomics – Long warrantees – Reliable with Low downtime – Low operating cost
- 39. External Customers • Retailers – Small and attractive packaging – Long shelf life – Low cost/performance and Exciting features • Maintenance – Ease of maintenance
- 40. External Customers • Government / Standards / Society – Conformance to laws and regulations – Promotion of public health and safety – Protection of environment – Solution to chronic problems in society • Traffic • Energy • Noise • Drugs, abuse and other crimes • Diversity / Social tolerance / Security
- 41. Internal Customers • Management – Make a big profit – On time delivery – Low failure risk – Documentation – Process: Conformance to company product development process
- 42. Internal Customers • Marketing – Attractive features to target buyers – Low production cost – Esthetics – Attractive packaging – On time delivery – Long Warrantees
- 43. Internal Customers • Manufacturing – Manufacturability using standard methods and schedules. – Conformance to company documentation formats. – Use of products from preferred vendors.
- 44. Internal Customers • Legal – No patent infringements – Safety • All required safety warnings and labels • Designed protection against reasonable abuse – Codes and regulations
- 45. Internal Customers • Shipping and Packaging – Ease of user assembly – Small packaged size – Ability of locking or fixing sensitive components – Resistance against damage due to dropping, vibrations, moisture, heat, and cold.
- 46. Performance cost Ease of use Reliability Safety Users ***** ***** ***** ***** ***** Buyers **** ***** ** ***** ***** Retailers *** *** *** ** ** Govrnmnt **** Mangmnt ** **** ** ** *** Marketng **** ***** *** **** ***
- 47. Product Design Specification • Elements of PDS – Performance (User) • Speed, • Capacity, • Power, • Accuracy, • etc.
- 48. Elements of PDS – Environment: (User) • Temperature range, humidity, dust and dirt, etc. – Life in service: (User) • 10 years, 5000 cycles, etc. – Maintenance: (User) • What is the market policy, what customers accept – Target production cost: (User) • Cost of comparable products and company policy.
- 49. Elements of PDS • Shipping: – Package sizes – Damage resistance
- 50. Elements of PDS • Quantity (Manufacturing) – Determined by market analysis. • Manufacturing facility (Manufacturing) – Is the design constrained by existing facility? – Are parts to be contracted and assembled in-house? – Does the company policy dictate certain facilities?
- 51. Element of PDS • Size and shape (Marketing) • Weight (Marketing) – What is the desired weight? – Should handles or lifting points be provided? – Should it be modular for better handling? • Aesthetics (Marketing,User) – Color, shape, form, texture, finish. – Market research.
- 52. Elements of PDS • Materials (Marketing, Codes, Regulations) – Left to designers unless company guidelines or regulations restrict certain materials (asbestos, lead). • Product life span (Marketing, Manufacturing) – Life of a product as a marketable entity. Several months or several years?
- 53. Elements of PDS • Laws, Codes, and standards (Government) • Ergonomics (User)
- 54. Elements of PDS • Quality and reliability (Marketing) – Company policy regarding warranties – Competitors warranty policies • Testing (Marketing, QA) – What tests would be performed to verify performance – Standard tests
- 55. Elements of PDS • Shelf life (storage) - Retail – Possibility of rust, decay, deterioration • Processes (company guidelines) – Use of certain standards (GD&T for example) – Use of certain procedures • Time-scales (deadlines) - Management – Whole design project, milestones
- 56. Elements of PDS • Safety (User, Government, Legal) – What safety requirements are mandated by government – Professional society's codes and standards – Need for warning labels – Likely degrees of abuse or misinterpretation of operating procedures.
- 57. Elements of PDS • Company constraints (Management) – Compatibility with other products • Documentation (Management – Legal) – A product design must include a full formal documentation per company guidelines. – Safety, Operation, and Service documents. – Etc.
- 58. Elements of PDS • Legal (Lawyers) – What product liability law suits are associated with similar products and why. – Note the legal terms: • “defect of specification” • “defect of design” • “defect of manufacture” – Relevant patents
- 59. Element of PDS • Installation (Installers) – Many products must interface with other products or be assembled with other products. • Disposal (Society) – Should any parts by recyclable? – bio-degradable?
- 60. Wording of the PDS Document • Format of most statements in PDS: – The device must …….. – The device is to …… – The device is desired to …. • Avoid mixing requirements. – One sentence per requirement. • Cast PDS statements in a positive format
- 61. PDS is a Dynamic Document • A design statement usually begins as a vague statement – The device is to be easy to use – The device is to be safe – The device is to be inexpensive – The device is to be rugged and reliable – The device is to be portable
- 62. Wording of the PDS Document • Example: ESCO’s Pin Remover – The pin-remover is to be light. – The pin-remover must work in a wet, cold, and dusty environment. – The Pin-remover must be safe – The Pin-remover must have a 3-year warranty.
- 63. PDS Example • The PR is to be rugged. • … must work with air pressure. • … is be easy to use. • … is to pass “HTS” tests. • … is to last 5 years in normal usage. • … is to be easy to carry.
- 64. PDS Example • … is to sell for less than $150. • … is to costless than $50 to make. • … is to have low maintenance needs. • … is to be difficult to use as a hammer. • … must not infringe on patented devices. • … Production volume is to be 300 per year
- 65. PDS Example • … is to be tested by June 2006. • … is to be released by Sep. 2006. • … is to be used with Dredge Point models. • … is to work faster than the hammer
- 66. Engineering Specifications • What is – “Fast, accurate, high-performing”? – “Light, Small, portable”? – “Easy to use”? – “Safe”? – “Stylish”?
- 67. Engineering Specifications –Verifiable PDS statements –Developed for important PDS statements –Have associated target numbers (Yes/No OK)
- 68. Engineering Specifications Tips –Set up metrics and targets so the designer has maximum options in accomplishing the PDS
- 69. Engineering Specifications Tips • PDS: The Dog Feeder must not tip over when bumped or pushed by a dog. –Bad: The DF must weigh 50 lbs –Good: The dog feeder must withstand 30 lbs applied to its top from side
- 70. A Typical PDS Page • Requirement: PR is to be easy to maintain – Primary customer: End users – Priority: High – Metrics and Targets • Daily maintenance: None • Weekly maintenance: < 10 minutes – field • Yearly maintenance: < 1 hour – Shop • Cost of weekly maintenance < 10c • Cost of yearly maintenance < $10
- 71. Customer Needs PDS Statements Engineering Requirements Competition I M P O R T A N C E Competition Relation Between Engineering and Customer Requirements Target
- 72. Design is a Process with Passion Professor Nhut Tan Ho Department of Mechanical Engineering California State University, Northridge
- 73. • Introduce the Design process: Passion and systematic Organization of Ideas • Example: Case Study of Yoyo • Active-learning activity: Work with you team to develop an FR, DP, A, R, RC Lecture Objectives and Activity
- 74. •The Challenge •What does Passion have to do with design? •Control the Passion with Determinism •Systematic Organization of Ideas •Example and exercise Design is Passion
- 75. Passion is Love, Focus, Perfection and Play What does Passion have to do with design?* *slide are from Slocum’s Design Book
- 76. “Get a clear notion of what you desire to accomplish, then you will probably get it Keep a sharp look-out upon your materials: get rid of every pound of material you can do without. Put yourself to the question, “What business has it there?” Avoid complexities and make everything as simple as possible Remember the get-ability of parts” Henry Maudslay Passion gives FOCUS so keep your eye on the prize : What does Passion have to do with design?* “You can’t always get what you want But if you try sometimes well you might find You get what you need” Mick Jagger & Keith Richards 1969 (1700’s a father of modern machine tools) from J. Roe English and American Tool Builders 1916 Yale Press *slide are from Slocum’s Design Book
- 77. What can a Deterministic Process do for me? Control the Passion with Determinism* *slide are from Slocum’s Design Book
- 78. Deterministic Design Process* *slide are from Slocum’s Design Book
- 79. Deterministic Design* *slide are from Slocum’s Design Book
- 80. Design is a Series of Steps Blended Together
- 81. Case Study – Fall 2005 Yoyo Design Challenge Your team is charged with the task of developing a new yoyo for fast food companies. The yoyo will be a toy in kid meals (e.g., McDonalds’ Happy Meal).
- 82. Passion is a LOVE for creating: What does Passion have to do with design? “Enthusiasm is one of the most powerful engines of success. When you do a thing, do it with all your might. Put your whole soul into it. Stamp it with your own personality. Be active, be energetic, be enthusiastic and faithful and you will accomplish your object. Nothing great was ever achieved without enthusiasm.” Ralph Waldo Emerson
- 83. Passion drives perfection and creates PLAY What does Passion have to do with design? “5 Point Holes” “Blades with Lights” 1 2 “Hourglass” “Pokeball” 3 4 “Push Button” “Tire” 5 6 “Basic” “Hamburger” 7 8
- 84. Passion drives perfection and creates PLAY What does Passion have to do with design? “McD’s Logo” “Team C” 9 10 “Football” “Sombrero” 11 12 “Turtle Shell” “Metroid” 13 14 “Rick’s Rim” 15
- 85. Functional Requirement s Design Paramete rs Analysis Reference s Risk Counter Measures Attractive Appearance make it appealing to kids - glow in the dark; neat shapes… Surveys and customer profiling Research different types of yoyo designs Mold becomes more complicated; harder to machine Make the design as simple as possible; try various colors Function Well Must perform in a typical manner; Simple, standard design a = g / (I/mr2 + 1) w = [2gx / (I/m+r2 )]1/2 t = (2L/g)1/2 (1+I/mr2 )1/2 v = [2gx / (1+I/mr2 )]1/2 Experiment al Investigatio n of Yoyo Design by Alma Bardon; Physics and Dynamics books improper application of equations; unbalanced design Study references; Design a good symmetrical design; Bench- level experiments EXAMPLE – FRDPARRC Sheet (incomplete)
- 86. CHOOSING THE BEST DESIGN CONCEPTS “5 Point Holes” “Blades with Lights” 1 2 “Hourglass” “Pokeball” 3 4 “Push Button” “Tire” 5 6 “Basic” “Hamburger” 7 8 CONCEPTS CONT…
- 87. 15 DESIGN CONCEPTS “McD’s Logo” “Team C” 9 10 “Football” “Sombrero” 11 12 “Turtle Shell” “Metroid” 13 14 “Rick’s Rim” 15
- 88. Design is a Process with Passion Which one is the best concept?
- 89. 1 5 Point Holes 2 4 4 4 14 3.50 2 Blades 5 3 5 3 16 4.00 3 Hourglass 2 3 5 5 15 3.75 4 Pokeball 5 4 3 4 16 4.00 5 Push-button 1 5 4 5 15 3.75 6 Tire 4 4 5 4 17 4.25 7 #1 Basic Yoyo 2 5 5 5 17 4.25 8 Hamburger 3 4 5 4 16 4.00 9 McD Logo Engrave 3 3 5 4 15 3.75 10 Team C Yoyo 5 2 5 2 14 3.50 11 Football 4 3 3 5 15 3.75 12 Sombrero 4 4 3 4 15 3.75 13 Turtle Shell 5 4 4 2 15 3.75 14 Rim Yoyo 4 3 4 3 14 3.50 15 Metroid Yoyo 4 3 4 3 14 3.50 TEAM C: SCORE: 1 5 John Nguyen POOR EXCELLENT Kevin O'Fallon John Osborn Marc Ouellette Yellow = 1st and 2nd choice Rich Pascua Light Blue = tied for 3rd choice TEAM C - PROJ ECT EVALUATION CONCEPT DESCRIPTION COST PERFOR - MANCE MANUFAC - TURABILITY TOTAL AVG AESTHETICS
- 90. Functional Requirement s Design Paramete rs Analysis Reference s Risk Counter Measures EXAMPLE – FRDPARRC Sheet for Your Project
- 91. Recap: Design Process • Design is • A process with passion • A series of steps blended together • Design success involves deterministic process with systematic organization of ideas • Homework: Teamwork assignment