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by Dan Frey
1 Design Processes
Design has been defined in many, slightly different ways by many different people. One
good definition is given by the Accreditation Board for Engineering and Technology 1
(ABET) which defines design as The process of devising a system, component, or
process to meet desired needs. This definition is simple yet covers the essentials of
design in all its various forms including mechanical design, software, architecture, and
even less technical fields such as fashion design.
ABET elaborates further describing design as a decision-making process (often
iterative) in which the basic sciences, mathematics, and engineering sciences are applied
to convert resources optimally to meet a stated objective. This elaboration is useful in
the sense that it adds elements important to modern engineering design. But these
additional statements ought not to be part of the definition of design. For example,
design cannot be called a decision-making process since it must also include generation
of alternatives as well as selection among them. It would be more accurate to say design
includes decision making processes within it as opposed to saying it is a decision making
process. This will be discussed more in the section
on Pugh Controlled Convergence. In addition, the ABET defines design as
application of sciences and the explicit use of The process of devising a
optimization may not always be present in every system, component, or
design activity. This will be explored further in the process to meet desired
needs.
section on historical context.
1.1 Motivation
1.1.1 Historical Context
As defined by ABET, design has an extremely long history. The earliest stone tools are
believed to have been crafted over one million years ago. The shapes of early stone tools
appear to have been devised for very specific purposes some for chopping wood, some
for grinding grains, some for the tips of spears used to hunt animals. It can fairly be said
that these tools must have been designed. The humanoids who fashioned these earliest
stone tools had brains far smaller than those of modern humans, they did not have
1
ABET is the body that accredits MITs engineering degrees and therefore is the same people who require
that you to take design courses like 2.007
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language (maybe they had a proto-language), and they apparently couldnt draw pictures.
The design process used to define the shapes of early stone tools surely wasnt very
sophisticated. Their design probably involved a lot of trial and error over generations of
individuals who slowly evolved the designs. Over time, shapes that worked well were
passed on. Small changes were made and, for the most part, only changes that led to
improvements were retained.
Consider by contrast the design of a spear thrower depicted in Figure 1 (sometimes called
and atlatl) which apparently dates to 14,000 BCE. Scientists argue that humans at the
time this design first appeared were essentially as intelligent people are today. They
could learn languages and draw pictures. However, there was no civilization at that time
and surely no science as we know it today. Yet looking at the spear thrower, there
appears to be some fairly sophisticated thought required to understand the physical
effects involved. To throw a spear farther by hand, it helps to move your hand faster.
But physical limits prevent even the most athletic people 2 from moving their hand more
than about 100 mph (45 m/s). Given that constraint and assuming low drag and an
approximately no lift, a simple ballistics model suggests the range of a spear could be as
much as 200 meters, but in practice its more like 100 meters3. But extending the point
of contact with the spear and involving the wrist in the throwing motion could extend the
time for applying force and increase the initial velocity of the spear increasing both the
range of the throw and the force with which it penetrates. Studies of this type of
throwing device suggest the device can roughly double the release speed and that an
atlatl dart can travel as far as 260 meters4. Exercise: Explain, in a
Enabling this kind of performance improvement, manner that a bright high
many details had to be worked out. Maintaining school student would
contact between the throwing device and the back of understand, why doubling
the spear places some demands on the shape of the the initial velocity of a
contact point. It is essential to apply force but also
projectile will quadruple its
allow the two bodies to freely rotate with respect to range assuming zero drag
one another. Proper release of the spear at the end of and zero lift and fixed
the throwing motion places further requirements on initial launch angle.
the shape at the contact area.
The fastest clocked baseball pitch in history was 104.8mph. It was thrown by Joel Zumaya of the Detroit
Tigers while playing in the American League Championship in 2006.
3
The world record in the javelin throw is 98.48 mters set in 1996 by Jan Zelezny of the Czech Republic.
4
The record distance is 258.64m by Dave Engvall in 1995
www.worldatlatl.org/Articles/Atlatl%20Experiments.pdf
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likely that much of the design was worked out by trial and error. In any case, a design
employing some complex physical effects can proceed first, and the underlying science
apparently can be developed later. This pattern also applied to many other developments.
Watts steam engine appeared in 1850 and the basic developments of thermodynamics by
Kelvin, Carnot, and others came at least three decades later. This pattern is changing
quickly in the modern engineering context with increasing dependence of design on a
science base.
Sullivan, John P., 1999, The relationship between organizational architecture, product architecture, and
product complexity, Thesis, MIT System Design and Management Program.
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Figure 2. A design process at a major company (in this case, Pratt and Whitney) might
be represented as a waterfall with a series of phases of increasing detail and
completeness ending in a complete plan for production.
Figure 3. A design process at a major company (in this case, Ford Motor
Company) might be represented as a V with requirements coming in one
end, flowing down to parts at the bottom, and with complete system designs.
emerging at the end.
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By contrast, Ford Motor Company describes its process as a V (see Fig 3) with
requirements being subdivided from vehicles to subsystems to components on one side.
Components are designed in the middle phase represented by the bottom of the V.
Then, on the ascending side of the V, the parts are composed into subsystems and then
subsystems are integrated into vehicles and all along tests are employed to verify the
design.
Pratt and Ford are just two examples. There is much more variety we could show across
successful companies. Some software companies describe their design process as a spiral
with requirements at the core leading to simple prototypes which are used to further
explicate the requirements in another layer of the spiral. Other companies describe their
design process as a funnel with many design concepts being considered in parallel with
refinement and selection to a smaller number of options over time.
Many of these differences among design process descriptions arise from the different
demands imposed by the nature of the artifact being designed, the rate of technical
change in the field, or the nature of the customers being served. Other differences have
more to do with the individual style of the people and the companies involved. For
example, the design processes used by the three largest jet engine manufacturers (General
Electric, Pratt and Whitney, and Rolls Royce) are vastly different even for products
where all three companies make engines that are performing essentially identical
functions. In some cases, three different engine designs can literally be bolted onto the
same aircraft and offered as different options for the airlines to choose, yet they are all
designed by quite different processes.
To summarize, the modern context of engineering design is characterized by tremendous
sophistication and broad variety. It is interesting to consider the implications for your
professional education. To add something valuable to the existing system, you will need
lots of knowledge, skill, and creativity. Those capacities can be developed through study
and practice which begins in school. To fit usefully into a broader engineering design
effort in a modern organization, you will need to adapt to a design process we cant teach
you while youre at a University, because we cant predict which process your company
will use. Being a designer in a modern context seems to require life-long learning. Each
design project you undertake will pose challenges -- many becoming familiar as you
accumulate experience, but always some new ones to master. This is something to
celebrate if you enjoy having a variety of life experiences.
desirability of creativity. This subsection reviews the essence of just two methods,
brainstorming and TRIZ.
Brainstorming is an activity in which a group of people quickly work to develop a
large number of solutions to a design challenge. It takes just about an hour to do, so there
is not much risk in giving it a try on any given project. The approach involves setting up
a room with plenty of paper, writing implements, and other props and inviting a diverse
set of people to participate. A typical goal is to develop 100 ideas in an hour. A
recommended group size is 5 to 7 as this provides enough variety of input. Larger groups
would tend to create too much production blocking wherein participants spend too
much time listening passively to others ideas and not enough time producing ideas of
their own. A key aspect of the method is adherence to the standard five rules of the
brainstorm:
Defer judgment
Build upon the ideas of others
One conversation at a time
Stay focused on the topic
Encourage wild ideas
Another widely known approach to generating ideas is known as the Theory of
Inventive Problem Solving, known most often as TRIZ (its acronym in Russian). The
approach was based on study of a large set of patents. Common solutions were
categorized in terms of the ways that inventions had resolved technical contradictions.
Technical contradictions are cases wherein the action to improve some feature
simultaneously appears to reduce some other needed property which sets up a conflict
among the two needs. Writing the conflict in this form provides a means to access a
database that is supposed to help access patents that are likely to inspire some useful
ideas that might be adapted to the given situation.
An example serves to illustrate the approach. To study the effects of acids on metal
alloys, specimens are placed into a hermetically sealed chamber filled with acid. The
acid reacts not only with the specimen but also the walls. The challenge is to invent a
system that avoids the adverse effects of the chamber walls on the testing procedure.
First the problem is re-stated as a contradiction, in this case, that the walls must be
present to contain the acid, but in a sense, the walls must be absent to avoid participating
in the reaction. The proposed solution from TRIZ is to make the wall out of the specimen
material itself. This sort of system simplification is frequently a feature of TRIZ
solutions as they promote evolution toward ideality.
The actual set of TRIZ methods are complex and the effectiveness of the approach in
practice shows at best mixed results. I would suggest taking away the key idea that
knowledge of lots of inventions is helpful in developing more inventions. Rather than
studying any specific creativity methodology, I would suggest you invest the same time
in another activity. Specifically, I suggest you find time every week to read some patents
from your field of engineering and some very good patents from other fields, this will be
a long term strategy for increasing your inventive capacity.
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Textooks and papers on Pughs method usually present neatly formatted tables to
explain the Pugh matrix, such as the one shown in Figure 4. This may contribute to a
misunderstanding of what is actually done. In practice, Pugh matrices are messy collages
of drawings and notes (such as the Pugh matrix from a software development team shown
in Figure 5). This is a reflection of the nature of early-stage design. The PuCC process is
simple and coarse-grained as it should be for use in early stage design. By contrast,
alternatives to Pugh's method often require greater resolution of the scale (suggesting five
or ten levels rather than just three) and often require numerical weighting factors. Pugh
found by experience that this sort of precision is not well suited to concept design.
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It is common practice to place summary scores along the bottom of the matrix. The
number of +, -, or S scores for each concept are counted and presented as a rough
measure of the characteristics of each alternative. This raises an important potential for
misunderstanding. These scores should NOT be interpreted as a means by which to
choose the single winning design. Although a single run of an evaluation matrix can help
reduce the number of design concepts under consideration, but is not meant to choose a
single alternative. A single matrix run can result in at least four kinds of decisions (not
mutually exclusive) including decisions to: 1) eliminate certain weak concepts from
consideration, 2) invest in further development of some concepts, 3) invest in information
gathering, and 4) develop additional concepts based on what has been revealed through
the matrix and the discussions it catalyzed.
Figure 6 illustrates how iterated uses of
Pugh matrices can lead to convergence. The
key feature to note is that controlled
convergence generally includes periods of
divergence of the set of concepts.
Experience shows that studying the relative
merits of design concepts is a good way to
prepare ones mind for concept generation.
Seeing the ways that one concept attains a
strength where another is weak may suggest
a means to bring the positives of one concept
on board to another concept.
When this
occurs, decision making is greatly facilitated
because trade-off is no longer necessary
between the involved criteria.
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Thomke, Stephan, 2001, Enlightened Experimentation: The New Imperative for Innovation, Harvard
Business Review, Feb, pg. 67-75.
7
Box, G. E. P. and P. T. Y. Liu, 1999, Statistics as a Catalyst to Learning by Scientific Method, Journal
of Quality Technology 31 (1): 1-29.
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right. Dont build a fancy prototype early if a simpler one would answer the
question.
Combine new and traditional technologies New technologies (well, relatively
new) at your disposal include CAD, 3D printing, and water-jet cutting. Thomkes
advice is that new technologies like this have the biggest payoff when used early
in the design process. This is especially true in 2.007 where some of these
technologies become over-tasked late in the term when everyone is clamoring for
access at the same time.
Making a machine that can function properly when every possible factor is at its
ideal value, such as when the machine is demonstrated under carefully controlled
laboratory conditions
Making a machine that can function properly under the full range of conditions it
is likely to experience in authentic field use
The distinction above is a key to having customers who are delighted by your product
and loyal to the brand. The alternative is to have former customers who are frustrated by
the constant breakdowns, recalls, warrantee service, and never-ending calls to tech help
lines.
In the context of commercial product development, robustness is not optional. Most
companies know that. A select few also have the set of tools and willingness to invest in
the steps needed to follow through on implementing robust design.
In the context of 2.007, it is easy to drift into the mindset that the first objective is
sufficient. Many students get some good results in the last weeks of the class. These
good outcomes appear when the machine exhibits no wear or distortion, when the battery
is at peak charge, when the radios are in mint condition, and when the opposing player is
not there to create other adverse conditions. Unless there has been adequate attention to
robust design, when any one of several factors drifts off the ideal state, the outcome is
poor.
Implementing robust design is conceptually simple.
1) You have to deliberately expose your design to a broad set adverse conditions.
2) You must do this early enough that you can repeat the process for multiple design
alternatives so that you can choose the options that perform better.
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performed at either the system or piece-part level. Ideally, it should begin as early as possible
in design and be used continually throughout the whole product life cycle in order to
structure information flow in the organization. The feature of FMEA is classification of the
effects of potential failure modes by severity, occurrence, and detection. FMEA can also be
used to prioritize the countermeasures. This may be done by calculating the risk priority
numbers (RPN) for each failure mode.
As an early step in conducting an FMEA, a list of potential failure modes must be compiled.
While it is not possible to anticipate every possible failure mode, it is very important to do
the search as thorough as possible. It is necessary for the FMEA to be conducted by a team of
experts with various views of the product. The designer of the product is essential, but as he
or she often lacks the necessary critical view of the product, so experts from other fields or
even the customer should be part of the team. Subsequent steps vary among practitioners,
but a good baseline process is:
a. Define the ideal function (or functions) of the design.
b. Determine all of the potential failure modes associated with each function
c. Write down the effects of these failure modes on each type of customer
d. Determine the failure mechanisms (sometimes called root causes) that can cause the
failure modes to occur
e. Identify a detection event (e.g. a set of design rules & standards, analytical methods, or
physical testing) that can discover and excite the failure mode via the determined
mechanism.
f. Determine the action that constitutes a countermeasure to the failure mode occurring
(either eliminate the cause, or mitigate the effect of the cause with appropriate design
modifications).
g. Verify the effectiveness of the failure mode avoidance action in f, and determine if
better detection events and/or more countermeasures might be required.
The output of the analysis is a FMEA Table (such as Table 1 below) which lists all the failure
modes together with possible effects on the system and other issues that may be important in
dealing with the failure. It is generally important to consider possible detection events. A
failure that cannot be detected clearly and early enough will often prove to have more serious
consequences. There is no universally accepted layout for the FMEA (although certain
standards exist within industries, for example automotive), but loosely they all follow the
sequence of information flow listed below, laid out on a landscape document reading
from left to right.
A major concern with FMEA is that it can devolve into a bureaucratic exercise That fills
up paper and takes up time, but doesnt really improve the design. To make FMEA
useful, you need to move beyond analysis, into avoidance of the failure mode through the
deployment of an effective counter measure. Tim Davis has proposed that we rethink
FMEA and rename it Failure Mode Avoidance to emphasize the changed mind-set. This
will require some further development to explain how FMEA, when practiced well, can
influence the design process and structure information flow among designers.
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S
Failure
Function
Effects (severity
mode
rating)
Fill tub
High
Liquid
level
spills on
sensor
customer
never
floor
trips
RPN
O
D
Current
CRIT (critical (risk
Cause(s) (occurrence
(detection
controls
charactertics) priority
rating)
rating)
number)
Fill
timeout
level sensor
based on
failed
2
time to
5
N
80
level sensor
fill to low
disconnected
level
sensor
Recommended
actions
Perform cost
analysis of adding
additional sensor
halfway between
low and high level
sensors
Responsibility
and target Action
completion taken
date
Jane Doe
10-Oct-2010
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Summary
Design is a process that has been around a long time. No doubt, our ancestors
survived substantially because of their skill in developing solutions to problems
they faced with the materials and technology that was available to them. They have
passed this skill onto you and I expect youll find you have natural ability to design.
Your natural ability can be improved by practice and by reflection on what makes
design processes work effectively. Some of the key lessons from scholars who have
studied design carefully include:
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