D. S. Strong D. S. Strong Queen’s University Queen’s University

The Engineering Design The Engineering Design Process Process

Methodology and ResponsibilityMethodology and Responsibility

Overview of DISCUSSIONOverview of DISCUSSION

Engineering and engineering designEngineering and engineering design Engineering in the global economyEngineering in the global economy The Design ProcessThe Design Process Key elements to successKey elements to success Responsibilities of design engineersResponsibilities of design engineers

DefinitionsDefinitions (Oxford) (Oxford)

Design: Design: Mental plan, scheme of attack, Mental plan, scheme of attack, contrive, propose, make preliminary contrive, propose, make preliminary sketch of, draw plan of….sketch of, draw plan of….

Engineer: Engineer: One who designs and One who designs and constructs,constructs,

Engineering: Engineering: Application of science for Application of science for ……

Engineering, According to ABETEngineering, According to ABET (a) an ability to apply knowledge of mathematics, science, and (a) an ability to apply knowledge of mathematics, science, and

engineeringengineering (b) (b) an ability to design and conduct experimentsan ability to design and conduct experiments , as well as , as well as

to analyze and interpret datato analyze and interpret data (c) (c) an ability to design a system, component, or process to an ability to design a system, component, or process to

meet desired needsmeet desired needs (d) (d) an ability to function on multi-disciplinary teamsan ability to function on multi-disciplinary teams (e) an ability to identify, formulate, and solve engineering problems(e) an ability to identify, formulate, and solve engineering problems (f) (f) an understanding of professional and ethical an understanding of professional and ethical

responsibilityresponsibility (g) (g) an ability to communicate effectivelyan ability to communicate effectively (h) the broad education necessary (h) the broad education necessary to understand the impact of to understand the impact of

engineering solutions in a global and societal contextengineering solutions in a global and societal context (i) a recognition of the need for, and an (i) a recognition of the need for, and an ability to engage in life-ability to engage in life-

long learninglong learning (j) a knowledge of contemporary issues(j) a knowledge of contemporary issues (k) (k) an ability to use the techniques, skills, and modern an ability to use the techniques, skills, and modern

engineering tools necessary for engineering practice.engineering tools necessary for engineering practice.”” - - ABET 2003-2004 Criteria for Accrediting Engineering Programs - ABET 2003-2004 Criteria for Accrediting Engineering Programs - Effective for Evaluations during the 2003-2004 Accreditation CycleEffective for Evaluations during the 2003-2004 Accreditation Cycle

What is Engineering Design?What is Engineering Design?

““The engineering sciences have their roots in mathematics The engineering sciences have their roots in mathematics and basic sciences but carry knowledge further toward and basic sciences but carry knowledge further toward creative application. These studies provide a bridge creative application. These studies provide a bridge between mathematics and basic sciences on the one hand between mathematics and basic sciences on the one hand and engineering practice on the other. Engineering design and engineering practice on the other. Engineering design is the process of devising a system, component, or process is the process of devising a system, component, or process to meet desired needs. It is a decision-making process to meet desired needs. It is a decision-making process (often iterative), in which the basic sciences, mathematics, (often iterative), in which the basic sciences, mathematics, and the engineering sciences are applied to convert and the engineering sciences are applied to convert resources optimally to meet these stated needs.” resources optimally to meet these stated needs.”

- - ABET 2003-2004 Criteria for Accrediting Engineering Programs – Proposed Changes (Proposed ABET 2003-2004 Criteria for Accrediting Engineering Programs – Proposed Changes (Proposed Revisions of the General Criteria)Revisions of the General Criteria)

What else is engineering design?What else is engineering design?

““Engineering design integrates mathematics, basic Engineering design integrates mathematics, basic sciences, engineering sciences and complementary studies sciences, engineering sciences and complementary studies in developing elements, systems and processes to meet in developing elements, systems and processes to meet specific needs. It is a creative, iterative and often open-specific needs. It is a creative, iterative and often open-ended process subject to constraints which may be ended process subject to constraints which may be governed by standards or legislation to varying degrees governed by standards or legislation to varying degrees depending upon the discipline. These constraints may depending upon the discipline. These constraints may relate to economic, health, safety, environmental, social or relate to economic, health, safety, environmental, social or other pertinent interdisciplinary factors.”other pertinent interdisciplinary factors.”

- - CCPE/CEAB 2002 Accreditation Criteria and ProceduresCCPE/CEAB 2002 Accreditation Criteria and Procedures

And from the President of NSERC…And from the President of NSERC…

Technology: the set of procedures and tools that predictably and reproducibly produces a specified desired effect in the material world

Science: the social system for generating knowledge that involves three sequential and interrelated activities: research conducted according to a prescribed method (the scientific method), processes for accepting (or not) the results of research as fact, and finally predictions based on facts

Engineering: the professional activity of creating artefacts and systems to meet people’s material needs, with design as the central creative process, scientific knowledge and economic considerations as its essential inputs, and public safety as its overriding responsibility

The main form of creative intellectual activity in science is research; it is both design and research in engineering.

The context for creative intellectual activity in science is an experiment, and in engineering it is most often a project.

Dr. Tom Brzustowski, P.Eng. President of NSERC

Engineers in the Global EconomyEngineers in the Global Economy

Domestic discipline specific Domestic discipline specific engineering specialists are, engineering specialists are, in some in some industriesindustries, an endangered species, an endangered species

Highly trained, technically competent Highly trained, technically competent “offshore” engineers can be “offshore” engineers can be contracted for 10-15% of the costcontracted for 10-15% of the cost

The solution?The solution?

> “Value-added” engineers> “Value-added” engineers

What is a “Value-added” Engineer?What is a “Value-added” Engineer?

Sound fundamental engineering skillsSound fundamental engineering skills Marketing/sales skills and awareness: user & Marketing/sales skills and awareness: user &

market research, business savvy (negotiation, market research, business savvy (negotiation, persuasion, confidence)persuasion, confidence)

Business finance skills: cost estimation, capital & Business finance skills: cost estimation, capital & expense, sensitivity, P&L > KNOW THE NUMBERSexpense, sensitivity, P&L > KNOW THE NUMBERS

Design Innovation: balance of creativity, Design Innovation: balance of creativity, practicality, and risk (Know and use THE TOOLS)practicality, and risk (Know and use THE TOOLS)

Leadership and Teamwork: balanced and effective Leadership and Teamwork: balanced and effective interaction with ALL disciplines and professionsinteraction with ALL disciplines and professions

Communication Excellence: clear and concise Communication Excellence: clear and concise presentations and reportspresentations and reports

Judgment: based on engineering principals, Judgment: based on engineering principals, awareness of capabilities, ethical considerations, awareness of capabilities, ethical considerations, social responsibilitysocial responsibility

The Design ProcessThe Design Process

Design problems are typically “open-Design problems are typically “open-ended” and “ill-structured”ended” and “ill-structured”

Design methodology is not discipline Design methodology is not discipline specific > it is a flexible processspecific > it is a flexible process

Good design usually includes pleasing Good design usually includes pleasing esthetics > the “art” of designesthetics > the “art” of design

Design is typically subject by Design is typically subject by “constraints”“constraints”

The design process can be applied The design process can be applied beyond engineeringbeyond engineering

The (Simplified) Design TriangleThe (Simplified) Design Triangle

Client

Designer User

You are here

Corp. Legal

Corp. Finance

Corporate Mgt.

Corp. Regulatory

Safety/Liability

Clients

CommunicationsFinance

Marketing

Sales

Business Mgt.Buyer/Agent

Regulatory Rep.

Test Tech.

Designer/Tech

Other Eng.

Proj. Eng./Lead

Reliability Eng.

Industrial Design

Eng. Mgt.

Model MakersMachine Shop

Safety Rep.

Pkg. Eng.

Who is involved in my design project?

Quality Eng.

Contractors

Manuf. Eng.

Industrial Eng.Purchasing

SuppliersProd. Associates

Reg. Bodies(CSA,UL)

Fed. Gov’t (DOT, FAA,DOF)

Safety Org’s.(CPSC)

Ind. Ass’n.ANSI,IEEE

EnvironmentalAgencies

Mun.Gov.

Prov. Gov.(MOT,MOE,MOL)

Eng. Reg.(PEO)

Who is the customer? Environment

Users

Society

Typical Requirements for Typical Requirements for Successful Design Projects Successful Design Projects

Thorough Research: problem identification, Thorough Research: problem identification, needs/market analysis, constraints > detailed needs/market analysis, constraints > detailed (and agreed) product/process specification(and agreed) product/process specification

Project Management: planning, organizing, Project Management: planning, organizing, leading, controlling> schedule & deliverablesleading, controlling> schedule & deliverables

Engineering science: estimation, math. and/or Engineering science: estimation, math. and/or physical modeling, analysis, optimizationphysical modeling, analysis, optimization

Teamwork: interdisciplinary and concurrentTeamwork: interdisciplinary and concurrent Communication: regularly and clearly within and Communication: regularly and clearly within and

beyond team> reports, presentations, forumsbeyond team> reports, presentations, forums Learning/Reflection: a lifelong requirementLearning/Reflection: a lifelong requirement

A Linear View of the Design ProcessA Linear View of the Design Process

Client Statement(Need) Problem Definition

Conceptual Design

Preliminary Design

Detailed Design

Validation & Documentation

Implementation

Client StatementClient Statement

The starting pointThe starting point May be from marketing, your May be from marketing, your

manager, your external clientmanager, your external client Typically brief with limited Typically brief with limited

information and directioninformation and direction Where do you go from here?Where do you go from here?

Problem Definition (Research) Problem Definition (Research) Clarify the ObjectivesClarify the Objectives

Client interview: objectives, constraintsClient interview: objectives, constraints Literature review: publications, IP Literature review: publications, IP

(patents), web(patents), web User Needs/Wants: surveys, interviews, User Needs/Wants: surveys, interviews,

questionnairesquestionnaires Compliance: regulatory codes and Compliance: regulatory codes and

standards, legal considerationsstandards, legal considerations Generate: revised problem statement, Generate: revised problem statement,

detailed objectives and functions, user detailed objectives and functions, user requirements, constraints, CTQ’srequirements, constraints, CTQ’s

Conceptual DesignConceptual Design Establish the detailed design specification – Establish the detailed design specification –

function, performance, attributes, features function, performance, attributes, features and benefits, metrics (to objectives)and benefits, metrics (to objectives)

Competitive Analysis: benchmarking, Competitive Analysis: benchmarking, reverse engineering (dissection)reverse engineering (dissection)

Generate design alternatives > Generate design alternatives > brainstorming, creativity techniques, brainstorming, creativity techniques, sketching/renderingsketching/rendering

Assess preliminary technical and economic Assess preliminary technical and economic feasibilityfeasibility

Tools: Morphological chart (feature/function Tools: Morphological chart (feature/function vs. means), QFD (house of quality), vs. means), QFD (house of quality), functional analysis (function means tree)functional analysis (function means tree)

Preliminary DesignPreliminary Design Analyze selected conceptual designs Analyze selected conceptual designs

(usually parallel path)(usually parallel path) Basic engineering analysis and preliminary Basic engineering analysis and preliminary

cost analysis cost analysis Consider safety, reliability, compliance, Consider safety, reliability, compliance,

environmental factorsenvironmental factors Construct early models and/or Construct early models and/or

“Frankenstein” prototypes“Frankenstein” prototypes Lab testing, preliminary field testing Lab testing, preliminary field testing

(preliminary test plan)(preliminary test plan) Client and user assessment and feedbackClient and user assessment and feedback Tools: TRIZ, pair-wise comparison chart, Tools: TRIZ, pair-wise comparison chart,

focus group feedback, intercepts, public focus group feedback, intercepts, public meetingsmeetings

Detailed DesignDetailed Design Iteration and verification stage Iteration and verification stage Select the best design option(s) > create Select the best design option(s) > create

(iterative) math and/or physical models(iterative) math and/or physical models Evaluate (analyze and/or test) > prove Evaluate (analyze and/or test) > prove

that design meets specification in terms of that design meets specification in terms of specifications: function, performance, user specifications: function, performance, user features, cost and compliancefeatures, cost and compliance

Detailed test plan is requiredDetailed test plan is required Refine and optimize the design > Refine and optimize the design >

maximize performance, minimize costmaximize performance, minimize cost Tools and methods: CAD, design reviews, Tools and methods: CAD, design reviews,

DFMA, DFD, (D)FMEA, (P)FMEA, Hazards DFMA, DFD, (D)FMEA, (P)FMEA, Hazards analysis, safety review, beta testing, analysis, safety review, beta testing, user/public feedbackuser/public feedback

Final Validation and DocumentationFinal Validation and Documentation

Final design review – all partiesFinal design review – all parties Final safety review – team & corp. sign-offFinal safety review – team & corp. sign-off Submission for regulatory compliance Submission for regulatory compliance

testing (where applicable)testing (where applicable) Documentation complete – “living” Documentation complete – “living”

documents closed and signed off, full documents closed and signed off, full fabrication specs such as 3D models, fabrication specs such as 3D models, detailed drawings, quality plan, detailed drawings, quality plan, purchasing/sourcing plan, implementation purchasing/sourcing plan, implementation scheduleschedule

ImplementationImplementation Organized technology transfer - don’t Organized technology transfer - don’t

“throw it over the wall”“throw it over the wall” Maintain communication with Maintain communication with

manufacturing, contractors, suppliersmanufacturing, contractors, suppliers Team effort continues until design is fully Team effort continues until design is fully

implementedimplemented Track progress where applicable: Track progress where applicable:

user/public feedback, warranty returns, user/public feedback, warranty returns, customer service; process/equipment customer service; process/equipment operator feedback, performance, reliabilityoperator feedback, performance, reliability

Design ownership: be prepared for Design ownership: be prepared for “tweaking”“tweaking”

What other elements are What other elements are required for all design projects?required for all design projects?

Project Management – Key to Project Management – Key to SuccessSuccess

Organization and schedulingOrganization and scheduling Teamwork and communication > respect, Teamwork and communication > respect,

empowerment, conflict managementempowerment, conflict management Concurrent Engineering – all parties Concurrent Engineering – all parties

involved early in the processinvolved early in the process Cost estimation and controlCost estimation and control Some common Tools/Methods: Some common Tools/Methods:

Gantt Chart, PERT Chart, Critical path Gantt Chart, PERT Chart, Critical path analysis, Phase-gate Process, Panel chartsanalysis, Phase-gate Process, Panel charts

Engineering EconomicsEngineering Economics

P&L statements – the language of P&L statements – the language of businessbusiness

Project Capital, Expense, Unit CostProject Capital, Expense, Unit Cost Cost estimation – material, labour, Cost estimation – material, labour,

shipping, tariffs, amortized tooling & shipping, tariffs, amortized tooling & equipmentequipment

Use the resources – learn the Use the resources – learn the language!language!

What else needs to be What else needs to be considered?considered?

Some thoughts on SafetySome thoughts on Safety

Should be considered from day 1Should be considered from day 1 Assume anything that can go wrong willAssume anything that can go wrong will Consider other ways that “customers” Consider other ways that “customers”

may use the productmay use the product Consider the safety issues over the long Consider the safety issues over the long

termterm NEVER underestimate the significance NEVER underestimate the significance

of a failure in product testingof a failure in product testing YOU are ultimately responsible YOU are ultimately responsible

Some thoughts on ReliabilitySome thoughts on Reliability

Rigorous reliability calculations are Rigorous reliability calculations are valuable in some casesvaluable in some cases

Thorough design analysis is critical (eg. Thorough design analysis is critical (eg. fatigue, creep, environmental factors)fatigue, creep, environmental factors)

ABR – application based reliabilityABR – application based reliability CDT – cycle destruct testingCDT – cycle destruct testing Failure Life Prediction – Weibull analysisFailure Life Prediction – Weibull analysis How much is testing is “enough”?How much is testing is “enough”?

Some thoughts on ResponsibilitySome thoughts on Responsibility

Ethical: cost, schedule & “spin” vs. Ethical: cost, schedule & “spin” vs. quality & safetyquality & safety

Professional: judgment, capability, Professional: judgment, capability, responsibility to the profession & responsibility to the profession & societysociety

Legal: ignorance is not an acceptable Legal: ignorance is not an acceptable excuse – you are ultimately excuse – you are ultimately responsibleresponsible

Practical NotesPractical Notes

The Design Process is not really The Design Process is not really linearlinear

Verification loops and re-starts are Verification loops and re-starts are commoncommon

Don’t lose sight of the objectivesDon’t lose sight of the objectives

The Design ChallengeThe Design Challenge

Speed

Cost Quality

It’s up to you to determine the right balance

The Value of Research and Communication in Design…

First prototype for testing

As proposed by the sales department

As understood by marketing

As written in the product description

As built by manufacturing

What the customer wanted!!