D. S. Strong Queen’s University

1. D. S. Strong Queen’s University The Engineering Design Process Methodology and Responsibility

2. Overview of DISCUSSION • Engineering and engineering design • Engineering in the global economy • The Design Process • Key elements to success • Responsibilities of design engineers

3. Definitions (Oxford) Design: Mental plan, scheme of attack, contrive, propose, make preliminary sketch of, draw plan of…. Engineer: One who designs and constructs, Engineering: Application of science for …

4. Engineering, According to ABET • (a) an ability to apply knowledge of mathematics, science, and engineering • (b) an ability to design and conduct experiments, as well as to analyze and interpret data • (c) an ability to design a system, component, or process to meet desired needs • (d) an ability to function on multi-disciplinary teams • (e) an ability to identify, formulate, and solve engineering problems • (f) an understanding of professional and ethical responsibility • (g) an ability to communicate effectively • (h) the broad education necessary to understand the impact of engineering solutions in a global and societal context • (i) a recognition of the need for, and an ability to engage in life-long learning • (j) a knowledge of contemporary issues • (k) an ability to use the techniques, skills, and modern engineering tools necessary for engineering practice.” - ABET 2003-2004 Criteria for Accrediting Engineering Programs - Effective for Evaluations during the 2003-2004 Accreditation Cycle

5. What is Engineering Design? “The engineering sciences have their roots in mathematics and basic sciences but carry knowledge further toward creative application. These studies provide a bridge between mathematics and basic sciences on the one hand and engineering practice on the other. Engineering design is the process of devising a system, component, or process to meet desired needs. It is a decision-making process (often iterative), in which the basic sciences, mathematics, and the engineering sciences are applied to convert resources optimally to meet these stated needs.” - ABET 2003-2004 Criteria for Accrediting Engineering Programs – Proposed Changes (Proposed Revisions of the General Criteria)

6. What else is engineering design? “Engineering design integrates mathematics, basic sciences, engineering sciences and complementary studies in developing elements, systems and processes to meet specific needs. It is a creative, iterative and often open-ended process subject to constraints which may be governed by standards or legislation to varying degrees depending upon the discipline. These constraints may relate to economic, health, safety, environmental, social or other pertinent interdisciplinary factors.” - CCPE/CEAB 2002 Accreditation Criteria and Procedures

7. 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 Technology:the set of procedures and tools that predictably and reproducibly produces a specified desired effect in the material world 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 And from the President of NSERC…

8. Engineers in the Global Economy • Domestic discipline specific engineering specialists are, in some industries, an endangered species • Highly trained, technically competent “offshore” engineers can be contracted for 10-15% of the cost • The solution? > “Value-added” engineers

9. What is a “Value-added” Engineer? • Sound fundamental engineering skills • Marketing/sales skills and awareness: user & market research, business savvy (negotiation, persuasion, confidence) • Business finance skills: cost estimation, capital & expense, sensitivity, P&L > KNOW THE NUMBERS • Design Innovation: balance of creativity, practicality, and risk (Know and use THE TOOLS) • Leadership and Teamwork: balanced and effective interaction with ALL disciplines and professions • Communication Excellence: clear and concise presentations and reports • Judgment: based on engineering principals, awareness of capabilities, ethical considerations, social responsibility

10. The Design Process • Design problems are typically “open-ended” and “ill-structured” • Design methodology is not discipline specific > it is a flexible process • Good design usually includes pleasing esthetics > the “art” of design • Design is typically subject by “constraints” • The design process can be applied beyond engineering

11. The (Simplified) Design Triangle Client Designer User

12. Who is involved in my design project? Safety Org’s. (CPSC) Corporate Mgt. Environmental Agencies Clients Corp. Finance Buyer/Agent Business Mgt. Fed. Gov’t (DOT, FAA,DOF) Corp. Legal Marketing Eng. Mgt. Safety/Liability Prov. Gov. (MOT,MOE,MOL) Finance Communications Corp. Regulatory Proj. Eng./Lead Sales Mun. Gov. Safety Rep. Industrial Design Reg. Bodies (CSA,UL) Reliability Eng. Other Eng. Quality Eng. Eng. Reg. (PEO) Regulatory Rep. Test Tech. Designer/Tech Manuf. Eng. Pkg. Eng. Ind. Ass’n. ANSI,IEEE Purchasing Machine Shop Model Makers Industrial Eng. Users Suppliers Prod. Associates Society Contractors Environment You are here Who is the customer?

13. Typical Requirements for Successful Design Projects • Thorough Research: problem identification, needs/market analysis, constraints > detailed (and agreed) product/process specification • Project Management: planning, organizing, leading, controlling> schedule & deliverables • Engineering science: estimation, math. and/or physical modeling, analysis, optimization • Teamwork: interdisciplinary and concurrent • Communication: regularly and clearly within and beyond team> reports, presentations, forums • Learning/Reflection: a lifelong requirement

14. A Linear View of the Design Process Client Statement (Need) Problem Definition Conceptual Design Preliminary Design Detailed Design Implementation Validation & Documentation

15. Client Statement • The starting point • May be from marketing, your manager, your external client • Typically brief with limited information and direction • Where do you go from here?

16. Problem Definition (Research) Clarify the Objectives • Client interview: objectives, constraints • Literature review: publications, IP (patents), web • User Needs/Wants: surveys, interviews, questionnaires • Compliance: regulatory codes and standards, legal considerations • Generate: revised problem statement, detailed objectives and functions, user requirements, constraints, CTQ’s

17. Conceptual Design • Establish the detailed design specification – function, performance, attributes, features and benefits, metrics (to objectives) • Competitive Analysis: benchmarking, reverse engineering (dissection) • Generate design alternatives > brainstorming, creativity techniques, sketching/rendering • Assess preliminary technical and economic feasibility • Tools: Morphological chart (feature/function vs. means), QFD (house of quality), functional analysis (function means tree)

18. Preliminary Design • Analyze selected conceptual designs (usually parallel path) • Basic engineering analysis and preliminary cost analysis • Consider safety, reliability, compliance, environmental factors • Construct early models and/or “Frankenstein” prototypes • Lab testing, preliminary field testing (preliminary test plan) • Client and user assessment and feedback • Tools: TRIZ, pair-wise comparison chart, focus group feedback, intercepts, public meetings

19. Detailed Design • Iteration and verification stage • Select the best design option(s) > create (iterative) math and/or physical models • Evaluate (analyze and/or test) > prove that design meets specification in terms of specifications: function, performance, user features, cost and compliance • Detailed test plan is required • Refine and optimize the design > maximize performance, minimize cost • Tools and methods: CAD, design reviews, DFMA, DFD, (D)FMEA, (P)FMEA, Hazards analysis, safety review, beta testing, user/public feedback

20. Final Validation and Documentation • Final design review – all parties • Final safety review – team & corp. sign-off • Submission for regulatory compliance testing (where applicable) • Documentation complete – “living” documents closed and signed off, full fabrication specs such as 3D models, detailed drawings, quality plan, purchasing/sourcing plan, implementation schedule

21. Implementation • Organized technology transfer - don’t “throw it over the wall” • Maintain communication with manufacturing, contractors, suppliers • Team effort continues until design is fully implemented • Track progress where applicable: user/public feedback, warranty returns, customer service; process/equipment operator feedback, performance, reliability • Design ownership: be prepared for “tweaking”

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

23. Project Management – Key to Success • Organization and scheduling • Teamwork and communication > respect, empowerment, conflict management • Concurrent Engineering – all parties involved early in the process • Cost estimation and control • Some common Tools/Methods: Gantt Chart, PERT Chart, Critical path analysis, Phase-gate Process, Panel charts

24. Engineering Economics • P&L statements – the language of business • Project Capital, Expense, Unit Cost • Cost estimation – material, labour, shipping, tariffs, amortized tooling & equipment • Use the resources – learn the language!

25. What else needs to be considered?

26. Some thoughts on Safety • Should be considered from day 1 • Assume anything that can go wrong will • Consider other ways that “customers” may use the product • Consider the safety issues over the long term • NEVER underestimate the significance of a failure in product testing • YOU are ultimately responsible

27. Some thoughts on Reliability • Rigorous reliability calculations are valuable in some cases • Thorough design analysis is critical (eg. fatigue, creep, environmental factors) • ABR – application based reliability • CDT – cycle destruct testing • Failure Life Prediction – Weibull analysis • How much is testing is “enough”?

28. Some thoughts on Responsibility • Ethical: cost, schedule & “spin” vs. quality & safety • Professional: judgment, capability, responsibility to the profession & society • Legal: ignorance is not an acceptable excuse – you are ultimately responsible

29. Practical Notes • The Design Process is not really linear • Verification loops and re-starts are common • Don’t lose sight of the objectives

30. The Design Challenge Speed Cost Quality It’s up to you to determine the right balance

31. The Value of Research and Communication in Design… As proposed by the sales department As understood by marketing As written in the product description First prototype for testing As built by manufacturing What the customer wanted!!