Bruce Mayer, PE Licensed Electrical & Mechanical Engineer BMayer@ChabotCollege.edu

1. Engineering 11 EngineeringDesign Cycle Bruce Mayer, PE Licensed Electrical & Mechanical EngineerBMayer@ChabotCollege.edu

2. PreReq  Identify an Opportunity • Idea emerges for an Engineered Product that will likely produce a minimum Return on Investment (RoI) • Described, at a minimum, by a list of Functional Requirements (FR’s) • Technical Function and Performance • Production Cost Target • Production Time Target

3. Design Elements  Need Schedule • Translate Functional Requirements (FR’s) into Quantitative & Object Design Requirements (DR’s) • e.g., FR = The product output has a UNIFORMITY of ±3% • DR1 = Temperature controlled 530 °C, ±4°C • DR2 = Pressure controlled to 290 kPa, ±15 kPa • DR3 = etc.

4. Design Elements  Need Schedule • BrainStorm Concepts • Preliminary: Analyze/Rank Concepts • Technical Risk/Feasibility • Search for “Fatal Flaws” • Schedule Risk/Feasibility • Cost Risk/Feasibility • Final: Evaluate most promising (no more than 3) Concepts • Detailed Calculations and/or Computer Models • SubScale Physical Testing • Cost & Schedule Comparisons • Select: Determine “best” Concept

5. Design Elements  Need Schedule • Conceptual Design • Explanation of HOW design MEETS the FR’s • Describe “Theory of Operation” • Form and Fit (LayOut Drawings) • Control System Schematics; e.g., Electrical, Plumbing, Optical, Ventilation, etc. • Identify & Describe System-Control Elements and the associated I/O points • Identify Suppliers for Critical Components

6. Design Elements  Need Schedule • Conceptual Design • Identify Fabrication Methods for Critical Components • Identify Critical Infrastructure; e.g., special buildings, machinery, instrumentation, etc. • CONCEPTUAL DESIGN REVIEW • CDR General Presentation Requirements • Be as detailed as your thoughts or concepts allow. • Clearly state where there are open questions or issues. • Be prepared for questions. Comments & Queries from the audience are encouraged.

7. Design Elements  Need Schedule • CONCEPTUAL DESIGN REVIEW • CDR Presentation content details • Define overall design constraints and requirements. • Describe concept(s) in detail, their features, tradeoffs, and how they will address the performance, cost, schedule, and customer requirements. • Define the top 3 reliability risks and how they will be mitigated • Show any test data obtained to date.

8. Design Elements  Need Schedule • CONCEPTUAL DESIGN REVIEW • CDR Presentation content details • Show key project milestones and decisions to be made between now and start of build. • COST REVIEW: Specific breakdown of cost estimates, including cost data sources • Detail Design • Fabricated-Part Drawings (BluePrints) • Material Selection • Material Processing/Finish • Tolerances and other inspection-Criteria

9. Design Elements  Need Schedule • Detail Design • Purchased-Part Specifications • Supplier: Name & Contact-Information • Supplier Part/Catalog number • Inspection/Test Criteria • Assembly Drawings and Instructions • Complete Parts List (a.k.a. Bill of Material) • Assembly Processes and Sequence-of-Events (SoE’s) • Assembly Specifications

10. Design Elements  Need Schedule • Detail Design • Detailed Control-System Schematics • Listing of I/O points • Describe Function of Each I/O point • CRITICAL DESIGN REVIEW • Test Data Supporting the Concept • C&F data presented where applicable or available • Design Presentation: How it meets subsystem and system requirements • Describe design, including performance and operation, critical design or build areas, how the design meets subsystem criteria

11. Design Elements  Need Schedule • CRITICAL DESIGN REVIEW • Functional Engineering BoM, ready for prototype release • Complete & Accurate BoM using Organization-Standard Format • BoM Cost estimate for production build • Purchasing quotes for "Big Hitter" items; std Company DataBase costs, Supplier quotes, published Catalog-Costs, educated estimates for other items

12. Design Elements  Need Schedule • CRITICAL DESIGN REVIEW • Fab and procurement drawings for prototype build • All fab drawings and new-component Item Control Sheet (ICS = Spec Sheet) used in that subassembly • Updated subsystem requirements table: IO, interfaces, performance & design requirements • Refined requirements that were presented at CDR, Detailed interface info

13. Design Elements  Need Schedule • CRITICAL DESIGN REVIEW • Listing of manufacturing risks • Simple statements of risks • Identification of manufacturing strategy: Make or Buy, Line or Cell, Manual or Automated, etc. • Simple statement attached to BoM components • Identification of supplier strategy: How/Who will supply components • Simple vendor ID attached to BoM components

14. Design Elements  Need Schedule • CRITICAL DESIGN REVIEW • Identification of inspection strategy: Supplier or Company inspection, critical areas • Simple statement of who is responsible for inspection of which critical parts • Inputs from Safety Engineering to assure compliance with Human-Safety and Ergonomics Standards (UL, CE, NEC, SEMI S2, ASME Pressure-Vessel Code, ANSI Z136 Lasers, etc.)

15. Design Elements  Need Schedule • CRITICAL DESIGN REVIEW • Inputs from Reliability Engineering for your subsystem: Reliability-Critical Items List (RCIL) compilation, suppliers needing audits or surveys • Simple identification of RCIL and affected suppliers • First-cut Identification of Field Replaceable Units (FRUs) • Preliminary FRU identification only

16. Design Elements  Need Schedule • CRITICAL DESIGN REVIEW • SubSystem Test Plans • Any level of subsystem test plan or subsystem test criteria is acceptable • Schedule for Open Items • Provide schedule for completion of any open CrDR deliverables

17. Design Elements  Need Schedule • ProtoType Construction & Testing • Built to CrDR BluePrints and Specifications; Iterate-on • Accuracy/Correctness of Documentation • Fabrication, Inspection, Assembly Process Improvements • Test & Iterate-on • Function • Performance • Reliability • SubSystem Testing

18. Design Elements  Need Schedule • ProtoType Construction & Testing • Test & Iterate-on • Inspection • EveryThing Else • Final Design • 99.99% Accurate (Goal is “Fire & Forget”) • Fabrication & Assembly BluePrints • Detailed INSTRUCTIONS if needed • Bill of Materials • Control-System Schematics

19. Design Elements  Need Schedule • Final Design • Finalized • Test Procedures • Inspection Documents • First Cut Instruction Manuals • Installation • Operation • Maintenance • Recommended Customer-Site Spare Parts

20. DilBertBrainStorming

21. All Done for Today EngineeringDesign Pyramid

22. Engineering 11 Appendix Bruce Mayer, PE Registered Electrical & Mechanical EngineerBMayer@ChabotCollege.edu

23. Rules for BrainStorming • Put judgment and evaluation aside temporarily. • Turn imagination loose, and start offering the results. • Think of as many ideas as you can. • Seek combination and improvement. • Record all ideas in full view. • Evaluate at a later session.

24. SCAMPER BrainStorming • S≡ substitute • C≡ combine • A≡ adapt • M≡ modify • P≡ put to another use • E≡ eliminate • R≡ reverse