lecture 3: introduction to engineering design eee2032: 공학입문설계 서강대학교...

Lecture 3: Introduction to Engineering Design

EEE2032: 공학입문설계

서강대학교 전자공학과 2012 학년도 1 학기

• Looking at what constitutes the design process.1. Recognizing the need for a product or a service,

2. Defining and understanding the problem (the need) completely,

3. Doing preliminary research and preparation,

4. Conceptualizing ideas for possible solutions,

5. Synthesizing the findings,

6. Evaluating good ideas in more detail,

7. Optimizing solutions to arrive at the best possible solution, and

8. Presenting the final solution.

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Engineering design process


• Step 1: Recognizing the need for a product or a service– Some of existing products are constantly being modified

to take advantage of new technologies.– In addition, new products are being developed every day

for the purpose of making our lives more comfortable, more reliable, and less laborious.

– “Every time someone complains about a situation, or about a task, or curses a product, right there, there is an opportunity for a product or a service.”

• What one has to do is to identify them.

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• Step 2: Defining and understanding the problem– One of the first thing to do as a design engineer is to fully

understand the problem.• The most important step in any design process.• By many questions:

– How much money are you willing to spend on this project?– Are there restrictions on the size or the type of materials that can be used?

– Engineers generally work in a team environment where they consult each other to solve complex problems.

• Good interpersonal and communication skills are increasingly important now because of the global market.

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• Step 3: Preliminary research and preparation– To collect useful information

• By searching to determine if a product already exists that closely meets the need of your client.

• This is the step the engineers spend lots of time not only with the client but also with other engineers and technicians.

• To review and organize the information in a suitable manner.

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• Step 4: Conceptualizing ideas for possible solutions– To generate some ideas or concepts that could offer

reasonable solutions to the problem• Without performing any detailed analysis, to come up with some

possible ways of solving the problem• Without looking at details of each possible solution yet, but

performing enough analysis to see whether the concepts have merit.

– The step includes creating milestone chart detailing the time plan for completing the project.

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• Step 5: Synthesizing the results– To begin to consider details

• To perform calculation, run computer models, narrow down the type of materials to be used, size the components of the system, and answer questions about how the product is going to be fabricated.

• To consult pertinent codes and standards and make sure that the design will be compliance with these codes and standards.

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• Step 6: Evaluating good ideas in more detail– Analyze the problem in more detail

• To identify critical design parameters and consider their influence in the final design

• To make sure all calculations are performed correctly• To perform experimental investigation if there are some uncertainties

in the analysis.• The best solution must be identified from alternations in this stage.

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• Step 7: Optimizing solutions to arrive at the best possible solution– Minimization or maximization– Two broad types of design:

• functional design• One that meets all of the preestablished design requirements but

allows for improvement to be made in certain areas• optimized design• Based on some particular criterion, such as cost, strength, size,

weight, reliability, noise, or performance.

– Optimizing individual components of a system does not necessarily lead to an optimized system

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• Step 7: Optimizing solutions to arrive at the best possible solution

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• Step 8: Presenting the final solution– To communicate the solution (design) to the client (boss,

another group in the company, or an outside customer).– An oral presentation and/or a written report– Engineers are required to give oral and written progress

reports on a regular time basis to various groups.

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• Economic factors always play important roles in engineering design decision making.– If a product is too expensive to manufacture, it can not be

sold at a price that consumers can afford and still be profitable to the company.

– Chapter 20 deals with the basics of engineering economics.

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Engineering economics

• Questions coming up when selecting material for products– How strong will the material be when subjected to an

expected load?– Would it fail, and if not, how safely would the material

carry the load?– How would the material behave if its temperature were

changed?– …

• Material properties and material cost are important design factors– Electrical, mechanical, and thermal– The manufacturers’ material property values should be

considered in the design. (Electrical resistivity, density…)

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Material selection

Consumer Product Engineering

• Acknowledgement: Boise State University and the William and Flora Hewlett Foundation

Engineers Improve Our World

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Engineers apply the principles of science and mathematics to develop

economical solutions to technical problems.

(US Dept. of Labor, Bureau of Labor Statistics, Occupational Outlook Handbook, http://www.bls.gov/oco/ocos027.htm )

“Science can amuse and fascinate us all, but it is engineering that

changes the world.”

Isaac Asimov (1920 – 1992)Russian-American biochemist & author

Consumer Products Engineering

• Engineers developing consumer products– They solve customer problems AND– Make money for their company

What Constitutes a Consumer Product?

• Tend to be high volume and mass produced (not “one-off” or limited run)

• Cost-effective solution based on market demands (quality vs. price tradeoff)

• Often low cost of manufacture is chosen over repair-ability by manufacturer

Developing a consumer product…

• Numerous engineering tasks required– Design products– Manufacture products– Test products– Distribute products– Support products

The best design is useless if it can’t be manufactured, distributed and purchased in a cost effective manner!

Engineering Design Process

• 1. Define the problem or need

Mice often carry hantavirus. Design a mousetrap to allow a person to trap and dispose of a mouse without exposure to

viruses carried by the mouse.

Engineering Design Process

• 1. Define the problem or need• 2. Gather information

– Shortcomings of existing solutions– Competitive Analysis– Environment for use– Economic factors

• 3. Brainstorm multiple solutions• 4. Select one solution• 5. Prototype and test the solution

Product Design Engineers*

• Start with an idea or problem to solve– Most successful when the customer needs are well

understood– Develop a set of product specifications

• Develop a solution – Iterative process– Invention - Intellectual Property– Intuitive and Ergonomic Use - Human Factors Engineers– Material selection & development– Material Science

Engineers– Component sourcing – Procurement Engineers

*Also known as:Research & Development (R&D) Engineers

Product Design Engineering Examples

Product Electrical / Computer Engineers

Mechanical Engineers

Cell Phones Configuration modes

Communication

Miniaturization

Design case / packaging

Durability

Personal Computers Design mother board & I/O boards

Performance

Design enclosures

Thermal management

Serviceability

Automobiles Instrumentation

Power Systems

Accessories – GPS, sound system, etc.

Design engine, drive train, chassis, etc.

Passenger safety

Product Development Models

• Internal Development• Original Equipment Manufacture (OEM)

– Sub-assemblies are sourced from another vendor• Personal computers - disk drives, fans, motherboards

• Outsourced development– Subassemblies or entire product developed by a 3rd

party per “customers” specifications• LaserJet printer engines developed by Canon with design

input from HP

• Re-branding 3rd party products– Near identical products sold as different options

• Automotive industry – Oldsmobile vs. Buick, Ford vs. Mercury

Engineering tasks become

progressively more project

management oriented!

Accessory Product Engineering

• Companies share interface specifications with 3rd parties to allow them to develop accessory products

• Why?– Provide greater capabilities for the “base product” = more

sales– Allows company to focus on “core competencies”

Accessory Products - iPOD

• “the market for iPod accessories is so huge that our offices can barely handle the periodic influx of new products ...”

• Broad Range of Choices…”transform the iPod into a fully functional stereo or just want to wrap it in a cool, scratch-resistant casing…”

http://reviews.cnet.com/4520-6450_7-1025145-1.html

Just a few examples… iPOD

• Belkin TuneStage • Bose SoundDock • CMO America ZipKord iPod USB

Synch & Charge • Creative i-Trigue i3350 • DLO HomeDock for iPod • FireJuice 4 (for iPod w/ Dock

Connector) • FireJuice 6 (for iPod w/ Dock

Connector) • Harmon JBL Creature • iCleaner iPod Scratch Remover

Pro • iPodSoft Pod Player 1.4.0 • Kensington Entertainment Dock

500 • Kensington StereoDock for iPod • Klipsch iFi

Klipsch iGroove Logic 3 i-Station8 (white)

Logitech Wireless Music System for iPod

Logitech mm50 Portable Speakers for iPod (white)

Monitor Audio i-Deck Onkyo DS-A1

Oregon Scientific iBall Radian iBlast (black)

SDI iHome iH5 Sonance iPort

Soundcast iCast Targus RemoteTunes digital

player accessory kit Tivoli Audio iSongBook

Rain Design iWoofer for iPod Apple iPod Hi-Fi

DLO HomeDock Deluxe

Manufacturing Engineering

• Manufacturing Process– Process design– Process support & maintenance– Continuous process improvement

• Product– Testing & quality control

The next unit will provide you with first-hand

experience!

Product Test Engineering

• Incoming raw materials to finished product• Design appropriate tests

– Meet product specification– Robust to survive use environment– Meet regulatory requirements

• Conduct testing & analyze results– During design phase– Monitor finished product quality

Product Distribution

• Supply-chain management & improvements– Opportunities for inventory management from production

to purchase– Requires significant Information Technology collaboration

• Technology improves efficiency– Barcodes– Radio Frequency ID (RFID) mircochips

Sales Engineering

• Used mainly for complex system sales• Specify system for customer environment• Technology - Customer Relationship Manager (CRM)

- institutionalize customer knowledge to provide better customer service

These are people-oriented jobs requiring excellent

communication skills & often frequent travel.

Product Support Engineering

• Problem solvers• Assist customer when problems arise• Determine “class” problems to be fixed with next

revision• Must balance customer satisfaction while

controlling warranty costs

Product Cost Contributors…

Raw Materials

Material Processing &

Manufacturing

Packaging

Marketing

Overhead

Margin

Final Purchase Price

Can you create a viable business where the purchase price =

$0.00?

Razors and Blades Business Model

• Pioneered by the King C. Gillette who used model to see razors and blades

• Base product sold at a substantial discount (or given away)

• Essential consumable or disposable parts are sold at a high profit margin

Examples – “Razors and Blades” businesses

• Electric toothbrushes and their brush heads • Computer printers and their ink cartridges• Game consoles and the games & peripherals• Cell phones and air time costs • Satellite television dishes/installation and

subscription costs • Blood glucose meters and costly single-use test

strips

ReferencesUS Dept. of Labor, Bureau of Labor Statistics, Occupational Outlook

Handbook, http://www.bls.gov/oco/ocos027.htm

The Engineering Student Survival Guide, Third edition, Krista Donaldson. McGraw-Hill’s Basic Engineering Series and Tools

http://en.wikipedia.org/wiki/Razor_and_blades_business_model

http://reviews.cnet.com/4520-6450_7-1025145-1.html CNET Reviews – Ultimate iPOD Accessories

“The World is Flat, A Brief History of the Twenty-first Century” by Thomas L. Friedman.

http://www.cio.com/research/crm/edit/crmabc.html Customer Relationship Management Research Center, The ABCs of CRM

“Engineers Toolkit, A First Course in Engineering”, Addison-Wesley Publishing Company, Inc.

• A design team: – a group of individuals with complementary expertise,

problem solving skills, and talent who are working together to solve a problem or achieve a common goal.

• Communication is an essential part of successful teamwork.– the individuals making up the team need to clearly

understand the role of each member and how each task fits together.

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Teamwork

• Employers are looking for individuals who not only have a good grasp of engineering fundamentals but who can work well with others in a team environment.1. The project that is assigned to a team must have clear

and realistic goals.2. The team should be made up of individuals with

complementary expertise, problem solving skills, background, and talent.

3. The team must have a good leader.4. The team leadership and the environment in which

discussions take place should promote openness, respect, and honesty.

5. Team needs and goals should come before individual needs and goals

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Common traits of good teams

• A team with members who represent the following secondary roles tends to be very successful.– Organizer

• Experienced and confident• Trusted by members of the team• Serves as a coordinator• Good at Clarifying goals and advancing decision making

– Creator• Good at coming up with new ideas, sharing them with other team

members, letting the team develop the dieas further, and solving difficult problems

• May have problems with following certain protocols

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• A team with members who represent the following secondary roles tends to be very successful.– Gatherer

• Enthusiastic and good at obtaining things, looking for possibilities, and developing contacts

– Motivator• Energetic, confident, and outgoing• Good at finding ways around obstacles and making objective

decisions

– Evaluator• Intelligent and capable of understanding the complete scope of the

project• Good at judging outcomes correctly


• A team with members who represent the following secondary roles tends to be very successful.– Team worker

• Tries to get everyone to come together• Does not like friction or problems among team members

– Solver• Reliable and decisive• Turn concepts into practical solutions

– Finishers• Counted on to finish his or her assigned task on time• Detail orientated• May worry about the beam’s progress toward finishing the

assignment

• Conflict could be the result of miscommunication, personality differences, or the way events and actions are interpreted by a member of a team.– Managing conflicts is an important part of a team

dynamic.

• Good communication is an integral part of any conflict resolution.– One of the most important rules in communication is to

make sure that the message sent is the message received – without misunderstanding.

– Team members must listen to each other.

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Conflict Resolution

• Project scheduling– A process that engineering managers use to ensure that a

project is completed on time and within the allocated budget.

– A good schedule will assign an adequate amount of time for various project activities.

– ex) MS Project: http://www.youtube.com/watch?v=przuiHWROlk

• A well planned schedule could improve the efficiency of the operation and eliminate redundancy in task assignments.

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Project scheduling and task chart

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Project scheduling and task chart

• Assigning a level of importance to each design criterion. (I)– A scale of 1 to 5: 1 means little importance, 5 for

extremely important.

• Rate each workable concept in terms of how well it meets each design criterion. (R)– 3 for high, 2 for medium, and 1 for low.

• Add the R×I scores for each design and select the design with the highest overall rating.

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Evaluating alternatives

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Evaluating alternatives

Team Work

• Design the best cellphone for the 1st year college student• 3/21, 3/23

• New designs and inventions need to be shared if they are to bring about improvements in everyone’s lives.

• At the same time the person(s) who comes up with a new idea should benefit from it.

• Means for protecting others from stealing someone’s new ideas and inventions -intellectual property.

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Patent, trademark, and copyright

• Patent– When you come up with an invention, in order to prevent

others from making, using, or selling your invention, you may file for a patent with the patent office.

• Trademark / service mark– Name, word, or symbol that a company uses to distinguish

its products (or services) from others. – ex) Coke®, Pepsi®

• Copyright– A form of protection provided to the authors of “original

works of authorship.” – literary, dramatic, musical, artistic, and other types of intellectual works and its obtainable for both published/unpublished.

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• Miscellaneous– Patent

• 특허와 실용신안등록의 요건• 자연법칙을 이용한 기술사상인가 ?• 산업상 이용할 수 있는 것인가 ?• 새로운 발명인가 ?• 종전의 있던 발명보다 진보된 발명인가 ?• 불특허사유에 해당되지 아니한 것인가 ? ( 공공질서 , 국방상 )• 명세서에 발명이 구체적으로 기재되고 청구범위는 명확한가 ?

– 다른사람보다 먼저 출원하였는가 ?• 존속기간• 특허 : 출원일부터 20 년 , 실용신안 : 출원일부터 10 년

• Why do we need standards and codes?– To ensure product safety and reliability in services.

– Standards and codes ensure uniformity in the size of parts and components that are made by various manufacturers around the world.

• Examples: – tires (page 56)

– Shoe and shirt sizes (table 3.5, page 57)

– credit cards and film speed (page 57)

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Engineering standards and codes

• ANSI (The American National Standards Institute)• UL (Underwriters Laboratories)

– A nonprofit organization that performs produce safety tests and certifications.

– Labs in US, England, Denmark, Hong Kong, India, Italy, Japan, Singapore, and Taiwan.

• ISO (The International Organization for Standardization)

• Standards in– Drinking water, outdoor/indoor air quality

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Examples of standards and code organizations

lecture 3: introduction to engineering design eee2032: 공학입문설계 서강대학교...

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