W1 ICD Intro v13

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ENG 4050L Interdisciplinary Competitive Design

Prof. F. Campean / 2013-14

ENG 4050L

INTERDISCIPLINARY

COMPETITIVEDESIGN

Week 1: Introduction

WHATIS

COMPETITIVEDESIGN?

Share your thoughts with your colleagues and

decide on two important features ofInterdisciplinary Competitive Design

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WHATFACTORSUNDERPIN

COMPETITIVEENGINEERINGDESIGN?

Consumers Viewpoint:Think of a product that you are likely to buyphone, camera, laptop, car,

Manufacturing Viewpoint:Think that you would have to manufacture this product

Business Viewpoint:

Think that this is your venture

Society Viewpoint:Think of your children

ENGINEERINGASPECTS

OFCOMPETITIVEDESIGN

Design and develop competitive products that people want (to buy);

that perform the required function in a reliable and robust

manner;

compliant with standards;

Sustainable and future proof;

Efficient design process reduced time to market

reduced development costs

Easy to manufacture

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WHATSKILLS DOYOUNEEDFORCOMPETITIVEDESIGN?

Competitive Design LecturingTeam

Prof. Felician Campean Ford Suite, B.1.33, x4569

Dr. Martyn Jupp

Mr. Nigel Revitt

Dr. Steve Wright

Prof. Ed Henshall RAEng Visiting Prof in Integrated System Design

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Module aims

Develop knowledge and skills in design

process and application of engineering tools

that support competitive design;

Enhance your readiness to work in industry

perform in a teamwith clear focus /

objectives / constraints;

Develop your skills to work independentlydefineplanexecutereport.

Organisation of module

Linked modulewill continue in Sem 2

Project based assessment

Student led projects

Focus on creativity, innovation and

comprehensive / integrated approach to

design

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Competitive Design Project

Group projectsteams of 3-5

A substantial piece of work!

Coursework Facts: 20 credit module means 200 hours of work per student,

i.e. 800 man-hours per group!

Circa 6,000 words equivalent per student, 24,000 per

group (cca 100 pages)


Coursework Schedule:

S1/week 3 - 4: Task given to

students

S1/week 8/9: Project Stage 1

submission + team presentations

and feedback;

S2/week 4/5: Project Stage 2

submission + team presentations

and feedback;

S2/week12: Final project

submission + poster

presentation.

Stage Submissions

formativeAND summative

assessment

i.e. you will be given

feedback which you can

incorporate in your final

submission, but interim

submissions are marked as

well!

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Project

PhaseContent Guideline Assessment

Weight in

final mark

Stage 1

Project definition / brief

Project planning

Initial work

Design Requirements

Report 1 (cca 1000 -

1500 wps)

Presentation (ppt)

10%

Stage 2

Literature review

Concept generation

Concept analysis / critical

evaluation

Concept selection

Report 2 (cca 3000 -

3500 wpscumulative

with R1)

Presentation (ppt)

20%

Stage 3 /

Final

Design development (for

selected concept)

Robustness, Failure Mode

Avoidance assessment Design Verification &

Validation

Final report (cca 6000

wps, cumulative with R1

&2)

Poster presentation

60%

10%


Examples of past projects: Sustainable commuter transport system for the Bradford ecoversity

A generic design for a spinal injuries unit

Development of an alternative synchronous power transmission / camshaft

actuation for an automotive IC engine application

Design of an alternative braking solution for cars

Steer -by-wire system for road vehicles

Use of metallic and polymer foams in automotive body shells

The design of a jacking device for use on rally cars

Design and build a prototype working roof system for the quantum H4 sports

car

Tyre pressure monitoring and control system

Evaluate the feasibility of utilising a turbo charger for driving ancillaries

Design a sensor systems for the detection of pedestrians

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Semester 1 & Semester 2: Formal lectures / talksseminar style

Directed study

Project work

Project clinics

B.1.31 Ford Suiteusually available as

resource for teamwork


Sem Week Date Lecture / Class activity Coursework Milestone

2 27-Sep Overview of Design Process

3 04-Oct Customer Focused Engineering

4 11-Oct Team Work Skills Coursework set-up (latest)

5 18-Oct Concept Generation and Selection

6 25-Oct Concept Generation and Selection

7 01-Nov Coursework Cl inic

8 08-Nov Systems Engineering9 15-Nov Coursework Cl inic

10 22-Nov Project Presentations Stage 1 Submission

11 29-Nov

12 06-Dec FMEA

13 13-Dec Coursework Cl inic

S

em1

Clinic & Feedback - Stage 1

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OVERVIEWOFSYSTEMSENGINEERINGDESIGN

What is Engineering Design?

What is Systems Engineering Design?

What are the Product Development

Process Steps?

Imagine designing the following products:

Automobile

Bicycle

Coffee maker

Commercial jet

Fishing reel

Mobile phone

Laser printer

Millenium Bridge

Spinal Injury Unit

GPS device

Hydrogen power generator

DAB radio

Are all design problems the same?

What is Design?

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What is Design?

FunctionsI want to get to the

ICD classI need to talk to my

friends ASAP...

Solutions

esign

Definition of Design

Set of decision making processes andproblem solving

activities to determine theform (architecture,

structure)of a product, given the customers desired

function.

Engineering 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 engineering sciences are

applied to convert resources optimally to meet a stated

objective

Accreditation Board for Engineering and Technology

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Engineering Design

Form ever follows function[Louis Sullivan]

Steps in Engineered Product Development: Identify the Function

Engineering design - deliver a product solution for the

desired function

Verify and validate


What is a system?

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What is a system?

Complex whole;

Set of connected things or parts;

Organized body of material or immaterial

things, arranged to work together.

- Oxford English Dictionary.

Every system

Has function or purpose Has inputs and outputs

Is not just a collection of parts

Contains interacting sub-systems

Systems Thinking

System is greater than sum of its parts

System is no stronger than weakest part

Optimising parts does not optimise the whole.

Interactions determine the performance of a

system

The whole system cant be fully understood by

breaking it down and analysing parts - yet

design is historically done by analysing parts.

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Systems Engineering

Systems Engineering is an interdisciplinary approach and

means to enable the realization of successful systems. It

focuses on defining customer needs and required

functionality early in the development cycle, documenting

requirements, then proceeding with design synthesis and

system validation while considering the complete problem:

Operations Performance Test

Manufacturing Cost Schedule

Training Support Disposal

INCOSE

International Council on Systems Engineering

Systems Engineering

Systems Engineering integrates all thedisciplines and specialty groups into a teameffort forming a structured developmentprocess that proceeds from concept toproduction to operation.

Systems Engineering considers both thebusiness and the technical needs of allcustomers with the goal of providing aquality product that meets the user needs.

INCOSE

International Council on Systems Engineering

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Systems Engineering Designthe

Vee Model

Vehicle

Sub-system

I

Sub-system

II

Sub-system

II

Sub-system

I

Vehicle

Compo-nent

Design Optimisation

Compo-nent

Systems Engineering [Ford Model]

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Systems Engineering [FHWA]

http://www.fhwa.dot.gov

Systems Engineering

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Design

intent

Customer

Requirements

Design

conceptManufacturing

concept

Product

Design

Production

Control

Plan

Design

Verification

Process

Design

This is a generic engineering design process

Product Creation Process

Design

intent

Customer

Requirements

Design


concept

Product

Design

Production

Control

Plan

Design

Verification

Process

Design

This is a generic engineering design process


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Design Intent

Finding out the Customer Requirements helps

to:

Identify/Define Product Functions/Functionality,

Establish Engineering Targets,

Define the PDS (Product Design Specification)

Design

intent

Customer

Requirements

Design


concept

Product

Design

Production

Control

Plan

Design

Verification

Process

Design


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Design ConceptThe Design Concept follows on from the Design Intent

and must meet the PDS:

Encourage innovation, but also look at what has been donebefore. Learn from other fields.

Get a team together; use structured techniques that supportinnovative thinking.

Use analytical methods to evaluate the functionality androbustness of a Design Concept - the Transfer FunctionApproach.

Use a structured (matrix based) approach to evaluatealternatives and select a winning concept (Pughs ConceptSelection)

Manufacturing concept

The Manufacturing Concepts must be developed

concurrently with the Design Concept:

Think about how you will make it while you are designing it -

Simultaneous Engineering.

Use analytical methods to evaluate the capability of

proposed manufacturing concepts - look for causes ofvariation and analyze their effects.

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Design

intent

Customer

Requirements

Design


concept

Product

Design

Production

Control

Plan

Design

Verification

Process

Design


Product Design

Complete the Detail Design to meet the PDS.

Includes engineering design (function) and

aesthetic design (form).

Integrated with manufacturing process design.

The functionality of the design must be confirmed

at all stages.

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Process Design

Complete the Process Design to meet the PDS

Consider:

Supplier / Customer Chain.

Business Processes.

Manufacturing Processes

Development Processes.

Verification and Validation Processes.

ISO standards.

Design

intent

Customer

Requirements

Design


concept

Product

Design

Production

Control

Plan

Design

Verification

Process

Design


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Design Verification & Validation

Verification: Have we got the product right?

Does the product achieve the specified function?

Validation:

Have we got the right product?

We need to be confident that the design will

deliver its intended function over its lifetime.

Process Validation

We also need to be confident that the process will

deliver a consistent product over its lifetime:

Confirm that the manufacturing process is stable and

capable.

Confirm that all manufacturing processes and business

processes are robust and reliable.

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Control Plan

Product Quality Plan

Material specifications,

Quality System procedures,

Product data,

Process control,

Inspection procedures,

Packaging and distribution specifications.

Design

intent

Customer

Requirements

Design


concept

Product

Design

Production

Control

Plan

Design

Verification

Process

Design


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Production

Once all these design steps are complete, the

Production phase can be started.

In practice, production will be ramped up through a

series of commissioning or trial production

operations.

At each stage the product characteristics and

process performance are measured to ensure that

the planned Design targets are met.

Remember that the best components dontnecessarily add up to the best system!

Systems Engineering design is about managing interfaces!

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Ulrich & Eppinger

Pughs Total Design

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Competitive Design Curriculum

Focused on tools that support the thought

experiments that are essential to good

engineering applied to complex / system

engineering design;

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Literature for Engineering Design

Pahl & Beitz - Engineering design : a

systematic approach

Ulrich & EppingerProduct Design and

Development

PughTotal Design

Clausing - Total quality development : a step-

by-step guide to world class concurrentengineering

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