CEID Annual Seminar 2012CEID Annual Seminar 2012
O Y Mi dOpen Your Mind: Technology for SystematicTechnology for Systematic
Inventing
Leonid Chechurin,Leonid Chechurin, Innovatics Theory Dept., Head, SPb State Politech University
cepreu4@gmail [email protected]
LUT 21 March 2012LUT, 21 March 2012
Chechurin, Leonid1993 – Graduated from Physics and Mechanics Dept. of SPbSPU
Chechurin, Leonid
1997 – received PhD in System Theory at Technical Cybernetics Dept. of SpbSPU1998 1999 invited Professor at Kum Oh National University of1998-1999 – invited Professor at Kum-Oh National University of Technology, South Korea1999-2001 – TRIZ consultant at Samsung Monitor Company (Seoul, South Korea)2001 – currently – Head of Innovatics Theory Dept. of SPbSPU2005 2006 Engineer for Design Engineering Group at LG Electronics2005-2006 – Engineer for Design Engineering Group at LG Electronics Production Engineering Research Institute (Osan, South Korea)2007- 2011 – TRIZ consultant at Algorithm (Gen3 Partners, Inc.) company (supplier for GE, Siemens, Wrigley, BAT, FMC, …) 2010 – received Doctor of Science Degree in Robustness Analysis of Dynamic SystemsDynamic Systems2011 Sept-November – Research Fellowship at Politecnico di Milano (Italy)
ContentsContentsContentsContents
Introduction. Creativity in Engineering,Introduction. Creativity in Engineering,
TRIZ inside Theor and methodologTRIZ inside. Theory and methodology outlines
TRIZ acceptance by the industry andTRIZ acceptance by the industry and academia
TRIZ: Теория Решения Изобретательских Задач
<Teorija Resheniya Izobretatel’skih<Teorija Resheniya Izobretatel skihZadach> =
Theory for Inventive Problem S l i (TIPS)Solving (TIPS)
What does it mean “to improve a pproduct, technology of service”?
1. Optimizing within a given structure over i t f t ( ll d l dgiven set of parameters (well developed
or heuristic methods of optimization)p )2. Development of new structure, new
t id i ti /i ticoncept, idea: invention/innovation
Optimization can be assisted by a number of powerful optimizing tools, but it is still the best choice from a given box “thinking in the box”the best choice from a given box, “thinking in the box”Finding innovative concept is not assisted by formal procedures, because formally speaking it is … incorrect problem set up or “Thinking out of the box”. There are first attempts only to enter this domain like topology optimization.
Picture source: Minimizing the acoustic coupling of fluid loaded plates using topology optimization. Khalid H Almitani, PhD Dissertation, University of Maryland: 2009
Abstract available at http://www.grin.com/en/doc/271915/minimizing-the-acoustic-coupling-of-fluid-loaded-plates-using-topology
Difficulties of InnovationsDifficulties of Innovations
3 000 Raw Ideas
10,000Innovations are
Difficult and Risky3,000 Raw Ideas
300 Solid Ideas
1000
Difficult and Risky
300 Solid Ideas
125 Projects100
9 Early Stage Developments104 In-Depth Developments
1.7 Market Enterings
1 Success1 1 Success1
1 2 3 4 5 6 7 Stages of New Product DevelopmentSource: G. Stevens and J. Burley, “3,000 Raw Ideas = 1 Commercial Success!” Research•Technology Management, 40(3): 16-27, May-June, 1997.
Product Development
S th P bl tSo, the Problem set up1. Innovation is the (only) way to survive in market economy.
[1] B.Klein “Dynamic Economy” Harvard Univ. Press, 1977
2 Innovations are risky Proper idea means a lot for the success
[1] B.Klein Dynamic Economy Harvard Univ. Press, 1977[2] Export/Import balances in royalties of developed countries
2. Innovations are risky. Proper idea means a lot for the success.
[3] G. Stevens and J. Burley, “3,000 Raw Ideas = 1 Commercial Success!” Research•Technology Management 40(3): 16-27 May-June 1997
3. Everything is CAD-ed, automated and/or virtualized. But conceptual design (design of idea) is not still
Research Technology Management, 40(3): 16 27, May June, 1997.
design (design of idea) is not still.
Design ManufacturingBefore CAD/CAM
Idea
Design ManufacturingAfter CAD/CAM (private evaluation based on experience)
Idea g g
[4] S.Pugh “Total Design” Addison-Wesley Publishing Company, UK, 1991
Innovation software kitSome of computer-aided technologies
Product Design
M ti M ti
Computer-aided architectural design (CAAD)Computer-aided design and drafting (CADD)Computer-aided industrial design (CAID)
? Drawing(Product)
Motionsimulation
(kinematics)
Motionsimulation(dynamics)
Simulation offields
Computer-aided engineering (CAE);Computer-aided manufacturing capability (CAMC);Computer-aided manufacturing (CAM);
?Manufacturing Process Design (Physical)
DrawingMotion
i l tiMotion
i l tiSimulation of
Computer-aided material information (CAMI);Computer-aided package selection (CAPS);Computer-aided process planning (CAPP)C t id d ft i i (CASE)Drawing
(Equipment)simulation
(kinematics)simulation(dynamics)
fieldsProduct
Data
Computer-aided software engineering (CASE);Component information system (CIS);Coordinate measurement (CMM);Electronic design automation (EDA);
Manufacturing Process Design (Operational)
E t i
Electronic design automation (EDA);Enterprise resource planning (ERP);Manufacturing Process Management (MPM)Manufacturing process planning (MPP);
Product/ProcessData
Technical Data Processing
EnterpriseResource Planning
EnterpriseOperation
Manufacturing process planning (MPP);Manufacturing resource planning (MRP);Product data management (PDM)Product lifecycle management (PLM)Product lifecycle management (PLM)Reverse engineering (RE)
Example of Conceptual Design: Moon Car Headlight bulb (196X USSR)Headlight bulb (196X, USSR)
2nd Example from Airspace IndustryIndustry
“Solution”
C i h Counter-weightCounter-weight Counter-weight
“The rocket holds itself”The rocket holds itself
Creativity: who is on the market?Creativity: who is on the market? Brainstorming (Osborn 1930x) Brainstorming (Osborn, 1930x) Morphological box (Zwick, 1942)
S ti (G d 1944) Synectics (Gordon, 1944) (?) General methods of Quality ( ) y
improvement: TQM, 6 sigma, QFD, others
Theory of inventive problem solving -TRIZ (G Altshuller 1956)TRIZ (G.Altshuller, 1956)
ContentsContentsContentsContents
Introduction. Creativity in Engineering,Introduction. Creativity in Engineering,
TRIZ inside Theor and methodologTRIZ inside. Theory and methodology outlines
TRIZ acceptance by the industry andTRIZ acceptance by the industry and academia.
Short history of TRIZ First publication in 1956. A method
of inventive thinking for engineersof inventive thinking for engineers, Based on the analysis of 40.000+ y
patents,Genrikh Altschuller, the founder of TRIZ
Was widely accepted at big manufacturing plants in the USSR
(1924-1998)
manufacturing plants in the USSR(Leningrad, Minsk, Kishinev, …).
TRIZ TodayClients: Ford Motor Company, Chrysler, Renault, Procter & Gamble, Oracle, Samsung Group, LG Group, POSCO, General Motors, General Electric, Intel, Wrigley, Alcoa,…
Service providers: (education/consulting) Algorithm (Russia, St.Petersburg)+Gen3 Partners (Boston, MA), Insyntec (Holland), CREAX, Systematic Innovations, School for Innovatics of SPbSPU,
Software: Knowledgist®, TechOptimizer® -> Goldfire (Invention Machine Co., Boston, MA), Co-Brain®, etc
“Competitors”: Trial and Error, Brainstorming, 6σ, TQM, 6 sigma, Taguchi method, fishbone analysis, othersy
TRIZ world: International Association of TRIZ (MATRIZ), ETRIA, RuTRIZ, TRIZ expert certification, TRIZ e-proceedings, web-sites and books.
Wh t i i id TRIZ?What is inside TRIZ? A way of (functional) modeling of a technical
system or a product. Formalism of modifying the models to
improve them. A set of best engineering practices to apply
the required modification to real system (C t di ti Eli i ti T h i Id l(Contradiction Elimination Techniques, Ideal Final Result Concept)T d f T i l E i i S t Trends of Typical Engineering System evolutionAl ith f b tt h d l i f Algorithms for better search and analysis of patents and technical information.
Modeling… why?
Formalism
λλ= β=β=/2World of Ideas
modeling interpreting,realization
“Reality”
I i i l Si i N Si iTrial and Error Method
Initial Situation New Situation
Modeling: ExamplesModeling: Examples1. Situation: cup drop Math model of free movement of a
body in gravity field
)( gtx
0
0
)0()0()(
xxxxg
where x(t) – linear coordinate of a body of mass 1, g – gravity constant.. etc
2. Situation: Operation of Function model in IDEF0 standardcompany department
Abstract Modeling Techniquesg q
Verbal model,
Function Model
Flow Model Mathematical model
St ti D iDrawing Static Dynamic
Description A Graph A Graph of System of System of pof the object and its functioning
pcontaining system elements and their
pFunction modelwhere certainparameters are
yequations describing the interactions of
yequations describing the interactions of
by natural language
interactions in the form of Functions
observed in their distribution
elements with each other and the environment
elements with each other and the
(“Flow”) over elements or operation time
environment in the past and in the
tpresent
Complex, speaks language thatis not understood by many Requires clear
Easy“Does not require mathematics!” is not understood by many. Requires clear
problem setup. Provides measurable results, has powerful model manipulation toolboxes
Does not require mathematics!Good for structural decisions only
No measurable quality index
Example. Trend of Dynamization and Adaptivity increase
Self-adaptive system
Adaptive system Y
R bAL
IT
Robustsystem
IDE
A
Rigid systemsystem
T I M E
Example: A Chair
?
initial robust(optimal)
adaptive Self-adaptive(optimal)
Example: A web-site interfaceExample: A web site interface design
DobroBienvenido!pozhalovat’! Bienvenido!
Welcome, Leonid!Your neck-tie is terrific.
rigid robust adaptive self-adaptive
Example of self-adaptivity: Apple iP diPod
US 20060107822 A1M i h i tiMusic synchronization
arrangement May 25, 2006
S lf d ti
Adaptive system
ITY
Self-adaptive system
Robust system
IDE
AL
IRigid
system
T I M E
Example: Technical ContradictionsEli i i T h iElimination Technique
BBE
TT
ER
PanelSize
SMstability
R W
O( , ((OR
SE
CRT panel has to be big,p gbut bigger Shadow Mask is unstable
Example: pFrench Door Refrigerator DIOS
Drawer sliding rail ( 2 kGf)
Problem
Drawer sliding rail (~2 kGf)
Problem decomposition
Drawer sealing with magnet strip ( 3 kGf)High drawer opening force (6 7 kGf)
Contradiction: For good energy efficiency the drawer sealing should be
Drawer sealing with magnet strip (~3 kGf)High drawer opening force (6..7 kGf)
Contradiction: For good energy efficiency the drawer sealing should be strong. But for easy opening it should be weak.
IFR: Perfect sealing being closed, zero resistance being opened. No changes in manufacturing
Easy Door Open
1. Drawer sliding railPresent
g
Rail Slider Spring ContradictionsContradictions
- should be strong to prove complete closing
- should be weak to open door easily
New Idea
p y
S ti i ti &TRIZ principles TRIZ principles
Separation in time & space
Reduce 17% opening forceEffectEffect
New idea can satisfy both open and closing situationVirtual prototyping
2. Drawer Sealing design
Current design Door
body
Current design
Door
bodyy
«Breaking the symmetry» idea
Virtual prototypingNew design
Implemented in all LG refrigerators, patented in Korea EU and USA without my name among inventors patented in Korea, EU and USA… without my name among inventors
In entingInventing:
Non Systematic3 years ago there was a similar problem in my uncle’s company….
Non-Systematicy g p y p y
?How about changing of color?..
We have to come up with FEM for all mechanics!!
Systematic InventingFunctional Modeling
Systematic Inventing
Contradictions
Trends
OT, OZ, IFR?
Contradiction Elimination
, ,
Concept of Solution
Not goodEvaluation
Good
Report
Example of the automation of Function Modeling
z
xy
Introducing trimming and function ranking to SolidWorks based on function analysisIntroducing trimming and function ranking to SolidWorks based on function analysisLeonid S. Chechurin, Wessel W. Wits, Hans M. Bakker & Tom H.J. VanekerIn Proceedings of the TRIZ Future Conference, Dublin, Ireland, pp. 215-225, 2-4 November 2011
Where to Apply?Where to Apply?P d t I t & P I t Product Improvement & Process Improvement
New Product Development & New Process Development T h l F ti Technology Forecasting
IP Strategy Development Design for Recycling and Reuse Innovation Opportunity Assessment Leveraging Technology Core Competence Technology Validation
T h l E l ti (T h i l D Dili ) Technology Evaluation (Technical Due Diligence) Technology Search Failure Exploration and Elimination Failure Exploration and Elimination Innovation Portfolio Analysis
Some quotations:"TRIZ as a creative approach to design has been the most valuable tool I've ever been exposed to in my engineering career. It is a necessary ingredient
f i i I h d d th TRIZ t th ifor reengineering. I have recommended the TRIZ courses to others in my company."
Mario Fantoni,Director (former), Oracle
"The ultimate worldwide impact of TRIZ upon technology driven businessesThe ultimate worldwide impact of TRIZ upon technology driven businesses could easily match the impact of CAD systems on new product design."James P. Dunn, Director (former), CTC, NASA Regional Technology
Transfer Center
ContentsContentsContentsContents
Introduction. Creativity in Engineering,Introduction. Creativity in Engineering,
TRIZ inside Theor and methodologTRIZ inside. Theory and methodology outlines
TRIZ acceptance by the industry andTRIZ acceptance by the industry and academia.
Industry TRIZ usersTRIZ has shared in the success of hundreds of companies and i di id l ld id O i iindividuals worldwide. Our position as a technological leader in the inventive problem-solving arena is the result of their visions, their ability to reach beyond the obvious andto reach beyond the obvious, and their unwavering commitment to excellence. Collectively, they serve as the catalyst that challenges us to continue to develop and advance ourcontinue to develop and advance our products and services. A few of them are:
A.Kynin Examples MLCC‐10083139
http://www.envisage-consultancy.com/clients.htm
Some TRIZ Success Cases
Boeing 767 refueling system by Boeingg g y y gTRIZ helped to develop a new refueling system forrefueling system forBoeing 767 aircraft, which resulted in extra sales of 1.5 billion US dollars.“A TRIZ k h l ti“A TRIZ workshop solution was developed for the 767 Tanker (air-to-air refueling) aircraft project. As a result of that TRIZ solution, the program was successfully launched with a customer who preferred thewith a customer who preferred the TRIZ solution over the competitions solution for the same system, thereby ordering aircraft from Boeing “ordering aircraft from Boeing.
Don MasingaleAd d R h E i iAdvanced Research Engineering Program Manager,Boeing, USA
http://www.xtriz.com/documents/TRIZSuccessCases.pdf
Crest Whitestrips by Procter & Gamble(Gen 3 Partners Project)(Gen 3 Partners Project)
“TRIZ was used to develop Crest Whi i ™ f P & G bl (P&G)Whitestrips™ for Procter & Gamble (P&G). From a TRIZ perspective, the key problem was that tooth whitener should be on the teeth to bleach, and it should not be on the teeth to avoid contact with saliva. A TRIZ concept, a thin flexible film saturated withconcept, a thin flexible film saturated with whitener that selectively adhered to teeth, proved to be the answer. Whitestrips was P&G's most successful product launchP&G s most successful product launch ever, generating $130 million dollars of sales in the first year of operation while
t i 45% f th hit icapturing over 45% of the whitening market.”Larry R. SmithPresident, Altshuller Institute for TRIZ Studies, Inc, USA
http://www.xtriz.com/documents/TRIZSuccessCases.pdf
Results of TRIZ application at Samsung pp g
43Prof. A.T.Kynin ©, 2010‐12 Introduction
Results of TRIZ application at Samsung pp g
44Prof. A.T.Kynin ©, 2010‐12 Introduction
TRIZ at AcademiaTRIZ in SCOPUS-indexed publications
Number of Publications
YearYear
Main Publishers of TRIZ papersJournal Amount of
P
Main Publishers of TRIZ papers
Papers
Procedia Engineering 60
Advanced Materials Research 31
IFIP International Federation for Information Processing 25
Computers in Industry 12
Jisuanji Jicheng Zhizao Xitong Computer Integrated Manufacturing S t CIMS
12Systems CIMS
Zhongguo Jixie Gongcheng China Mechanical Engineering 10
ASEE A l C f d E iti C f P di 10ASEE Annual Conference and Exposition Conference Proceedings 10
International Journal of Product Development 10
E t S t ith A li ti 9Expert Systems with Applications 9
Lecture Notes in Computer Science Including Subseries Lecture Notes in Artificial Intelligence and Lecture Notes in
9Notes in Artificial Intelligence and Lecture Notes in
Bioinformatics
TRIZ t A d iTRIZ at AcademiaWorld: see matriz.org “TRIZ at Academia”.
Russia: Part of Obligatory Curricula for the Russian Universities licensed to teach Innovatics (60 Universities) –Universities licensed to teach Innovatics (60 Universities) –part of “Federal Educational Standard”
Finland: Kalevi Rantanen (TRIZ OY, Finland): a number of seminars with a Finnish youth organization consultingseminars with a Finnish youth organization, consulting, science/engineering journalism (kalevi rantanen@kolumbus fi )([email protected] )Prof. Asko Riitahuhta (University of Tampere)
Conclusions1. Creativity can be taught (…or outsourced)outsourced)2. Conceptual Design can be systematic, assisted by a methodologymethodology3. TRIZ acceptance is growing, faster i i d t th i i din industry then in science and academia.
Thank you!
and visit the first TRIZ conference…and visit the first TRIZ-conference in Finland!!
TRIZfest-2012TRIZfest-2012
L t U i it f T h lLappenranta University of Technology,Aug 2-4, 2012
http://www lut fi/trizfest2012http://www.lut.fi/trizfest2012
Annex: Some Examples and pDiscussions
?
Why Real Mathematician is not the best partner for Engineerfor Engineer
Model of the problemExample or Engineering Problem
Reaction of a mathematician
1. Find the best candidate over 1. Good problem!1. Optimize the
t f
pEngineering Problem mathematician
candidate over the given discrete space f ti
amount of spikes in the spike wheel of options
2. Find the best 2. Challenging but
spike wheel
2. Optimize the fil f th 2. Find the best
candidate over the given infinite
t f ti
good problem!profile of the spike
set of options
3. Find the best 3. “Your problem is 3. “Optimize” the
wheel design bi i 3. Find the best
candidate over the indefinite
( ) f
not well-defined”.
combining available technologies, space(s) of
options…
technologies, materials, …
DiscussionThe easiest way to improve the situation that is described by the
mathematical model is to optimize. That is what is taught in p guniversities! So, “math is needed for optimization” attitude
M th ti i lik i f t t i fil d (“N liMathematicians, like engineers, prefer to stay in one filed (“Nonlinear Equations”, “Control Theory”, “Oscillation theory”… It is also thinking inertia that can result in unnecessary limitations.y
“Mathematics is the art of giving the same name to different things” (Henri P i )Poincare)
99% of real life engineering problems would be called “incorrect g g pproblems” by mathematicians. Problem description and the goal are unclear
What “small changes” mean for a mathematical model? Sometimes it is possible to introduce a quantitive index of “simplicity” in math,
“Ssometimes not. “Simple” in mathematics is not necessarily simple in physical realization. (But it is true for TRIZ as well…)
Example 1: History of the Problem of p yRotation at required rate
?
Ancient example: How to grill a piece of food properly while the fire is not uniform (sometimes weak, sometimes strong)?
Example 1: History of the Problem of p yRotation at required rate
S d d A i S l i Hi OStandard Ancient Solution: Hire Operator
Example 1: History of the Problem of p yRotation at required rate
S d d A i E l i S C ll D iStandard Automation Era solution: Sensors, Controller, Drive.
Example 1: History of the Problem of p yRotation at required rate
I i f L d d Vi i (XVI ) G ill i lfInvention of Leonardo da Vinci (XVI century): Grill rotates itself
Example 1: History of the Problem of p yRotation at required rate
Industrial era example: How to ensure constant rotational rate of a steam-driven machine while load profile is not uniform (sometimes idle, sometimes loaded)?
Example 1: History of the Problem of p yRotation at required rate
steam supply valvesteam supply valve
Invention of James Watt (1788): Automatic (“itself”) steam supply i
rotation at a certain rate
governing
No mathematics involved, but… it turned out to be unstable:
ω(t), rotational rate
t, time
Example 1: History of the Problem of R t ti t i d tRotation at required rate
00123 xaxaxaxa
Only analysis of mathematical model of governed (closed loop) machine dynamicsOnly analysis of mathematical model of governed (closed loop) machine dynamics by J.Maxwell and I.Vyshnegradsky (1868—1876) lead to inventions that changed the structure of the governor (introduction of additional friction element, changing the geometry of governor). Photos below: Collection of improved Watt governors atthe geometry of governor). Photos below: Collection of improved Watt governors at Baumana State Technical University Museum (Moscow)
Example 2: History of the Problem of p yRotation (at required rate)
Vibration reduction: How to reduce rotating shaft vibration while any shaft has an offset?
Mathematical model of Rotating body dynamics is complex (nonlinear) and full of interestingcomplex (nonlinear) and full of interesting phenomena. These phenomena could be used for rotor self-stabilization (Ideal Final Result), like
t ti b d th “ iti l d” iti ithrotating beyond the “critical speed” or cavities with small masses (balls) in the rotor body.
A Brief History andvState of the Art of Rotor Dynamics, By Dr. Rajiv Tiwari, Department of MechanicalA Brief History andvState of the Art of Rotor Dynamics, By Dr. Rajiv Tiwari, Department of Mechanical Engineering, Indian Institute of Technology Guwahati, Short Term Course on Theory & Practice of Rotor Dynamics(15-19 Dec 2008) http://www.iitg.ernet.in/engfac/rtiwari/resume/rtiwari01.pdf