Final MECH 223

Backwards. Rap 5: Optimization - Sustainable Development

Sustainable Development

meets the needs of the present without compromising the ability of future generations to meet their own needs

Triple Bottom Line

combines societal, environmental, and economic considerations in order to measure performance.

cradle to grave analysis

considers environmental impacts from extraction to recycling/disposal

Innovation Categories

Trend following, mental invention, need spotting, market research, random events, and solution spotting

trend following

Develop a product based on what other companies are doing

mental invention

Design a product based on a creative thought that does not focus on the market

need spotting

innovations that identify the need before developing the product

market research

study the market to identify what people would be willing to buy

random events

Develop a product to satisfy a need that arises through random occurrences (e.g. a natural disaster)

solution spotting

Identify ways to adapt existing technology to new applications

most successful innovation categories

solution spotting, random events, market research

least successful innovation categories

trend following, mental invention, need spotting

4 rules of invention

adopt a disruptive approach, use appropriate product integration, leverage the right capabilities, disrupt competitors not customers

disruptive innovation

enters the low end of the market and goes on to displace existing technologies and companies in the market through simplicity and low cost

integrated products

products are specialized and not designed to work with similar products from other manufacturers, in emerging markets

non-integrated products

modular and use standardized components, in well-developed markets

leverage the right capabilities

new venture should return profit quickly, and then grow to a larger scale

Patents

grant exclusive rights to the patent holder to make, use, or sell an invention, issued by a government and are time-limited

Trademarks

logos, designs, words, or other features used to distinguish the goods or services of a person or company

Trade secrets

difficult- to-ascertain information that is kept secret from competitors

Copyrights

gives the creator of an original piece of creative, intellectual, or artistic work the sole right to reproduce that work

Industrial Design Registration

protects the visual features of a product, including elements such as shape, contours, patterns, and ornamentations

Integrated circuit topographies

prohibits others from reproducing or manufacturing the topography (does not protect function)

Novelty (Patent Criteria)

must be the original inventor of your idea (or the assignee of the inventor), and the idea must be the first of its kind in the world

Utility (Patent Criteria)

something that works, and that has a useful function

Ingenuity (or non-obviousness) (Patent Criteria)

a development or an improvement that would not have been obvious beforehand to workers of average skill in the technology involved

Patent Criteria

Novelty, Utility, Ingenuity

Design For Manufacture

Minimize separate parts, minimize fasteners, use standard parts/sizes/fasteners, assemble in one direction, maximize part symmetry, provide orienting features, provide alignment features

Design for Usability (Ergonomics)

use appropriate affordances, make things visible, use mapping, use feedback, provide constraints against incorrect action

FMEA

Failure Modes and Effects Analysis

Severity, Occurrence, Detection

3 FMEA Elements

Concept/System FMEA

failure caused by deficiencies in the interaction of functions in the (sub)system design, early design process

Design FMEA

focuses on failure caused by deficiencies in component design, before detailed design

Process FMEA

failure caused by deficiencies in the manufacturing and assembly process

service FMEA

deficiencies in the process/system used to provide service to a customer

failure mode

the manner or way a part could fail to perform its intended function

effect

the consequence of the failure as experienced by the end user

severity

a numerical rating of the seriousness of the effect of a failure

cause

the defect in design or manufacture that leads to a failure mode

control

design, manufacturing, or operation actions to detect the cause of a failure mode before effects are experienced by the user (calculations, inspecting assemblies, replacement of components)

detection

a numerical rating of the Likelihood a control will detect a failure mode cause

Risk Priority Number (RPN)

a numerical rating of risk based on the product of severity, occurrence, and detection ratings (1 - 1000, SxOxD)

cash flow

the movement of money in or out of a business venture or project

Development costs

initial spending on the project design, testing, and refinement

ramp-up costs

initial costs to begin production, such as tooling, equipment, and production training

marketing and support costs

costs to support the product, such as launch, promotion, direct sales, distribution, and service costs

production costs

on-going costs for material, labour, power, and overhead

sales revenue

money made by selling the product

F = P(1+r)^n

Time value of money

Opportunity cost of capital

the expected return from other opportunities that is missed in order to pursue the project

discount rate

the percentage rate a company uses to calculate the present value of future cash flows

hurdle rate

the threshold rate for which a project is feasible

net present value

summation of all of a project’s cash flows, expressed in terms of present value

sunk costs

costs that have already been incurred

removal methods

taking material away from a part

deforming

changing the shape of a part

accumulating

adding material to form a part

machining

removing chips of material from a part

abrading

abrasive material rubs against a part

punching/shearing

shear load is applied to separate two parts of same piece, hole material is discarded

blanking

edge of material is discarded and hole material is retained

forging

compressive forces compress and reshape a workpiece that has typically been softened by heating (internal grain is deformed, improving strength)

stamping

deformation of material done cold (shearing, bending, etc)

extruding

material is forced through an opening of desired cross-section (high costs)

fabricating

joining pieces together using fasteners, welds, and adhesives

moulding

molten/liquid material is pressed (forced under pressure)

casting

molten/liquid material is poured into an enclosed shape

composite manufacturing

combining two materials together into a single structure

lapping/honing, grinding, turning, die casting

machining operations with smaller tolerances

sand casting, forging, drilling

machining operations with larger tolerances

setup costs

preparing manufacturing equipment for a production run

tooling costs

building or revising manufacturing equipment to make a specific product

material costs

cost of raw materials, as well as any unused waste

processing costs

cost to run the equipment (electricity, labour, overhead costs)

basic dimension

theoretical exact size of a shape/location/feature

bilateral tolerance

size variation can either be positive or negative

unilateral tolerance

size variation can only be in one direction

fits

standardizes system for determining tolerance ranges for parts

running and sliding fits (RC)

allow relative motion between two parts, while still providing accurate location

locational fits

determine the location of mating parts

locational clearance (LC)

allows for some freedom of motion

locational interference (LN)

provides a slight interference between mating parts

force fits (FN)

require an external force to assemble parts, such that elastic deformation of the material holds the parts together

shrink fit

heating part to expand a hold, and then allowing it to shrink about the shaft

expansion fit

cooling a shaft, and then allowing it to expand inside a hole

Design Guidelines

use direct load paths, incorporate triangular elements, utilize hollow cylinders and I-beams, avoid buckling, use conforming surfaces, incorporate merging shapes

Proof of concept or critical function

Concept Evaluation Stage Prototypes to assess feasibility, collect feedback/data to verify concept functions as intended

form study prototypes

non-functioning physical models that capture the size and feel of a product

proof of product prototype

detailed design stage prototype to clarify the physical embodiment of a design to assess production feasibility

proof of production prototype

build stage prototypes used to examine issues related to manufacturing and assembly

alpha and beta prototypes

late stage prototypes which represent nearly completed devices, may lack final styling details and ergonomic aspects

alpha prototype

first fully functional prototype which undergoes extensive testing and analysis

beta prototype

second late stage prototype

low-fidelity

prototypes are simple and in-expensive

high fidelity

prototypes are sophisticated and more expensive

concept generation prototypes

inspire creative thinking, quick sketches

specification stage prototypes

simple blocks or static models to identify appropriate size and weight of a device to be designed

Introversion/Extraversion

whether your prefer to direct your energy inward or outward

Sensing/iNtuition

whether you tend to rely on details or the big picture when gathering information

Thinking/Feeling

whether you tend to make decisions objectively or subjectively