Intro to Design Thinking - Midterm Review

spring clamp

clamping force is generated by a torsion spring

decision risk

the chance that the choices made will not turn out as expected

trade study

structured evaluation tool for making a decision about a design/component/system

contains comprehensive information about

• design requirements/engineering specs

• alternatives considered

• metrics for comparison/evaluation

• tradeoffs

• budgetary info (usually)

• process for making decision

product risk

what happens if the product fails

project/process risk

what happens to the company/design team if the project fails?

• what can go wrong that will cause the project to:

  • fall behind schedule

  • go over budget

  • not meet engineering specs

• consequences and probability of occurance

f-style bar clamp

screw mechanism slides on the bar; screw can be used to increase clamping force

Irwin Quick-Grip Bar Clamp

bar clamp; the compressive force can be applied by squeezing the trigger; can be tightened with 1 hand

Hand Screw Wood Clamp

mainly used in woodworking; less prone to marring the workplace; can clamp awkward shapes; screws used to apply clamping force

Chuck

rotary part for gripping drill bits

Reverse Switch

changes direction of rotation or locks drill; forward/CW - drives in a screw; reverse/CCW - removes a screw

Torque Adjustment/Clutch

limits the max. torque provided; reduces chances of over-driving screws or stripping screw heads; most drills have a “max” torque setting indicated with the little drill icon

Speed/Gear Switch

1 is usually the slower speed, 2 is usually the faster speed; drilling holes: use max. speed and max. torque; driving screws: use slower speed and limit torque to minimum necessary

Driver

Screwdrivers

• come in many shapes and sizes

• tip style + size

  • SAE sizes are in fractions of an inch

  • metric sizes are in millimeters

• driving/removing screws

• types

  • allen wrenches/allen keys/hex keys/wrenches

  • 6-sided head/hexagon

Allen Wrenches/Allen Keys/Hex Wrenches

Long-Nose/Needle-Nose Pliers

pliers that have long, thin gripping prongs

slip-joint pliers

pliers that have 2 size settings

lineman’s pliers

pliers that have:

• a stu nose

• flat gripping surface

• angular edge

• wire cutters

• crimper (for wires)

• insulated handles

channel lock pliers (water-pump pliers)

pliers that have many size settings; mainly used for gripping pipes of different diameters; very versatile

vice grips (locking pliers)

work like normal pliers; can be locked in place while producing clamping force; used for gripping items without having to maintain grip force manually

rotary tools

cutting metal/shortening a screw, sanding, buffing, sharpening, etching

most common: dremel

combination wrench

one end is open, easier to slide onto a nut; the other end is a box, must be put on over the top of the nut, provides more contact between the tool and the surface

open-ended wrench

usually each end has a different size, or different orientation but same size

box wrench

a wrench where both sides have box ends

crescent wrench/adjustable wrench/adjustable spanner

a wrench with an opening adjustable with a thumbscrew

socket wrench/ratchet wrench

the sockets fit over the top of a nut or bolt head; the sockets mount into the ratchet; the direction is set with the switch on the back of the ratchet

pipe wrench

a wrench used primarily to fasten or dismantle pipes

torque wrench

purpose is to enable user to apply a specified amount of torque

tap

for creating threaded holes so that a bolt can be screwed into the material

die

for creating threads on the outside of a cylindrical shaft so it can act like a screw

professional societies

advocate for those practicing the profession

professional engineering license

required to prepare, sign and seal, and submit engineering plans and drawings to a public authority for approval, or seal engineering work for public and private clients

requirements:

• 4-year degree

• FE

• 4 years experience under a licensed PE

• PE

FE exam

PE exam

Fundamental Canons of Ethics from NSPE

1. engineers shall hold paramount the safety, health, and welfare of the public

2. perform services only in areas of their competence

3. issue public statements only in an objective and truthful manner

4. act for each employer or client as faithful agents or trustees

5. avoid deceptive acts

6. conduct themselves honorably, responsibly, ethically, and lawfully, so as to enhance the honor, reputation, and usefulness of the profession

What is required to be an ethical engineer?

ethical reasoning, understanding applicable codes, virtue to do what is believed to be right

product

a designed object

design process

the organization and management of people and the information they develop in the evolution of a product

• project definition, product definition, conceptual design, product development, product support

project definition

• discover design projects

  • make money

  • fill a new market need

  • use resources

• choose design projects

  • SWOT Analysis

  • pro-con list

  • decision matrix

• plan design projects

product definition

understand the design problem + customer needs —> technical description and engineering specifications

the heart of design thinking

conceptual design

product development

design for sustainability

design for manufacturing

Hannover Principles

designing for sustainability; developed for the EXPO 2000 World Fair in Hannover, Germany;

• insist on rights of humanity and nature to coexist

• recognize interdependence

• accept responsibility for the consequences of design

• create safe objects of long-term value

• eliminate the concept of waste

• rely on natural energy flows

• understand the limitations of design

• seek constant improvement by the sharing of knowledge

• respect relationship between spirit and matter

additive manufacturing

product life cycle

measures of design success

cost, quality, time to market

assembly

component

selective design

involves choosing a product of object from already existing possibilities

variant design

a main product is designed, then the company designs variations of this product to meet the desires of the customers

configuration design

essentially how to pack or arrange all the components; packaging design

parametric design

involves finding values for the features that characterize the object being developed

• length

• width

• thickness

• weight

• which material

original design

the development of an entirely new product, process, or assembly; almost always requires several or all of the previously mentioned design problems

redesign

the design of a new product starting with the design of a currently existing product

product decomposition

answers the question of how something is made

general knowledge

information that most people know and apply regardless of their expertise and experience

domain-specific knowledge

information on the form or function of an individual object or a class of objects

procedural/process knowledge

“knowing what to do next"

short-term memory

long-term memory

internal vs. external problem solving behavior

energy source, information management, information language, deliberation style, closure style

design team contracts

a great first step for a student design team; covers team behaviors for success

meeting minutes

often include:

• who spoke

• on which topics

• what questions were asked

• what tasks were assigned

• who were the tasks assigned to

• the due dates for task completion

• reviewed at the beginning of the next meeting

quality

• how well it does its task

• long term value

• takes what it needs to be good - resources

• meets customer standards

• aesthetically pleasing

• reliable

• maintanable

• easy-to-operate

• durable

• safe

• efficient

• robust

• starts with the DESIGN, not the manufacturing

design reviews

a written report that documents the choices made, lists the proposed next steps, proposes a timeline and budget for next step

a presentation to decision makers in the company

examples/types

• systems requirements review (SSR)

• preliminary design review (PDR)

• system definition review (SDR)

• critical design review (CDR)

critical design review

executive summary

the section in a design report that provides key information up front

• first sentence MUST contain the most essential info that you wish to convey

• written as if the reader is totally uninformed abt the project and isn’t going to read the report

• one page or less, max. one figure

bill of materials

the section in a design report that includes the parts costs of the items included in the final design

include

• manufacturer

• part number

• part description

• supplier

• quantity

• cost

project plan

the section in a design report that includes a detailed plan of all the resources need with targeted decision dates and deliverables

Gantt chart

show a complete listing of the major tasks to be performed, a time schedule for completing them, and which team member has the primary responsibility (and who will be held accountable) for each task

product life cycle management

ISO 9000/ISO 9001

companies must have quality systems that:

• standardize, organize, and control operations

• provide for consistent dissemination of info

• improves various aspects of the business-based use of statistical data and analysis

• enhances customer responsiveness to products and services

• encourages improvement

• try to reduce costs associated with poor quality

on-site visit required

SWOT analysis

a matrix for each project evaluating internal strengths and weaknesses, and external opportunities and threats

pro-con analysis

aimed at making a decision between two alternatives, two columns; crossing-out of equal importance

decision matrix

can be used to make any type of decision

• which project to pursue

• which sensor to choose for the product

step 1: clarify the issue

step 2: itemize the alternatives

step 3: itemize measures + weight

step 4: build (evaluation and results)

works best carried out individually, then comparing scoring results

stage-gate project plan

stages are defined (rectangles)

there can be as many stages as necessary

clear decision gates/reviews are made in between stages (diamonds)

sequential assumption

iterative

waterfall project plan

spiral project plan

prototype

a physical model of a product

proof-of-concept prototype

used for developing the function of the product to meet customer needs

proof-of-product prototype

purpose is to help refine the components and assemblies

proof-of-process prototype

used to verify the manufacturing process of the product

proof-of-production prototype

used to verify the entire production process

project planning

the process for how to allocate resources of time, money, and people

should be one of the first steps

• consider

  • time to market

  • goal deadlines

  • who should be on the design team

  • budget + space needed

  • tools/resources needed

  • testing?

an actual (living) document that formulizes the design process

engineering specifications

quantitative, measurable criteria that the product is designed to satisfy

must contain:

• a metric for the target value

• a target value

• engineering units for the target value

must be:

• discriminatory

  • reveals the difference between alternatives

• measurable

  • quantitative, specific

• orthogonal

  • each spec should be independent of other specs and identify a unique feature of the alternative

• universal

  • applied to every alternative

• external

  • black box

customer needs/requirements

Kano Model of Customer Satisfaction: basic features, performance features, excitement features

QFD (Quality Function Deployment)

• developed the “House of Quality”

• mid 70s Japan

• Toyota

• clear process for systemic quality

• reduced development time by 30%

• what, then how (form follows function)

House of Quality

1. who - who the customers are

2. what - what the customers want to product to do

3. who vs. what - to whom is the what important

4. now + now vs. what - what is the competition for the product + what opportunities are there for improved produce developments

5. how - how to measure the product’s performance

6. what vs. how - how does the product performance meet customers’ requirements

7. how much - target information

8. how vs. how - interrelationship between the engineering specifications

Kano Model of Customer Satisfaction

concept

an idea that is sufficiently developed to evaluate the physical principles that govern its behavior

means for providing function

function

the logical flow of energy (including static forces), material, or information between objects or the change of state of an object caused by one or more of the flows

reverse engineering/functional decomposition

answers the question of how the function was produced

brainstorming

a concept-generating method that includes:

1. defer judgment

2. encourage wild ideas

3. build on the ideas of others

4. stay focused on the topic

5. one conversation at a time

6. be visual

7. go for quantity

analogies

a concept-generating method that involves asking and answering the question, “what else provides a similar function?”

trade journals

a concept-generating method that involves searching through reference books and publications put out by industry to make people aware of technologies, services, and products

experts

a concept-generating method that involves gaining expertise by a team or hiring expertise from a company or individual

inversions

a concept-generating method that involves thinking about the opposite or inverse of what is needed

extremes

a concept-generating method that involves thinking about the extreme limits of the product