2. The Product Design Process
• Introduction and Importance of Product Design
• The Design Process – A Simplified Approach
• Considerations of a Good Design
• Detailed Description of Design Process
• Marketing
• Organization for Design
• Computer-Aided Engineering
• Designing to Codes and Standards
• Design Review
• Technological Innovation and the Design Process
3. Some Important Concepts
• Design: “ to fashion after a plan” (Webster Dictionary)
leaves out the essential fact that to design is to create
something that has never been
• Synthesis: “pulling together”
• Ability to design is both a science and an art
The science “can be learned” through techniques &
methods
The art is best “learned by doing” design
• Discovery: “getting the first sight of, or the first knowledge
of something”, as when Columbus discovered America
• Invention: requires the design be a step beyond the limits
of existing knowledge (beyond the state of the art). Some
designs are truly inventive, but most are not
5. Definition of Design
• Design establishes and defines solutions to
and pertinent structures for problems not
solved before, or new solutions to problems
which have previously been solved in a
different way
6. Good Design requires both Synthesis & Analysis
• Typically, we approach complex problems like design by
decomposing the problem into manageable parts or
components
– Because we need to understand how the part will perform in service
we must be able to calculate as much about the part’s behavior as
possible by using the appropriate disciplines of science and
engineering science and the necessary computational tools
– This is called Analysis and usually involves the simplification of
the real world through models
– Synthesis involves the identification of the design elements that
will comprise the product, its decomposition into parts, and the
combination of the part solutions into a total workable system
• In the typical design you rarely have a way of knowing the
correct answer. Hopefully, your design works, but is it the
best, most efficient design that could have been achieved
under the conditions? Only time will tell
7. The Four Challenges (C’s) of the
Design Environment
• Creativity
– Requires creation of something that has not existed
before or not existed in the designer’s mind before
• Complexity
– Requires decisions on many variables and parameters
• Choice
– Requires making choices between many possible
solutions at all levels, from basic concepts to smallest
detail of shape
• Compromise
– Requires balancing multiple and sometimes conflicting
requirements
8. Product Design Process
• Engineering design process can be applied to several
different ends
– Design of Products, whether they be consumer goods
and appliances or highly complex products such as
missile systems or jet planes
– Another is a complex engineered system such as an
electric power generating station or a petrochemical
plant
– Yet another is the design of a building or bridge
• The principles and methodology of design can be usefully
applied in each of these situations. However, the emphasis
is on product design and in this course is complex product
design, specifically Aerospace Systems
9. Goal
• Provide insight into the current best
practices for doing product design
• The design process should be conducted so
as to develop quality cost-competitive
products in the shortest time possible
• Is necessary, but insufficient for Aerospace
Systems Design
10. Japanese Auto Industry and The U.S. Auto Industry
90%
Total Japanese
Changes Complete
U.S. Company
Japanese
Company
20-24
Months
14-17
Months
1-3
Months
Job
#1
+3
Months
Number
of
Engineering
Product
Changes
Processed
Japanese/U.S. Engineering Change Comparison
11. The Quality Engineering Process
provides Recomposition Methods & Tools
Customer
Quality
Function
Deployment
Off-Line
Seven
Management
and Planing
Tools
Off-Line
Statistical
Process
Control
On-Line
Robust
Design Methods
(Taguchi, Six -
Sigma, DOE)
Off-Line
Knowledge Feedback
•Needs
• Identify
Important
Items
•Variation
Experiments
•Make
Improvements
•Hold Gains
•Continuous
Improvement
Having heard the “voice of the customer”, QFD prioritizes where improvements are
needed;Taguchi provides the mechanism for identifying these improvements
12. Traditional Design & Development Using only a Top
Down Decomposition Systems Engineering Process
13. IPPD Environment for System Level Design Trades and
Cycle Time Reduction
SYSTEM
PROCESS
RECOMPOSITION
SYSTEM
FUNCTIONAL
DECOMPOSITION
COMPONENT
FUNCTIONAL
DECOMPOSITION
COMPONENT
PROCESS
RECOMPOSITION
PART
PROCESS
RECOMPOSITION
PART
FUNCTIONAL
DECOMPOSITION
Product
Trades
Process
Trades
Product
Trades
Process
Trades
PRELIMINARY
DESIGN
(PARAMETER)
PRELIMINARY
DESIGN
(PARAMETER)
DETAIL
DESIGN
(TOLERANCE)
DETAIL
DESIGN
(TOLERANCE)
MANUFACTURING
PROCESSES
CONCEPTUAL
DESIGN
(SYSTEM)
Process
Trades
INTEGRATED
PRODUCT
PROCESS
DEVELOPMENT
Product
Trades
14. CC04264506.ppt
Typical System Life Cycle Cost
Cumulative
Percent
of LCC
Production, Deployment,
Operations and Support
E&MD
PD & RR
Con Exp
•
•
•
•
•
•
100%
75%
50%
25%
0%
Life Cycle Cost
Actually Expended
Life Cycle Cost
Effectively Rendered
Unchangeable for
a Given Design
15. Ramifications of the Quality Revolution
• Decisions made in the design process cost very
little in terms of the overall product cost but have
a major effect on the cost of the product
• Quality cannot be built into a product unless it is
designed into it
• The design process should be conducted so as to
develop quality cost-competitive products in the
shortest time possible
16. Design Process Paradigm Shift
(Research Opportunities in Engineering Design, NSF Strategic Planning Workshop Final
Report, April 1996)
• A paradigm shift is underway that
attempts to change the way complex
systems are being designed
• Emphasis has shifted from design for
performance to design for
affordability, where affordability is
defined as the ratio of system
effectiveness to system cost +profit
• System Cost - Performance
Tradeoffs must be accommodated
early
• Downstream knowledge must be
brought back to the early phases of
design for system level tradeoffs
• The design Freedom curve must be
kept open until knowledgeable
tradeoffs can be made
17. Static vs Dynamic Products
• Some products are static, in that the changes in
their design concept take place over a long time
period; rather, incremental changes occur at the
subsystem and component levels (most air
vehicles are static)
• Other products are dynamic, like
telecommunications systems and software, that
change the basic design concept fairly frequently
as the underlying technology changes (avionics
and mission equipment & software are dynamic)
18. Simplified Design Process
• Definition of the Problem
• Gathering Information
• Generation of Alternative Solutions
• Evaluation of Alternatives
• Communication of the Results
19. Georgia Tech Generic IPPD Methodology
COMPUTER-INTEGRATED ENVIRONMENT
PRODUCT
DESIGN
DRIVEN
PROCESS
DESIGN
DRIVEN
REQUIREMENTS
& FUNCTIONAL
ANALYSIS
SYSTEM DECOMPOSITION
&
FUNCTIONAL ALLOCATION
SYSTEM SYNTHESIS
THROUGH MDO
SYSTEM ANALYSIS
&
CONTROL
ESTABLISH
THENEED
DEFINETHEPROBLEM
ESTABLISH
VALUE
GENERATEFEASIBLE
ALTERNATIVES
EVALUATE
ALTERNATIVE
7 M&PTOOLS AND
QUALITY FUNCTION
DEPLOYMENT (QFD)
ROBUST DESIGN
ASSESSMENT &
OPTIMIZATION
ON-LINEQUALITY
ENGINEERING &
STATISTICAL
PROCESS
MAKEDECISION
SYSTEMS
ENGINEERING M ETHODS
QUALITY
ENGINEERING M ETHODS
TOP-DOWN DESIGN
DECISION SUPPORT PROCESS
20. Detailed Description of Design Problems
(Morris Asimow’s Morphology of design)
• Phase I. Conceptual Design
• Phase II. Embodiment Design (Preliminary Design)
• Phase III. Detail Design
• Phase IV. Planning for Manufacture
• Phase V. Planning for Distribution
• Phase VI. Planning for Use
• Phase VII. Planning for Retirement of the Product
23. Classification of Products Based on Market
• Platform Product
– Is built around a preexisting technological subsystems, e.g. Apple
Macintosh operating systems
– Is similar to a technology-push product
• Process-Intensive Products
– Manufacturing process places strict constraints on the properties of
the product
– Examples are automotive sheet, steel, food products,
semiconductors chemicals and paper
• Customized Products
– Variations in configuration and content created in response to a s
25. The Systems Engineering Process
Process Input
• Customer Needs/Objectives/
Requirements
- Missions
- Measures of Effectiveness
- Environments
- Constraints
• Technology Base
• Output Requirements from Prior
Development Effort
• Program Decision Requirements
• Requirements Applied Through
Specifications and Standards
Requirements Analysis
• Analyze Missions & Environments
• Identify Functional Requirements
• Define/Refine Performance & Design
Constraint Requirement
Functional Analysis/Allocation
• Decompose to Lower-Level Functions
• Allocate Performance & Other Limiting Requirements to
All Functional Levels
• Define/Refine Functional Interfaces (Internal/External)
• Define/Refine/Integrate Functional Architecture
Synthesis
• Transform Architectures (Functional to Physical)
• Define Alternative System Concepts, Configuration
Items & System Elements
• Select Preferred Product & Process Solutions
• Define/Refine Physical Interfaces (Internal/External)
System Analysis
& Control
(Balance)
Verification
Requirement Loop
Design Loop
• Trade-Off Studies
• Effectiveness Analysis
• Risk Management
• Configuration Management
• Interface Management
• Performance Measurement
- SEMS
- TPM
- Technical Reviews
Process Output
• Development Level Dependant
- Decision Data Base
- System/Configuration Item
Architecture
- Specification & Baseline
Related Terms:
Customer = Organization responsible for Primary Functions
Primary Functions = Development, Production/Construction, Verification,
Deployment, Operations, Support Training, Disposal
Systems Elements = Hardware, Software, Personnel, Facilities, Data, Material,
Services, Techniques
26. CC04264864.ppt
Systems Engineering, Its Purpose
To satisfy a mission need with a system
that is cost effective, operationally
suitable, and operationally effective.
27. CC04264865.ppt
Systems Engineering Objectives
• Translate customer needs into balanced system/subsystem
design requirements and product
• Integrate technical inputs of the entire development
community and all technical disciplines into a coordinated
program effort
• Transition new technologies into product and abatement
program
• Ensure the compatibility of all functional and physical
interfaces
• Verify that the product meets the established requirements
• Conduct a formal risk management and
28. CC04264792.ppt
What Is a System?
• A system is a collection of components
(subsystems) that
– Interact with one another
– Have emergent capabilities - capabilities above
and beyond what the same collection of
components would if they did not interact
– Interacting components implies architecture
29. CC04264867.ppt
Elements of a System
• Elements
– Equipment Hardware
– Software
– Facilities
– Personnel
– Data
• All elements are interrelated
30. CC04264868.ppt
System Element Constituents
• Equipment Hardware
– Mission hardware
– Ground equipment
– Maintenance equipment
– Training equipment
– Test equipment
– Special equipment
– Real Property
– Spares
32. CC04264029.ppt
Systems Engineering Principles Apply to All Acquisition
Phases at All Levels of the Engineering Hierarchy
Levels in the
System Hierarchy
CED - Concept Exploration/Definition
PDRR - Program Definition & Risk Reduction
System of
systems
System
Segment
Subsegment
Item
CED
PDRR
EMD
P/D
Acquisition
Phases
EMD - Engineering/Manufacturing Definition
P/D - Production/Deployment Pre-CED
35. CC04264870.ppt
System Element Constituents (cont.)
• Personnel
– Training
– Tasks
– Number
– Types and skills
• Data
– Parts Manuals
– Maintenance Manuals
– Operating Manuals
37. CC04264791.ppt
Roles of Systems Engineers*
• Requirements Owner
• System Designer
• System Analyst
• Validation/Verification
Engr
• Logistics/Ops
Engineer
• Glue Among
Subsystems
• Customer Interface
• Technical Manager
• Information Manager
• Process Engineer
• Coordinator
• Classified Ads SE
38. CC04264792.ppt
What Is a System?
• A system is a collection of components
(subsystems) that
– Interact with one another
– Have emergent capabilities - capabilities above
and beyond what the same collection of
components would if they did not interact
– Interacting components implies architecture
39. CC04264793.ppt
Examples of Systems
• Aircraft engine vs a collection of parts
• Aircraft with engines and avionics
• Air traffic control with aircraft, airfields,
radars, controllers, CCS
• Air transportation with air traffic control,
airlines, passengers, cargo, maintenance,
pickup and delivery
40. CC04264794.ppt
More Complex Systems
Systems of Systems
•Individual systems can operate on their
own
•Systems of systems not owned and
controlled as a whole by single entity
41. CC04264795.ppt
Examples of Systems of
Systems
• Internet
• Auto and truck transportation
• Air Defense System – maybe
• National Airspace System (NAS)
• Future Combat Systems (FCS) for
the Objective Force Brigade (Unit
of Action)
42. CC04264796.ppt
Technical Director Is the Systems
Thinker
• If not, objectives, approaches, and
decisions will not reflect systems
thinking
• Technical Directors who don’t think
systems inhibit systems thinking on
their project
43. CC04264797.ppt
Why Is Systems Thinking
Good?
• Intractable problems often have solutions in
the design space of the larger system
• Solutions in the larger systems space are
often less costly or less risky
• Integration with external systems are
addressed
early in the development
