Advanced Mfg for Engineers

Design Process

The engineering design process is a series of steps that engineers follow

when solving problems. There are many variations of the design
process in use and every situation or problem will have different
elements that you should investigate. The steps listed below as well as
the bullets included should inform the process but not dictate the
process for every situation.

Design Process

Conduct Preliminary Research

• Research Background Information and Identify Vocabulary.
• Identify Criteria and Constraints for the Problem
• Define Limits of the Problem to be Solved
• Refine the Problem Statement in the Context of Criteria and
Constraints
• Define Areas of Research Needed to Solve the Problem
• Independent Research
• Enabling Activities
• Lab Activities

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Create the Project Management Plan
• Overview
• Scope
• Schedule
• Budget
• Communication
• Closure

Create a Design Brief

• Objectives and Goals of the Design
• Client and Context
• Scope of the Project
• Problem Statement or Description
• Resources and Budget
• Constraints
• Time Needed

Brainstorm Possible Solutions

• Generation of Ideas
• Preliminary Sketches

Design Testing Methods and Protocol for Critical Assumptions

• Introduction
• Test Strategy
• Data Collection Plan; Sampling Plan
• Definition of a Successful Test, Pass / Fail Criteria
• Test Conditions, Setup Instructions
• Logistics and Documentation:
• Analysis of Data
• Conclusion

Create Optimization Matrix for Decision Making and Select Solution

• Design Matrix
• Identify Key Criteria
• Assign Value to Each
• Rate Possible Solutions

Develop, Refine and Document Selected Solution

• Creation of Design Documentation
• Identify New Issues

Create a Prototype

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• Turning the Plans into a Prototype

Test and Acquire Data

• Design Testing to Evaluate the Prototype
• Acquire Testing Data

Analyze Test Data

• Creation of Graphs and Charts
• Statistical Examination of Data

Refine and Iterate the Design

• Apply the Changes Suggested by the Analysis of the Test Data.
• Retesting of the Prototype
• Repeat

Finalize Documentation of Design

• Complete Documentation of Changes
• Finalize Analysis

Prepare Communication Plan for Authentic Audience

• Research Audience
• Plan for Explanations and Graphics
• Plan for Feedback

Prepare Communication Documents

Reports
• Design Documentation
• Design Proposals
• Presentations for the Authentic Audience

Present/Defend to an Authentic Audience with Feedback

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An Engineering Notebook is known by several names depending on the

person and industry it is being used in. It is a bound book that contains
the time-sequential written documentation of the development of the
ideas of its author, along with all notes, data, observations, calculations,
and other information relevant to the discovery or experiment being
conducted. It provides an important record of the progress of an
engineer, scientist’s or inventor's work. When properly maintained, it
may be submitted as a legal document for patent purposes or legal
records.

It is the equivalent of a technical diary and has multiple uses. It presents

the author's thought process and work in an easy to access manner,
allowing an author to confirm conclusions, details, or dates.

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Engineering research and development organizations usually require
their engineers to keep a running record of their activities. In the event
that a project is shelved or the person leaves employment it can provide
others working on a project the paths of inquiry that have been
investigated, and can offer justification for decisions or courses of action
taken.

Use a bound notebook with a stitched binding. Do not use a loose leaf
or Spiral bound notebook.

All entries should be in ink not pencil.

The title, project number, and book number should be accurately

recorded when starting a new Page.

All data is to be recorded directly into the notebook. Elaboration of

details is preferable. Notes and calculations should be recorded in the
notebook. In the case of an error, draw a single line through the
incorrect data. Do not erase or use correction fluid. All corrections
should be initialed and dated. When making a correction, make a
notation of the page number where the correct information is found.

After entering your data, sign and date all entries. Witness or witnesses
should sign and date each entry. The witness must observe the work
that is done, and have sufficient knowledge to understand what they
have read. Names of all who were present during any demonstration,
phone conversation or discussion should also be recorded.

Never leave any White Space: "X" out or Crosshatch all unused space,
and don't forget to initial and date the entry. Use both sides of the page.

When the notebook is full, begin a new notebook with the title, project
number, and book number. Also make a notation of the preceding
notebook number. Archive the full notebook in a safe location.

If necessary, items may be taped into the notebook with a handwritten

date and title. Permanently attach inserted items (glue is preferred).
Sign across the edge of the inserted sheet with half of the signature on
the page.

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Following this procedure can help students. It will foster improved
documentation, research and sketching skills. It can help with time
management skills and provide a convenient method for class closure.
Early adoption by students of the use of the Engineering Notebook will
help with project reports they will be expected to complete.

An example can be found at:

[Link]

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Design Documentation

• A design isn’t “read” it is “used”.

• The design process goes from least specific to most specific.
• Never write a paragraph when a sentence will do.
• Never write a sentence when a bullet point will do.
• Use Diagrams.
• A good table replaces long narratives.
• Never use adjectives. That is the function of sales people and
project managers. (Examples: great, beautiful, wonderful, etc.)
• Use appendixes for supportive information that you think is
relevant.

Design documentation is the collection of details about the final design

requirements and specifications that illustrate and thoroughly describe
a designed product. Writing effective design documentation (like
design itself) is really all about making sure you serve the needs of your
audience.

Each document must have identification such as Project title, original

date of document and names of students in the team, name of person
approving the original document, dates of revisions and name of
person approving the revision and brief explanation of the revision.
Each design might include conceptual drawings, assembly drawings,
parts’ list, parts drawings, process drawings, flowcharts, state diagrams,
use cases, relational tables, tables, programs developed, charts, graphs,
rules, symbol diagrams, decision matrix, ladder diagrams, CNC Control
programs, schematics, etc.

Items might include:

• 3D CAD Design
• Analysis
●​ Finite Element Analysis (FEA)
●​ Stress o Load Distribution
●​ Fluid Flow
●​ Heat Transfer
• Conceptual Designs
• Flowcharts • Instructions
• Linkage Diagrams Reference Guides

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• Sketches
• Specifications
• Tutorials
• Working Drawings
• Prototypes
●​ Black Box Prototype: An existing enclosure or box with
mechanical, electrical, optical and or software internals fully
functioning.
●​ Concept Model: formally describing some aspects of the
physical and social world around us for the purposes of
understanding and communication
●​ Evolutionary Prototyping (also known as breadboard
prototyping) a very robust prototype in a structured manner
with the ability to constantly refine it.
●​ Feasibility Prototype: Determine feasibility of various
solutions o Functional Storyboarding: Determine useable
sequences for presenting information
●​ Horizontal Prototype: Demonstrates outer layer of human
interface only, such as windows, menus, and screens
●​ Mathematical Prototype: algorithm development for
analysis operations
●​ Mock up: A rough construction using crude materials such
as cardboard, foam, paper or wood typically done to show
the idea in 3D form.
●​ Model: A form built and painted for aesthetic appearance
only o Presentation Prototype: representation of the
product as it will be manufactured. Often used for
promotional purposes.
●​ Proof of Concept: The use of existing materials, parts and
components to prove the new Idea works or not.
●​ Rapid Prototype: A group of techniques used to quickly
fabricate a scale model of a part or assembly using three
dimensional CAD data. Frequently associated with 3D
printing.
●​ Usability prototypes used to define, refine, and demonstrate
user interface design usability, accessibility, look and feel.
●​ Vertical Prototype: Refine database design, test key
components early
●​ Virtual Prototype: 3D Computer Aided Design (CAD)
rendering

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●​ Working Prototype: A fully functioning item yet may not be
fully designed & engineered for manufacturability, nor it
may not be appearance like.

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Problem Statement

The problem statement is the statement that the students write from
their preliminary research and is their definition, or redefinition, of the
problem as they understand it. It is a clear and concise description of
the issues that need to be addressed by the team.

The problem statement becomes part of the Design Brief and consists
of several parts in a few sentences. It includes:
• The Vision Statement: This statement describes the goals, values
or the desired results that solving the issue will have.
• The Issue Statement: This statement is a sentence or two that
describes the problem or what is preventing the vision from
being accomplished using specific issues. This would consist of
the “Who, What, When, Where, and Why” of what is getting in the
way of solving the issue.
• The Method Statement: This describes the approach the team
will take to solve the problem.

Example:

Bicycles are an efficient and low pollution method of

transportation in overcrowded urban areas that frequently move
faster than motorized transportation. Secure storage, passenger
safety and inclement weather all impact the desirability of
adopting this mode of transportation. We are proposing to design
an enclosed hybrid pedal powered vehicle that will allow use in all
weather, provide greater passenger safety and have the same
ability to be secured as a car while taking up a fraction of the
space.

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Design Brief

A design brief is used to provide a summary of how a problem will be

approached. This way the customer will know the exact problem you
will be solving for them and a projection of the resources needed. This is
usually a one to two page document meant to quickly communicate
the scope and goals of a specific design project. The document is
focused on the desired results of design. It is frequently done in
conjunction with the client.

Design briefs should have the following sections.

• Objectives and Goals of the Design

• Client and Context
• Scope of the Project
• Problem Statement or Description
• Resources and Budget
• Constraints
• Time Needed
• Other (depending on need)

Example:

Client and Context of the Problem Reflective Gear, manufacturer

of safety gear for cyclists is designing a new line of gear for people
who cycle or run in periods of low light. Accidents are four times
more probable at night.

Problem Statement:

Ideally the clothing should be lightweight, comfortable to wear,

durable and washable. Existing clothing is either uncomfortable
or not reflective enough for safety in dark environments. The
company has contacted us to design new reflective designs,
either passive such as reflective tape or active LED based systems.

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Criteria and Constraints:

The design proposed needs to provide a reflected light with

minimum loss so it is plainly visible at 100 feet. If we select an LED
system it must be visible at 100 feet and have a minimum battery
life of 50 hours. The design must survive repeated washings and
not lose reflectivity. The total weight allowed is 6.5 ounces in
addition to the base clothing.

Objectives and Goals:

We will experiment and report back on various ways to achieve

the necessary visibility within the weight and comfort limits.

Scope of the Project:

We will test various methods of utilizing reflective strips. We will

develop a method of attaching the reflective strips with the goal
of less than 1% failure after 10 washings. We will experiment with
various methods of using LEDs in clothing. We will not design the
clothing, only using clothing provided by Reflective Gear. We will
not test for clothing survival over a period of years.

Resources Needed:

Our team will need access to the latest clothes designs from
Reflective Gear. We will need access to reflective materials and
plastic strip sealer/heaters to experiment with easy methods used
to incorporate the reflective material. LED strips and power
sources will also be needed. We will need resources for three
members of the team for a month along with necessary
computer and measuring resources.

Time needed:

It is our estimate that testing and reporting can be done in one

month’s time from the date of the agreement. We will provide
our report and examples of our visibility solution with the report.

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