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ENG 4050L Interdisciplinary Competitive Design
Prof. F. Campean / 2013-14
ENG 4050L
INTERDISCIPLINARY
COMPETITIVEDESIGN
Week 1: Introduction
WHATIS
COMPETITIVEDESIGN?
Share your thoughts with your colleagues and
decide on two important features ofInterdisciplinary Competitive Design
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ENG 4050L Interdisciplinary Competitive Design
Prof. F. Campean / 2013-14
WHATFACTORSUNDERPIN
COMPETITIVEENGINEERINGDESIGN?
Consumers Viewpoint:Think of a product that you are likely to buyphone, camera, laptop, car,
Manufacturing Viewpoint:Think that you would have to manufacture this product
Business Viewpoint:
Think that this is your venture
Society Viewpoint:Think of your children
ENGINEERINGASPECTS
OFCOMPETITIVEDESIGN
Design and develop competitive products that people want (to buy);
that perform the required function in a reliable and robust
manner;
compliant with standards;
Sustainable and future proof;
Efficient design process reduced time to market
reduced development costs
Easy to manufacture
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ENG 4050L Interdisciplinary Competitive Design
Prof. F. Campean / 2013-14
WHATSKILLS DOYOUNEEDFORCOMPETITIVEDESIGN?
Competitive Design LecturingTeam
Prof. Felician Campean Ford Suite, B.1.33, x4569
Dr. Martyn Jupp
Mr. Nigel Revitt
Dr. Steve Wright
Prof. Ed Henshall RAEng Visiting Prof in Integrated System Design
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ENG 4050L Interdisciplinary Competitive Design
Prof. F. Campean / 2013-14
Module aims
Develop knowledge and skills in design
process and application of engineering tools
that support competitive design;
Enhance your readiness to work in industry
perform in a teamwith clear focus /
objectives / constraints;
Develop your skills to work independentlydefineplanexecutereport.
Organisation of module
Linked modulewill continue in Sem 2
Project based assessment
Student led projects
Focus on creativity, innovation and
comprehensive / integrated approach to
design
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ENG 4050L Interdisciplinary Competitive Design
Prof. F. Campean / 2013-14
Competitive Design Project
Group projectsteams of 3-5
A substantial piece of work!
Coursework Facts: 20 credit module means 200 hours of work per student,
i.e. 800 man-hours per group!
Circa 6,000 words equivalent per student, 24,000 per
group (cca 100 pages)
Competitive Design Project
Coursework Schedule:
S1/week 3 - 4: Task given to
students
S1/week 8/9: Project Stage 1
submission + team presentations
and feedback;
S2/week 4/5: Project Stage 2
submission + team presentations
and feedback;
S2/week12: Final project
submission + poster
presentation.
Stage Submissions
formativeAND summative
assessment
i.e. you will be given
feedback which you can
incorporate in your final
submission, but interim
submissions are marked as
well!
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ENG 4050L Interdisciplinary Competitive Design
Prof. F. Campean / 2013-14
Competitive Design Project
Project
PhaseContent Guideline Assessment
Weight in
final mark
Stage 1
Project definition / brief
Project planning
Initial work
Design Requirements
Report 1 (cca 1000 -
1500 wps)
Presentation (ppt)
10%
Stage 2
Literature review
Concept generation
Concept analysis / critical
evaluation
Concept selection
Report 2 (cca 3000 -
3500 wpscumulative
with R1)
Presentation (ppt)
20%
Stage 3 /
Final
Design development (for
selected concept)
Robustness, Failure Mode
Avoidance assessment Design Verification &
Validation
Final report (cca 6000
wps, cumulative with R1
&2)
Poster presentation
60%
10%
Competitive Design Project
Examples of past projects: Sustainable commuter transport system for the Bradford ecoversity
A generic design for a spinal injuries unit
Development of an alternative synchronous power transmission / camshaft
actuation for an automotive IC engine application
Design of an alternative braking solution for cars
Steer -by-wire system for road vehicles
Use of metallic and polymer foams in automotive body shells
The design of a jacking device for use on rally cars
Design and build a prototype working roof system for the quantum H4 sports
car
Tyre pressure monitoring and control system
Evaluate the feasibility of utilising a turbo charger for driving ancillaries
Design a sensor systems for the detection of pedestrians
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ENG 4050L Interdisciplinary Competitive Design
Prof. F. Campean / 2013-14
Organisation of module
Semester 1 & Semester 2: Formal lectures / talksseminar style
Directed study
Project work
Project clinics
B.1.31 Ford Suiteusually available as
resource for teamwork
Organisation of module
Sem Week Date Lecture / Class activity Coursework Milestone
2 27-Sep Overview of Design Process
3 04-Oct Customer Focused Engineering
4 11-Oct Team Work Skills Coursework set-up (latest)
5 18-Oct Concept Generation and Selection
6 25-Oct Concept Generation and Selection
7 01-Nov Coursework Cl inic
8 08-Nov Systems Engineering9 15-Nov Coursework Cl inic
10 22-Nov Project Presentations Stage 1 Submission
11 29-Nov
12 06-Dec FMEA
13 13-Dec Coursework Cl inic
S
em1
Clinic & Feedback - Stage 1
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ENG 4050L Interdisciplinary Competitive Design
Prof. F. Campean / 2013-14
OVERVIEWOFSYSTEMSENGINEERINGDESIGN
What is Engineering Design?
What is Systems Engineering Design?
What are the Product Development
Process Steps?
Imagine designing the following products:
Automobile
Bicycle
Coffee maker
Commercial jet
Fishing reel
Mobile phone
Laser printer
Millenium Bridge
Spinal Injury Unit
GPS device
Hydrogen power generator
DAB radio
Are all design problems the same?
What is Design?
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ENG 4050L Interdisciplinary Competitive Design
Prof. F. Campean / 2013-14
What is Design?
FunctionsI want to get to the
ICD classI need to talk to my
friends ASAP...
Solutions
esign
Definition of Design
Set of decision making processes andproblem solving
activities to determine theform (architecture,
structure)of a product, given the customers desired
function.
Engineering is the process of devising a system,
component, or process to meet desired needs. It is a
decision-making process (often iterative) in which the
basic sciences, mathematics, and engineering sciences are
applied to convert resources optimally to meet a stated
objective
Accreditation Board for Engineering and Technology
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ENG 4050L Interdisciplinary Competitive Design
Prof. F. Campean / 2013-14
Engineering Design
Form ever follows function[Louis Sullivan]
Steps in Engineered Product Development: Identify the Function
Engineering design - deliver a product solution for the
desired function
Verify and validate
What is Systems Engineering Design?
What is a system?
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ENG 4050L Interdisciplinary Competitive Design
Prof. F. Campean / 2013-14
What is Systems Engineering Design?
What is a system?
Complex whole;
Set of connected things or parts;
Organized body of material or immaterial
things, arranged to work together.
- Oxford English Dictionary.
Every system
Has function or purpose Has inputs and outputs
Is not just a collection of parts
Contains interacting sub-systems
Systems Thinking
System is greater than sum of its parts
System is no stronger than weakest part
Optimising parts does not optimise the whole.
Interactions determine the performance of a
system
The whole system cant be fully understood by
breaking it down and analysing parts - yet
design is historically done by analysing parts.
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Systems Engineering
Systems Engineering is an interdisciplinary approach and
means to enable the realization of successful systems. It
focuses on defining customer needs and required
functionality early in the development cycle, documenting
requirements, then proceeding with design synthesis and
system validation while considering the complete problem:
Operations Performance Test
Manufacturing Cost Schedule
Training Support Disposal
INCOSE
International Council on Systems Engineering
Systems Engineering
Systems Engineering integrates all thedisciplines and specialty groups into a teameffort forming a structured developmentprocess that proceeds from concept toproduction to operation.
Systems Engineering considers both thebusiness and the technical needs of allcustomers with the goal of providing aquality product that meets the user needs.
INCOSE
International Council on Systems Engineering
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ENG 4050L Interdisciplinary Competitive Design
Prof. F. Campean / 2013-14
Systems Engineering Designthe
Vee Model
Vehicle
Sub-system
I
Sub-system
II
Sub-system
II
Sub-system
I
Vehicle
Compo-nent
Design Optimisation
Compo-nent
Systems Engineering [Ford Model]
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ENG 4050L Interdisciplinary Competitive Design
Prof. F. Campean / 2013-14
Systems Engineering [FHWA]
http://www.fhwa.dot.gov
Systems Engineering
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ENG 4050L Interdisciplinary Competitive Design
Prof. F. Campean / 2013-14
Design
intent
Customer
Requirements
Design
conceptManufacturing
concept
Product
Design
Production
Control
Plan
Design
Verification
Process
Design
This is a generic engineering design process
Product Creation Process
Design
intent
Customer
Requirements
Design
conceptManufacturing
concept
Product
Design
Production
Control
Plan
Design
Verification
Process
Design
This is a generic engineering design process
Product Creation Process
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ENG 4050L Interdisciplinary Competitive Design
Prof. F. Campean / 2013-14
Design Intent
Finding out the Customer Requirements helps
to:
Identify/Define Product Functions/Functionality,
Establish Engineering Targets,
Define the PDS (Product Design Specification)
Design
intent
Customer
Requirements
Design
conceptManufacturing
concept
Product
Design
Production
Control
Plan
Design
Verification
Process
Design
Product Creation Process
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ENG 4050L Interdisciplinary Competitive Design
Prof. F. Campean / 2013-14
Design ConceptThe Design Concept follows on from the Design Intent
and must meet the PDS:
Encourage innovation, but also look at what has been donebefore. Learn from other fields.
Get a team together; use structured techniques that supportinnovative thinking.
Use analytical methods to evaluate the functionality androbustness of a Design Concept - the Transfer FunctionApproach.
Use a structured (matrix based) approach to evaluatealternatives and select a winning concept (Pughs ConceptSelection)
Manufacturing concept
The Manufacturing Concepts must be developed
concurrently with the Design Concept:
Think about how you will make it while you are designing it -
Simultaneous Engineering.
Use analytical methods to evaluate the capability of
proposed manufacturing concepts - look for causes ofvariation and analyze their effects.
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ENG 4050L Interdisciplinary Competitive Design
Prof. F. Campean / 2013-14
Design
intent
Customer
Requirements
Design
conceptManufacturing
concept
Product
Design
Production
Control
Plan
Design
Verification
Process
Design
Product Creation Process
Product Design
Complete the Detail Design to meet the PDS.
Includes engineering design (function) and
aesthetic design (form).
Integrated with manufacturing process design.
The functionality of the design must be confirmed
at all stages.
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ENG 4050L Interdisciplinary Competitive Design
Prof. F. Campean / 2013-14
Process Design
Complete the Process Design to meet the PDS
Consider:
Supplier / Customer Chain.
Business Processes.
Manufacturing Processes
Development Processes.
Verification and Validation Processes.
ISO standards.
Design
intent
Customer
Requirements
Design
conceptManufacturing
concept
Product
Design
Production
Control
Plan
Design
Verification
Process
Design
Product Creation Process
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ENG 4050L Interdisciplinary Competitive Design
Prof. F. Campean / 2013-14
Design Verification & Validation
Verification: Have we got the product right?
Does the product achieve the specified function?
Validation:
Have we got the right product?
We need to be confident that the design will
deliver its intended function over its lifetime.
Process Validation
We also need to be confident that the process will
deliver a consistent product over its lifetime:
Confirm that the manufacturing process is stable and
capable.
Confirm that all manufacturing processes and business
processes are robust and reliable.
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ENG 4050L Interdisciplinary Competitive Design
Prof. F. Campean / 2013-14
Control Plan
Product Quality Plan
Material specifications,
Quality System procedures,
Product data,
Process control,
Inspection procedures,
Packaging and distribution specifications.
Design
intent
Customer
Requirements
Design
conceptManufacturing
concept
Product
Design
Production
Control
Plan
Design
Verification
Process
Design
Product Creation Process
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ENG 4050L Interdisciplinary Competitive Design
Prof. F. Campean / 2013-14
Production
Once all these design steps are complete, the
Production phase can be started.
In practice, production will be ramped up through a
series of commissioning or trial production
operations.
At each stage the product characteristics and
process performance are measured to ensure that
the planned Design targets are met.
Remember that the best components dontnecessarily add up to the best system!
Systems Engineering design is about managing interfaces!
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ENG 4050L Interdisciplinary Competitive Design
Prof. F. Campean / 2013-14
Ulrich & Eppinger
Pughs Total Design
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ENG 4050L Interdisciplinary Competitive Design
Prof. F. Campean / 2013-14
Competitive Design Curriculum
Focused on tools that support the thought
experiments that are essential to good
engineering applied to complex / system
engineering design;
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ENG 4050L Interdisciplinary Competitive Design
Literature for Engineering Design
Pahl & Beitz - Engineering design : a
systematic approach
Ulrich & EppingerProduct Design and
Development
PughTotal Design
Clausing - Total quality development : a step-
by-step guide to world class concurrentengineering
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