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1. Interdisciplinary Engineering Design Course John Callister & Marty Murtagh NCIIA Conference San Jose, California March 21, 2014.

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Page 1: 1. Interdisciplinary Engineering Design Course John Callister & Marty Murtagh NCIIA Conference San Jose, California March 21, 2014.

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Page 2: 1. Interdisciplinary Engineering Design Course John Callister & Marty Murtagh NCIIA Conference San Jose, California March 21, 2014.

Interdisciplinary Engineering Design Course

John Callister & Marty Murtagh

NCIIA Conference San Jose, California

March 21, 2014

Page 3: 1. Interdisciplinary Engineering Design Course John Callister & Marty Murtagh NCIIA Conference San Jose, California March 21, 2014.

Marty MurtaghMaterial Sci.

Tobias HanrathChemical Eng.

Rhett WeissJohnson School

John CallisterMechanical Eng.

Page 4: 1. Interdisciplinary Engineering Design Course John Callister & Marty Murtagh NCIIA Conference San Jose, California March 21, 2014.

Cornell Engineering

Page 5: 1. Interdisciplinary Engineering Design Course John Callister & Marty Murtagh NCIIA Conference San Jose, California March 21, 2014.

Cornell Engineering

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MSE = Material Science and Engineering

ChemE = Chemical Engineering

MAE = Mechanical Engineering

Acronyms

Page 7: 1. Interdisciplinary Engineering Design Course John Callister & Marty Murtagh NCIIA Conference San Jose, California March 21, 2014.

• MSE had traditionally been focused on preparing undergraduates for graduate school, and on its graduate program

• But, some students went into industry after getting their bachelors

• Employers noted that these students lacked design skills

Background – Material Science at Cornell

Page 8: 1. Interdisciplinary Engineering Design Course John Callister & Marty Murtagh NCIIA Conference San Jose, California March 21, 2014.

Background – Material Science at Cornell

Page 9: 1. Interdisciplinary Engineering Design Course John Callister & Marty Murtagh NCIIA Conference San Jose, California March 21, 2014.

• Adjunct Professor Marty Murtagh, full-time Corning Inc. engineer, was given the task of updating the design courses in MSE.

• MSE 3070 Materials Design Concepts I (junior level) and MSE 4070 Materials Design Concepts II (senior level) were the results of this.

Background – Material Science at Cornell

Page 10: 1. Interdisciplinary Engineering Design Course John Callister & Marty Murtagh NCIIA Conference San Jose, California March 21, 2014.

• While these courses were big improvements, all of the other MSE courses remained very laboratory based involving materials at small scales.

• The students still tended to have a lab rat approach.

Background – Material Science at Cornell

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• Disclaimer: It is actually called the School of Chemical and Biomolecular Engineering

• Recently, Professor Tobias Hanrath introduced a new nanotechnology senior product design class.

• Historically, the ChemE department had only offered a senior process design class.

Background – Chemical Engineering at Cornell

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Background – Chemical Engineering at Cornell

Process Design

Page 13: 1. Interdisciplinary Engineering Design Course John Callister & Marty Murtagh NCIIA Conference San Jose, California March 21, 2014.

• MAE does not have a senior capstone design class.

• Seniors take add-on one-credit design projects that are affiliated with courses.

• Or, seniors can take an independent design project to fulfill this requirement.

• Students have to fill out the form….

Background – Mechanical Engineering at Cornell

Page 14: 1. Interdisciplinary Engineering Design Course John Callister & Marty Murtagh NCIIA Conference San Jose, California March 21, 2014.

Background – Mechanical Engineering at Cornell

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• MSE has a new senior design class, but the designs are a bit flat.

• ChemE has a new product design class, but there was some dissatisfaction with it.

• MAE has a very flexible senior design requirement, so one could quite easily extend this to a new class, at least for awhile.

Background

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• An anonymous donor wants to fund an interdisciplinary design course or program of some kind.

• There are 7 digits in the dollar number.

Background

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• MSE students will provide the materials-enabled part of the design.

• ChemE students will be able to design a large-scale process to make the new product in quantity.

• MAE students will be able to help with CAD and machining, as they learn this in the MAE sophomore design class.

Interdisciplinary Design Course

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• Can’t fit all the lectures on design AND the business case material into one semester!

Interdisciplinary Design Course - Planning

Page 19: 1. Interdisciplinary Engineering Design Course John Callister & Marty Murtagh NCIIA Conference San Jose, California March 21, 2014.

• Solution: MBA Mentors! They will assist students with the business case.

Interdisciplinary Design Course - Planning

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• MSE: “home” of the course• ChemE: cross-listed• MAE: cross-listed• Johnson: volunteer MBA mentors

Interdisciplinary Design Course - Planning

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• MSE: most entrepreneurial department?

Interdisciplinary Design Course - Planning

Page 22: 1. Interdisciplinary Engineering Design Course John Callister & Marty Murtagh NCIIA Conference San Jose, California March 21, 2014.

• MSE: most entrepreneurial department?

Interdisciplinary Design Course - Planning

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• Form groups of five students• Start the semester with 6 weeks of lectures

Interdisciplinary Design Course – Course Design

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Lecture Topics

• Innovation staging (1)• Design essentials (6)• Intellectual property (2)• Reliability (2)• House of quality (1)• Marketing overview (1)• Guest lectures (3)

– “Sustainability as guide to Product Development”– “Theory of Inventive Problem Solving (TRIZ )”– “The Startup Business Case”

(# of lectures)

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• Case Study• Each group studies an existing company and

reports on it.• Focus is on innovation and intellectual

property.

Interdisciplinary Design Course – Course Design

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Page 27: 1. Interdisciplinary Engineering Design Course John Callister & Marty Murtagh NCIIA Conference San Jose, California March 21, 2014.

• Startup Initiation Worksheet• Each group proposes the product they will

design• The scope of the invention is spelled out

clearly.

Interdisciplinary Design Course – Course Design

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Interdisciplinary Design Course – Course Design

Page 29: 1. Interdisciplinary Engineering Design Course John Callister & Marty Murtagh NCIIA Conference San Jose, California March 21, 2014.

• House of Quality• Each group surveys its target market• The voice of the customer is determined• This is used to find the product requirements.

Interdisciplinary Design Course – Course Design

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Page 31: 1. Interdisciplinary Engineering Design Course John Callister & Marty Murtagh NCIIA Conference San Jose, California March 21, 2014.

• Weekly Design Reviews• Each group meets for 45 minutes (or more)

with faculty• The objective is getting through the Level

One (proof of concept) and Level Two (feasibility) gates

Interdisciplinary Design Course – Course Design

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Innovation Staging

I Gather

KnowledgeR

Innovation Product Development Hierarchy*

IIAssess

Feasibility R&D

IIIScrutinize

UtilityD&E

IVDemonstrate Profitability

E&M

VOversee

Life CycleM

Decision Gate

Startup focus

*Adapted from Corning Incorporated Global Innovation Effectiveness 2010

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Design Review13 March 2013

Tesla Energy SystemsJustin Araway, Matt Boban, Sophie Zhu, Nick Chartrain

1

Page 34: 1. Interdisciplinary Engineering Design Course John Callister & Marty Murtagh NCIIA Conference San Jose, California March 21, 2014.

Responsibilities

• Matt Boban: CTO– Technology and IP

• Justin Araway: CFO– Operations, Financial Projections, Supply Chain

• Sophie Zhu: CMO– Market Research, Branding, Sales

• Nick Chartrain: CEO– Business Plan, Putting it all Together

2

Page 35: 1. Interdisciplinary Engineering Design Course John Callister & Marty Murtagh NCIIA Conference San Jose, California March 21, 2014.

Design Gateway Level 1

• Market– Customer Pull– Problem customers experience is well defined

• Product– IP position has been well researched, strategy not defined– Product function has been well defined

• Process– Process will be a vital part of our IP position

• Business Case– Patent preferable to trade secret– Has financial viability

3

Page 36: 1. Interdisciplinary Engineering Design Course John Callister & Marty Murtagh NCIIA Conference San Jose, California March 21, 2014.

• Had 25 students, put into 6 groups. • Not really enough MAE, ChemE students.• None of the groups produced a working

prototype by the end of the semester.• Progress was made by all.• All groups followed the design process.

Interdisciplinary Design Course – Outcomes

Page 37: 1. Interdisciplinary Engineering Design Course John Callister & Marty Murtagh NCIIA Conference San Jose, California March 21, 2014.

Interdisciplinary Design Course – Outcomes

Page 38: 1. Interdisciplinary Engineering Design Course John Callister & Marty Murtagh NCIIA Conference San Jose, California March 21, 2014.

Interdisciplinary Design Course – Outcomes

Page 39: 1. Interdisciplinary Engineering Design Course John Callister & Marty Murtagh NCIIA Conference San Jose, California March 21, 2014.

• Process was a success• It is difficult to get around roadblocks quickly• There was a lot of pressure on the one MAE

student in each group to be really good at CAD

• MBA mentors helped a great deal• Student evaluations were very good• Course is being taught this year…16 students

Interdisciplinary Design Course – Outcomes

Page 40: 1. Interdisciplinary Engineering Design Course John Callister & Marty Murtagh NCIIA Conference San Jose, California March 21, 2014.

Interdisciplinary Design Course

• Q&A• John Callister, [email protected]