[email protected] • ENGR-11_Engineering_Design_Cycle_Details.ppt 1 Bruce Mayer, PE Engineering-11: Engineering Design Bruce Mayer, PE Licensed Electrical & Mechanical Engineer [email protected] Engineering 11 Engineering Design Cycle
Dec 28, 2015
[email protected] • ENGR-11_Engineering_Design_Cycle_Details.ppt1
Bruce Mayer, PE Engineering-11: Engineering Design
Bruce Mayer, PELicensed Electrical & Mechanical Engineer
Engineering 11
Engineering
Design Cycle
[email protected] • ENGR-11_Engineering_Design_Cycle_Details.ppt2
Bruce Mayer, PE Engineering-11: Engineering Design
PreReq Identify an Opportunity
Idea emerges for an Engineered Product that will likely produce a minimum Return on Investment (RoI)
Described, at a minimum, by a list of Functional Requirements (FR’s)• Technical Function
and Performance• Production Cost Target• Production Time Target
[email protected] • ENGR-11_Engineering_Design_Cycle_Details.ppt3
Bruce Mayer, PE Engineering-11: Engineering Design
Design Elements Need Schedule
Translate Functional Requirements (FR’s) into Quantitative & Object Design Requirements (DR’s)• e.g., FR = The product output has a
UNIFORMITY of ±3%– DR1 = Temperature controlled 530 °C, ±4°C– DR2 = Pressure controlled to 290 kPa, ±15 kPa– DR3 = etc.
[email protected] • ENGR-11_Engineering_Design_Cycle_Details.ppt4
Bruce Mayer, PE Engineering-11: Engineering Design
Design Elements Need Schedule BrainStorm Concepts
• Preliminary: Analyze/Rank Concepts– Technical Risk/Feasibility
Search for “Fatal Flaws”– Schedule Risk/Feasibility– Cost Risk/Feasibility
• Final: Evaluate most promising (no more than 3) Concepts– Detailed Calculations and/or Computer Models– SubScale Physical Testing– Cost & Schedule Comparisons
• Select: Determine “best” Concept
[email protected] • ENGR-11_Engineering_Design_Cycle_Details.ppt5
Bruce Mayer, PE Engineering-11: Engineering Design
Design Elements Need Schedule Conceptual Design
• Explanation of HOW design MEETS the FR’s– Describe “Theory of Operation”
• Form and Fit (LayOut Drawings)• Control System Schematics; e.g.,
Electrical, Plumbing, Optical, Ventilation, etc.– Identify & Describe System-Control Elements
and the associated I/O points
• Identify Suppliers for Critical Components
[email protected] • ENGR-11_Engineering_Design_Cycle_Details.ppt6
Bruce Mayer, PE Engineering-11: Engineering Design
Design Elements Need Schedule Conceptual Design
• Identify Fabrication Methods for Critical Components
• Identify Critical Infrastructure; e.g., special buildings, machinery, instrumentation, etc.
CONCEPTUAL DESIGN REVIEW• CDR General Presentation Requirements
– Be as detailed as your thoughts or concepts allow.– Clearly state where there are open questions or issues.
• Be prepared for questions. Comments & Queries from the audience are encouraged.
[email protected] • ENGR-11_Engineering_Design_Cycle_Details.ppt7
Bruce Mayer, PE Engineering-11: Engineering Design
Design Elements Need Schedule
CONCEPTUAL DESIGN REVIEW• CDR Presentation content details
– Define overall design constraints and requirements.
– Describe concept(s) in detail, their features, tradeoffs, and how they will address the performance, cost, schedule, and customer requirements.
– Define the top 3 reliability risks and how they will be mitigated
– Show any test data obtained to date.
[email protected] • ENGR-11_Engineering_Design_Cycle_Details.ppt8
Bruce Mayer, PE Engineering-11: Engineering Design
Design Elements Need Schedule CONCEPTUAL DESIGN REVIEW
• CDR Presentation content details– Show key project milestones and decisions to
be made between now and start of build.– COST REVIEW: Specific breakdown of cost
estimates, including cost data sources
Detail Design• Fabricated-Part Drawings (BluePrints)
– Material Selection– Material Processing/Finish– Tolerances and other inspection-Criteria
[email protected] • ENGR-11_Engineering_Design_Cycle_Details.ppt9
Bruce Mayer, PE Engineering-11: Engineering Design
Design Elements Need Schedule
Detail Design• Purchased-Part Specifications
– Supplier: Name & Contact-Information– Supplier Part/Catalog number– Inspection/Test Criteria
• Assembly Drawings and Instructions– Complete Parts List (a.k.a. Bill of Material)– Assembly Processes and Sequence-of-Events
(SoE’s)– Assembly Specifications
[email protected] • ENGR-11_Engineering_Design_Cycle_Details.ppt10
Bruce Mayer, PE Engineering-11: Engineering Design
Design Elements Need Schedule Detail Design
• Detailed Control-System Schematics– Listing of I/O points– Describe Function of Each I/O point
CRITICAL DESIGN REVIEW• Test Data Supporting the Concept
– C&F data presented where applicable or available
• Design Presentation: How it meets subsystem and system requirements– Describe design, including performance and
operation, critical design or build areas, how the design meets subsystem criteria
[email protected] • ENGR-11_Engineering_Design_Cycle_Details.ppt11
Bruce Mayer, PE Engineering-11: Engineering Design
Design Elements Need Schedule
CRITICAL DESIGN REVIEW• Functional Engineering BoM, ready for
prototype release– Complete & Accurate BoM using Organization-
Standard Format
• BoM Cost estimate for production build – Purchasing quotes for "Big Hitter" items; std
Company DataBase costs, Supplier quotes, published Catalog-Costs, educated estimates for other items
[email protected] • ENGR-11_Engineering_Design_Cycle_Details.ppt12
Bruce Mayer, PE Engineering-11: Engineering Design
Design Elements Need Schedule
CRITICAL DESIGN REVIEW• Fab and procurement drawings for
prototype build– All fab drawings and new-component Item
Control Sheet (ICS = Spec Sheet) used in that subassembly
• Updated subsystem requirements table: IO, interfaces, performance & design requirements– Refined requirements that were presented at
CDR, Detailed interface info
[email protected] • ENGR-11_Engineering_Design_Cycle_Details.ppt13
Bruce Mayer, PE Engineering-11: Engineering Design
Design Elements Need Schedule
CRITICAL DESIGN REVIEW• Listing of manufacturing risks
– Simple statements of risks
• Identification of manufacturing strategy: Make or Buy, Line or Cell, Manual or Automated, etc.– Simple statement attached to BoM components
• Identification of supplier strategy: How/Who will supply components– Simple vendor ID attached to BoM components
[email protected] • ENGR-11_Engineering_Design_Cycle_Details.ppt14
Bruce Mayer, PE Engineering-11: Engineering Design
Design Elements Need Schedule
CRITICAL DESIGN REVIEW• Identification of inspection strategy:
Supplier or Company inspection, critical areas– Simple statement of who is responsible for
inspection of which critical parts
• Inputs from Safety Engineering to assure compliance with Human-Safety and Ergonomics Standards (UL, CE, NEC, SEMI S2, ASME Pressure-Vessel Code, ANSI Z136 Lasers, etc.)
[email protected] • ENGR-11_Engineering_Design_Cycle_Details.ppt15
Bruce Mayer, PE Engineering-11: Engineering Design
Design Elements Need Schedule
CRITICAL DESIGN REVIEW• Inputs from Reliability Engineering for your
subsystem: Reliability-Critical Items List (RCIL) compilation, suppliers needing audits or surveys– Simple identification of RCIL and affected
suppliers
• First-cut Identification of Field Replaceable Units (FRUs)– Preliminary FRU identification only
[email protected] • ENGR-11_Engineering_Design_Cycle_Details.ppt16
Bruce Mayer, PE Engineering-11: Engineering Design
Design Elements Need Schedule
CRITICAL DESIGN REVIEW• SubSystem Test Plans
– Any level of subsystem test plan or subsystem test criteria is acceptable
• Schedule for Open Items– Provide schedule for completion of any open
CrDR deliverables
[email protected] • ENGR-11_Engineering_Design_Cycle_Details.ppt17
Bruce Mayer, PE Engineering-11: Engineering Design
Design Elements Need Schedule ProtoType Construction & Testing
• Built to CrDR BluePrints and Specifications; Iterate-on– Accuracy/Correctness of Documentation– Fabrication, Inspection, Assembly Process
Improvements• Test & Iterate-on
– Function– Performance– Reliability– SubSystem Testing
[email protected] • ENGR-11_Engineering_Design_Cycle_Details.ppt18
Bruce Mayer, PE Engineering-11: Engineering Design
Design Elements Need Schedule
ProtoType Construction & Testing• Test & Iterate-on
– Inspection– EveryThing Else
Final Design• 99.99% Accurate (Goal is “Fire & Forget”)
– Fabrication & Assembly BluePrintsDetailed INSTRUCTIONS if needed
– Bill of Materials– Control-System Schematics
[email protected] • ENGR-11_Engineering_Design_Cycle_Details.ppt19
Bruce Mayer, PE Engineering-11: Engineering Design
Design Elements Need Schedule
Final Design• Finalized
– Test Procedures– Inspection Documents
• First Cut Instruction Manuals– Installation– Operation– Maintenance
Recommended Customer-Site Spare Parts
[email protected] • ENGR-11_Engineering_Design_Cycle_Details.ppt20
Bruce Mayer, PE Engineering-11: Engineering Design
DilBert BrainStorming
[email protected] • ENGR-11_Engineering_Design_Cycle_Details.ppt21
Bruce Mayer, PE Engineering-11: Engineering Design
All Done for Today
EngineeringDesign
Pyramid
[email protected] • ENGR-11_Engineering_Design_Cycle_Details.ppt22
Bruce Mayer, PE Engineering-11: Engineering Design
Bruce Mayer, PERegistered Electrical & Mechanical Engineer
Engineering 11
Appendix
[email protected] • ENGR-11_Engineering_Design_Cycle_Details.ppt23
Bruce Mayer, PE Engineering-11: Engineering Design
Rules for BrainStorming
Put judgment and evaluation aside temporarily.
Turn imagination loose, and start offering the results.
Think of as many ideas as you can. Seek combination and improvement. Record all ideas in full view. Evaluate at a later session.
[email protected] • ENGR-11_Engineering_Design_Cycle_Details.ppt24
Bruce Mayer, PE Engineering-11: Engineering Design
SCAMPER BrainStorming
S ≡ substitute C ≡ combine A ≡ adapt M ≡ modify P ≡ put to another use E ≡ eliminate R ≡ reverse