Concept Generation Facts –Concepts are best generated by individually –Concept selection is best performed by groups Opinion –Systematic “Idea generation” methods do not work – even hinder creativity.

The five-step Methodology Clarify Problem Search Externally Search Internally Explore Alternatives Reflection Sub-problems

Step - I :Clarify Review all the specification targets in PDS Perform a functional decomposition (if possible) –Divide complex functions into many simpler ones. –Follow the flow of materials to determine what functions are required. –Postpone specific solutions to the end.

Functional Decomposition Example: Cardboard pallet forming device Following material flow: –Raise and position cardboard sheets –Slide cardboard out of loading storage –Apply glue to cardboard –Position cardboard for forming –Form cardboard crease marks –Bend and form reinforcement shapes in cardboard –Insert reinforcement shapes [manual] into cardboard –Close flaps of cardboard

Functional Decomposition Position cardboard for forming –Apply force to cardboard –Guide cardboard –Stop cardboard –Secure cardboard for bending Prevent cardboard motion laterally. Prevent cardboard lift up.

Functional Decomposition Signal flows –Sense cardboard level –Trigger feed mechanism –Verify the cardboard position Sense cardboard face contact Sense edge contact –Trigger glue application

External Search (Pin Remover) Direct competition - Same products - None Similar functions on related products –Bearing removers –Cork removers –Pneumatic hammers and nailers –Car jacks –Vises –Industrial presses and hammers –Winches

Searching for Ideas External Sources of Ideas –Patents (Overall function or sub-functions) –Published literature Research and trade journals Interview lead users Consult experts Benchmark related products Internet

Searching for Ideas Search internally – Brainstorming –Work individually or in a group –Generate a lot of ideas Allows extracting useful features Stimulates other ideas –Include ideas which may seem infeasible –Do not allow time for rational thinking!

Exploring Systematically Organizing solution fragments Concept Classification Tree –Classifies possible approaches to a sub-problem Concept Combination Table –Combines various solutions –Some combinations may not make sense

Exploring Systematically –Example: Power sources. –Example: Cardboard feeder (roller, suction, pusher) –Example: Pad washer “ nozzle pad surface ” Move nozzles over pad only Move pad and nozzles Move pad only –Example: Bolt tester power and force source

Explore Systematically

Exploring Systematically Concept Combination Table –Combines solutions to sub-problems –Some combinations may not make sense