ENGR-11_Engineering_Design_Cycle_Details.ppt 1 Bruce Mayer, PE Engineering-11: Engineering Design Bruce Mayer, PE Licensed Electrical & Mechanical Engineer Engineering 11 Engineering Design Cycle

ENGR-11_Engineering_Design_Cycle_Details.ppt 2 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

ENGR-11_Engineering_Design_Cycle_Details.ppt 3 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.

ENGR-11_Engineering_Design_Cycle_Details.ppt 4 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

ENGR-11_Engineering_Design_Cycle_Details.ppt 5 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

ENGR-11_Engineering_Design_Cycle_Details.ppt 6 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.

ENGR-11_Engineering_Design_Cycle_Details.ppt 7 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.

ENGR-11_Engineering_Design_Cycle_Details.ppt 8 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

ENGR-11_Engineering_Design_Cycle_Details.ppt 9 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

ENGR-11_Engineering_Design_Cycle_Details.ppt 10 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

ENGR-11_Engineering_Design_Cycle_Details.ppt 11 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

ENGR-11_Engineering_Design_Cycle_Details.ppt 12 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

ENGR-11_Engineering_Design_Cycle_Details.ppt 13 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

ENGR-11_Engineering_Design_Cycle_Details.ppt 14 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.)

ENGR-11_Engineering_Design_Cycle_Details.ppt 15 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

ENGR-11_Engineering_Design_Cycle_Details.ppt 16 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

ENGR-11_Engineering_Design_Cycle_Details.ppt 17 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

ENGR-11_Engineering_Design_Cycle_Details.ppt 18 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 BluePrints  Detailed INSTRUCTIONS if needed –Bill of Materials –Control-System Schematics

ENGR-11_Engineering_Design_Cycle_Details.ppt 19 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

ENGR-11_Engineering_Design_Cycle_Details.ppt 20 Bruce Mayer, PE Engineering-11: Engineering Design DilBert BrainStorming

ENGR-11_Engineering_Design_Cycle_Details.ppt 21 Bruce Mayer, PE Engineering-11: Engineering Design All Done for Today Engineering Design Pyramid

ENGR-11_Engineering_Design_Cycle_Details.ppt 22 Bruce Mayer, PE Engineering-11: Engineering Design Bruce Mayer, PE Registered Electrical & Mechanical Engineer Engineering 11 Appendix

ENGR-11_Engineering_Design_Cycle_Details.ppt 23 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.

ENGR-11_Engineering_Design_Cycle_Details.ppt 24 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