1. Concept Generation Integrated Product and Process Design ME 475

2. Fall Schedule 2 P. 26 Guidebook

3. Fall Assignments P. 35-62 Guidebook

4. Objectives for Today: OK—now that we have discussed how to identify the Whats, (i.e. Customer Needs and resulting Functional Specs.), how do we best come up with possible Hows to meet those needs and specifications? Summary 4 Need a BBQ Grill?

5. Structured Design Process… Perform Economic Analysis Benchmark Competitive Products Build and Test Models and Prototypes Identify Customer Needs Establish Target Specifications Generate Product Concepts Select Product Concept(s) Set Final Specifications Plan Downstream Development Mission Statement Test Product Concept(s) Development Plan Moving forward in the Design process; from What to How… Integrated Product and Process Design 3 Documentation

6. Concept Generation Creating and developing concepts (and sub-concepts) involves one of the most fulfilling and uplifting aspects of engineering design… Research has shown that the best way to have a really good idea is to have lots of ideas….. Integrated Product and Process Design 4 (Speaking of BBQ’s...)

7. The Essence of Engineering is Design… Apollo 13 Example

8. Creation Brings Fulfillment… “The desire to create is one of the deepest yearnings of the human soul….Creation brings deep satisfaction and fulfillment. We develop ourselves and others when we take unorganized matter [and create something]. Creation means bringing into existence something that did not exist before….” “Don’t let fear of failure discourage you…” President Dieter F. Uchtdorf 8

9. Structured Design Process The Concept Generation portion of the design process stresses not setting our minds on a specific solution, at first— instead, our efforts should yield a number of alternatives for later evaluation….

10. Concept Generation… Four Principles What existing concepts might be adapted for our application? What new concepts might satisfy our key customer needs and specifications? What methods can be used to facilitate the generation of concepts? How can I increase my creativity? Integrated Product and Process Design 7

11. OK, So What is A Concept? A Concept (or sub-concept) is: An approximate description of the technology, working principles and form of an idea, device, or process… A description of how the device (or portions of the device—or process), might work so that what the customer needs and wants might be satisfied… Usually defined (at first) by a sketch and a textual description… A concept may be made up of a number of sub- concepts… Integrated Product and Process Design 9

12. Concept Generation Process… Clarify the problem… Problem Decomposition Search externally… Lead Users Experts Patents Literature Benchmarking Search internally… Individual Methods Group Methods Explore Systematically… Classification Tree Combination Table Reflect on the Process and its results… Clarify Problem Search Internally Search Externally Explore Systematically Reflect on Process Integrated Product and Process Design 8

13. Concept Generation Process 1.Clarify the problem Problem Decomposition 2.Search externally Lead Users Experts Patents Literature Benchmarking 3.Search internally Individual Methods Group Methods 4.Explore Systematically Classification Tree Combination Table 5.Reflect on the Process Clarify Problem Search Internally Search Externally Explore Systematically Reflect on Process Integrated Product and Process Design 10

14. Clarify the Problem: Power Nailer Example… Integrated Product and Process Design 11

15. Clarify the Problem: Nail Gun… We translate Key customer needs into metrics & target values, which results in product specifications… The nail Gun: - Accommodates Nail lengths from 50 to 75 mm - Provides maximum nailing energy of 80 joules/nail - Provides a nailing force up to 2,000 newtons - Can nail at rate of up to 1 nail/second - Can insert nails between standard stud/joists (368 mm-14.5 inches-opening) - …. Integrated Product and Process Design 12

16. Clarify The Problem (cont’d) Problem Decomposition: Functional (or other) decomposition -Step 1, Think of the device, (product, or process) we are going to create as a black box… -Step 2, Divide the black box into sub-functions, each sub-function contributing to what the total product, (or process) will do…. End result is a function diagram containing sub- functions categorized into types… Integrated Product and Process Design 13

17. Problem Decomposition: Function Diagram for Nail Gun NOTE: verb- noun pattern Integrated Product and Process Design 14 Step 1 Step 2 Note 7 sub- functions

18. 18 Integrated Product and Process Design 51 Once we note sub- functions (using a verb noun pattern of thinking), our mind will more readily think of ways-- “hows” (sub- concepts) to accomplish these sub-functions…

19. Function Decomposition: Wheelchair Integrated Product and Process Design 15 Note 4 sub- functions

20. Individual Exercise: Take 4 Minutes: - Quickly list four sub-functions for your project using chart handed out at beginning of class… - Identify three sub-concepts that might accomplish just one of these needed sub-functions… - Tape the chart in your Guidebook… - Be prepared to share your results with the class

21. Sub-Functions and sub-Concepts…

22. Concept Generation Process 1.Clarify the problem Problem Decomposition 2.Search externally Lead Users Experts Patents Literature Benchmarking 3.Search internally Individual Methods Group Methods 4.Explore Systematically Classification Tree Combination Table 5.Reflect on the Process Clarify Problem Search Internally Search Externally Explore Systematically Reflect on Process Integrated Product and Process Design 16

23. Search Externally: Hints for Finding Related Solutions Lead Users benefit from improvement innovation source Benchmarking competitive products Related/unrelated products Experts technical experts experienced customers Patents search related inventions Literature technical journals trade literature Integrated Product and Process Design 17

24. Capture Innovation from Lead Users: Utility Light Example Integrated Product and Process Design 18

25. Search Externally: Benchmarking Competitive Products…….. 19 Integrated Product and Process Design

26. Search Externally: Benchmarking Integrated Product and Process Design 20

27. Search Externally: unrelated/related products Hardware stores, Sears……. e.g. gripping function, etc. Integrated Product and Process Design 28

28. Search Externally: Unrelated Products Do these products have anything in common? Integrated Product and Process Design 29

29. Both Doors Snap Closed… The train car inspired the cam design that closes the battery door on the Palm Treo Dock Integrated Product and Process Design 30

30. Search Externally: Getting help from experts… Experts in the field - Within your company - Other companies (vendors) Faculty and researchers at universities Other Integrated Product and Process Design 21

31. Search Externally: Finding Ways to Achieve Functions from Patents Three types of patents 1. utility--describes how a device or method works. Generally most helpful! 2. design--describes the look or form of a device 3. Plant—genetically engineered living things Two reasons for patent law(Intellectual Property-IP) Web patent search sites www.uspto.gov www.google.com/patents Law Library: Ask for help at reference Desk or visit BYU Technology Transfer Office (west side of Lee Library) Integrated Product and Process Design 22

32. Search Externally Example: Bottle Opener (Patent Search) Integrated Product and Process Design 24

33. Integrated Product and Process Design 25

34. Integrated Product and Process Design 26

35. Integrated Product and Process Design Patent Drawings… 27

36. Search Externally: Finding concepts from literature Technical articles—Lee Reference Librarian can help (Peter Zuber, 2321 HBLL, 422-2321) - Technical journals - Conference proceedings - Database searches - Trade magazines - Machine design - Popular Science - etc. Reference books (4 vol. Ingenious Mechanisms) Other Integrated Product and Process Design 23

37. “Everyday” Experiences Learn to use everyday experiences to generate ideas…

38. Search Externally: Web Integrated Product and Process Design 32

39. Concept Generation Process 1.Clarify the problem Problem Decomposition 2.Search externally Lead Users Experts Patents Literature Benchmarking 3.Search internally Individual Methods Group Methods 4.Explore Systematically Classification Tree Combination Table 5.Reflect on the Process Clarify Problem Search Internally Search Externally Explore Systematically Reflect on Process Integrated Product and Process Design 33

40. Internal Search: Hints for Generating Many Concepts (pg.109-110) Make analogies Get non experts Wish and wonder Use related stimuli Use unrelated stimuli Set quantitative goals Use gallery method TRIZ Methodology - Look for conflicts between two or more desirable characteristics - 40 basic principles help to overcome conflicts - Bicycle tail light example Integrated Product and Process Design 34

41. Concept Generation Process 1.Clarify the problem Problem Decomposition 2.Search externally Lead Users Experts Patents Literature Benchmarking 3.Search internally Individual Methods Group Methods 4.Explore Systematically Classification Tree Combination Table 5.Reflect on the Process Clarify Problem Search Internally Search Externally Explore Systematically Reflect on Process Integrated Product and Process Design 48

42. How do we Synthesize sub-concepts into Total Product Concept Solutions? - Concept Classification Tree - Concept Combination Table - Other 52 Integrated Product and Process Design

43. Concept Classification Tree… Integrated Product and Process Design 53

44. Concept Combination Table Integrated Product and Process Design 54

45. Reflect on the Results of the Process and the Process… Are we pleased with the results we have obtained? Is the team developing confidence that the total solution space has been fully explored? Should we consider alternative function or decompositional diagrams? Are there alternative ways to decompose the problem? Have external sources been thoroughly pursued? Have internal ideas from everyone been accepted for consideration and integration into the process? Integrated Product and Process Design 55

46. Concept Generation Process Clarify the problem Problem Decomposition Search externally Lead Users Experts Patents Literature Benchmarking Search internally Individual Methods Group Methods Explore Systematically Classification Tree Combination Table Reflect on the Process Clarify Problem Search Internally Search Externally Explore Systematically Reflect on Process Integrated Product and Process Design 8

47. Summary Once customer needs are interpreted and specifications developed, generate lots of sub-concepts and concepts… A structured process can help generate lots of ideas… Document, Document, and document Have Fun! Next time: How can I increase my creativity? 47

48. Thank You! 48