1. Product Development Chapter 6

3. Hardware & Software Techniques Block diagram the system (Visio) Redundancy  Active: failure of one parallel component - the second still works  Standby: failure of component – replacement MTBF=mean time between failures = 1/λ  Active MTBF=3/(2λ)  Standby MTBF=2/λ

4. MIL-HDBK-217 Where to get λ? Google MIL-HDBK-217… For example, see www.sqconline.com/reliability/index.html www.sqconline.com/reliability/index.html Try wire wound resistor in a missile…

5. Component Selection Considerations Component reliability  Vendor assessment (Hx, failure, etc.)  Vendor audit (check facility)  Vendor evaluation (inspect incoming)  Vendor qualification (on-list?) Component history  military & reliability groups  government info bases Safety (FMEA, etc.)

6. Hardware & Software Techniques ctd. Component Derating  Practice of limiting the stresses  Use 2 watt R in 1 watt situation, decrease failure rate >30% (T, humidity, P, V, I, friction, vibration)  Usage ratio = max stress/stress rating (.5-.9)  Goal is reliability!  Pacemaker example

7. Hardware & Software Techniques ctd. Safety Margin  =(mean safety factor) - 1 =(mean strength/mean stress) - 1  Elevator – safety margin~2  Medical devices – Fries -.5 and up. Load Protection Environment (see 112) Product misuse Design for variation (6 sigma)

8. Experimental Design Statistical Approach  Effective approach for multivariable situations  Taguachi method Design Process  System design  Parameter design  Tolerance design Two types of variables  Control factors  Noise factors Apply this to design

9. Software Development and Engineering Management Planning for safety (FDA!) Planning for risk assessment Planning for method  Waterfall  Incremental delivery  Spiral  Cleanroom  Code and fix, …

10. Software Development and Engineering Management Choose design method  Top-down  Data driven  OOP Language (Assembler/C++/Qbasic etc.) Testing Requirements Hazard Analysis!!! (FDA)

11. Software Development and Engineering Management Requirements traceability (FDA) Software architecture design  Well defined modules (logical)  Other vendor – standalone  Single purpose modules  Cohesion & coupling Implementation (coding) Integration

12. Structured/Unstructured Design Techniques Computer/database assisted:  Ideation - ‘Innovation Workbench’  TRIZ  Techoptimizer  Others… Example done in class, another in text

13. Axiomatic Design Nam Suh, MIT Requirements, design parameters, process variables, customer needs = vectors Try to solve, disassociate functional requirements and design parameters Highly mathematical Acclaro Software

14. Reverse Engineering and Redesign Opportunities increase with age of technology Disassembly of product and inventory and analysis of parts Allows for the potential update or modification of the parts with technological advances Can drastically increase productivity or effectiveness in a dated product

15. Design Techniques Very structured approach  Pahl and Beitz, Engineering Design  Design method contains 8 distinct steps Semistructured  Wilcox, Engineering Design for Electrical Engineers  Ulrich and Eppinger Product Design and Development

16. The Clean-Room Approach To Reverse-Engineering: “One person or group takes a device apart and describes what it does in as much detail as possible at a higher level of abstraction than the specific code. That description is then given to another group or person who has absolutely no knowledge of the specific device in question. This second party then builds a new device based on the description. The end result is a new device that works identically to the original but was created without any possibility of specifically copying the original. “ -Mathew Schwartz