1. Creative Problem Solving

2. Creative vs. Analytical Analytical – one solution Creative Many possible solutions Divergent Phases Search for ideas More = Better! Convergent Phases Narrow the possibilities Define “Best”

3. Engineering Problem Solving Identify the need Define the problem Search for information Develop alternative solutions Analyze the alternatives Decide which solution is “best”

4. Identify the Need What is wrong? Look for the underlying need. Ask “Why” several times. Challenge “needs” that are really solutions.

5. The operators of a 40-ton punch press have had several near misses and one serious accident where the press activated while the operator’s arm was inside. The owner wants you to design a guard to limit how far the operator can reach into the press. Owner thinks he needs a guard. Why? Note solution in definition Need? What’s Wrong?

6. Define the Problem Use a broad problem statement. Use “decision tree” to define the range of possibilities.decision tree Symptoms vs. Causes Avoid jumping to a solution.

7. Avoid Obstacles Limit constraints Dump old paradigms Divide complex problems into parts Allow for incubation Consider non- engineering solutions

8. Constraints Affect Decisions Tom, Dick, Harry, and Al are married to May, June, Sue, and Bea, though not necessarily in that order. Given the following information, who is married to whom? June, who is Dick’s sister, has five children. Tom has never introduced his wife to Sue, who is carrying on an extra- marital affair with Dick. (May is considering telling Dick’s wife about it.) Tom’s wife want to wait a few more years before starting a family. Dick and Harry are twin brothers.

9. Problem Definition The client needs a means to prevent the 40-ton press from activating with the operator’s arm inside.  Constraint: existing 40-ton press must be used  Paradigm: operator places parts in press – or – The client needs a means to prevent employee accidents while producing cab frames.

10. Search for Information Existing Solutions Internet Library Indexes Thomas Register or Sweets Catalog Journals Government Documents Professional Organizations Vendor Catalogs Individuals

11. Alternative Solutions More ideas = Better chance for success Brainstorming Affinity Diagram Morphological Diagram

12. Brainstorming Small to medium-sized groups List all possible ideas May be written or oral Comments on ideas are not allowed! Write down everything! One idea may lead to others - build!

13. How to kill an idea... That’ll never work! We tried that once, but it didn’t pan out. When you’ve been here a bit longer you’ll understand the problem better. Get Marketing and Finance to agree and we’ll talk.

14. Affinity Diagrams Write ideas on Post-it notes Group them on a board to broadly identify concepts Allow time to review ideas and build related ones Good for larger groups Identifies related thoughts Recorder not overloaded

15. Morphological Diagram BladeReelString Gas Electric

16. Analyzing Alternatives Function - Does it solve the problem? Physical Specifications Human Engineering Marketing Production Economics

17. Human Engineering Human/machine Interfaces Ergonomics Safety

18. Decision Criteria - What’s Best? Decision matrix

19. Decision Matrix

20. Decision Criteria - What’s Best? Decision matrix Weighted matrix

21. Weighted Matrix

22. Decision Criteria - What’s Best? Decision matrix Weighted matrix Intangibles? Rank order “Show Me the Money!”

23. Rank Ordering

24. “Show Me the Money!” Works well for Affinity Diagrams - Give each person $20 to distribute