Transcript Functional Decomposition and Concept Generation MSD I Workshop 3 prepared by Prof.

Functional Decomposition and
Concept Generation MSD I Workshop 3
prepared by Prof. Margaret Bailey (ME)
Copyright © 2007 Rochester Institute of Technology
All rights reserved.
EDGE™
Today’s Workshop Overview
• 9 – 10:30 AM
• 10:30 – Noon
• Noon - 2 PM
• 2 - 2:30 PM
• 2:30 – 3 PM
• By 3:30 PM
Interactive Exercise on
Functional Decomposition and
Concept Generation
Functional Decomposition and
Concept Generation on Project
Lunch and Activity Hour Break
Team Work Session (cont.)
Create Summary of Workshop
Activities
Review Team Concept Generation
Activities with Guide
EDGE™
Morning Session Overview
• Introduce Concept Generation
• Explore Five-Step Concept Generation
Method
• Demonstrate Above Steps on Various
Examples
• Discuss Common Dysfunctions and Tips
• Apply Concept Generation Steps to Team
MSD I Project
EDGE™
Concept Development Process
Mission
Statement
Identify
Customer
Needs
Establish
Target
Specifications
Generate
Product
Concepts
Select
Product
Concept(s)
Test
Product
Concept(s)
Set
Final
Specifications
Plan
Downstream
Development
Perform Economic Analysis
Benchmark Competitive Products
Build and Test Models and Prototypes
Karl T. Ulrich and Steven D. Eppinger, 2004, Product Design and
Development, Exhibit 6-2, Chapter 6, 4th Edition, p. 98, Irwin McGraw-Hill
EDGE™
Development
Plan
Concept Generation
"Fail Often, Fail Fast, Fail Cheap"
Customer Needs
Target Specifications
Concept
Generation
Phase
SET of Possible Concepts
Goal: By the end of this phase, your
team should feel confident that the full
spectrum of options has been explored.
EDGE™
Concept Generation Process
• Clarify the Problem
– Problem Decomposition
• External Search
–
–
–
–
–
–
Lead Users
Experts
Benchmarking
Patents/ Literature
Professional Societies
Standards
• Internal Search
– Individual Methods
– Group Methods
• Systematic Exploration
– Classification Tree
– Combination Table
• Reflect on the Process
– Continuous Improvement
Karl T. Ulrich and Steven D. Eppinger, 2004, Product Design and Development,
Exhibit 6-3, Chapter 6, 4th Edition, p. 100, Irwin McGraw-Hill
EDGE™
Clarify the Problem
• Decompose or divide a complex problem into simpler
problems that can more easily be solved in a focused
manner.
• Several “decomposition” methods available, such as:
– Sequence of User Actions
– Key Customer Needs
– FUNCTIONS, known as Functional Decomposition
• Division process occurs until sub-functions can be worked
on easily
• Function diagram useful for documenting but they are not
unique; several decompositions may be found for a given
problem
• A simple list of sub-functions (without connections shown)
is also acceptable
EDGE™
Function Diagram: Hand Held Nailer
INPUT
OUTPUT
Energy (?)
Energy (?)
Material (nails)
Hand-held
nailer
Signal (tool "trip")
Signal (?)
Store or
accept
ext ernal
energy
Conv ert
energy t o
translational
energy
Nails
Store
nails
Isolate
nail
"Trip" of
tool
Sense
trip
Trigger
tool
Energy
Material (driven nail)
Apply
translational
energy t o nail
Karl T. Ulrich and Steven D. Eppinger, 2004, Product Design and Development,
Exhibit 6-4, Chapter 6, 4th Edition, p. 102, Irwin McGraw-Hill
Driven
nail
EDGE™
Review Functional Decomposition
on MSD I Project
• What are your “must
haves”?
• Develop function diagram
(showing connections or
flows) and/or list of subfunctions for your MSD I
project
• Identify sub-functions
that could be considered
critical
– Most critical to the
success of the product
– Most likely to benefit from
novel or creative solutions
EDGE™
Concept Generation Process
• Clarify the Problem
– Problem Decomposition
• External Search
–
–
–
–
–
–
Lead Users
Experts
Benchmarking
Patents/ Literature
Professional Societies
Standards
• Internal Search
– Individual Methods
– Group Methods
• Systematic Exploration
– Classification Tree
– Combination Table
• Reflect on the Process
– Continuous Improvement
Karl T. Ulrich and Steven D. Eppinger, 2004, Product Design and Development,
Exhibit 6-3, Chapter 6, 4th Edition, p. 100, Irwin McGraw-Hill
EDGE™
Patents/Literature
• US Patent and Trademark Office Web Site
– http://www.uspto.gov/
– http://www.uspto.gov/web/offices/com/iip/index.htm
• European Patent Office
– http://www.european-patent-office.org/online/
• Academic Journals
– Database tools such as web of science, engineering index,
compendex, science citations index, etc.
• Conference Proceedings
• Internet Resources
– Search engines: Google, Metacrawler, …
– Government Web Site (Foreign and Domestic)
– DO NOT rely exclusively on internet search resources. They
are often good, but they are also often WRONG and
INCOMPLETE
EDGE™
Professional Societies
•
•
•
•
•
•
•
Project Management Institute (PMI)
Institute of Electrical and Electronics Engineers (IEEE)
The technical objectives of the IEEE focus on advancing the theory and practice of
electrical, electronics and computer engineering and computer science.
Software Engineering Institute
The SEI mission is to provide leadership in advancing the state of the practice of
software engineering to improve the quality of systems that depend on software.
The International Society for Optical Engineering (SPIE)
The society's fundamental mission is to provide world-class education and information
services that enhance and promote the profession and field of optical engineering and
that add quality and value to the careers of the members it serves.
Society of Automotive Engineers (SAE)
SAE provides technical information and expertise used in designing, building,
maintaining, and operating self-propelled vehicles for use on land or sea, in air or space.
American Society for Testing and Materials (ASTM)
The society promotes public health and safety, and the overall quality of life; contributes
to the reliability of materials, products, systems and services.
Society of Manufacturing Engineers (SME)
The society is dedicated to serving its members and the manufacturing community
through the advancement of professionalism, knowledge, and learning.
EDGE™
Standards
• Private Companies & Organizations
– Underwriter’s Laboratory
– International Organization for Standards (ISO)
– European Environment Agency
• Government
– Occupational Safety & Health Administration
– MIL standards
– Codes
• Societies
– Design standards
– Accepted practices
EDGE™
Develop External Search Strategy
for MSD I Project
• Identify lead users and
experts
• Create benchmarking
plan
– Closely related products
– Functionally related
products
• Describe your reverse
engineering plan.
• Discuss usefulness of
patent/literature
search for various subfunctions
EDGE™
Concept Generation Process
• Clarify the Problem
– Problem Decomposition
• External Search
–
–
–
–
–
–
Lead Users
Experts
Patents/ Literature
Professional Societies
Standards
Benchmarking
• Internal Search
– Individual Methods
– Group Methods
• Systematic Exploration
– Classification Tree
– Combination Table
• Reflect on the Process
– Continuous Improvement
Karl T. Ulrich and Steven D. Eppinger, 2004, Product Design and Development,
Exhibit 6-3, Chapter 6, 4th Edition, p. 100, Irwin McGraw-Hill
EDGE™
Tips for Idea Generation
•
•
•
•
•
•
•
•
Focus on generating a large QUANTITY of ideas
Do not criticize individuals, ideas, or suggestions
Do not pass judgment on the statements made
Do not evaluate the merits of an idea – welcome ideas
that may first appear infeasible
Set goals – either fixed number of ideas in a session, or
maximum ideas in a fixed length of time
Analogies – What other devices solve related problem?
Wish and wonder – Consider new possibilities
Related stimuli – Work on your neighbor’s idea list
EDGE™
More Tips for Idea Generation
• Balance Individual and Group Search
• Individuals generate ideas more quickly than groups
– Analogies – What other devices solve related problem?
– Wish and wonder – Consider new possibilities
• Group interaction is critical for refinement,
combination, and critique of the solutions
– Group sessions build team consensus that solution space has
been adequately explored
– Gallery Method – Display many concepts created by various
individuals at once (via post-its, etc.)
• Explain
• Improve/refine
• Identify related concepts
EDGE™
Begin Internal Search Process for
MSD I Project
• Focus on generating a
large QUANTITY of
ideas for a critical subfunction
• Use individual and group
techniques
• Record concept
generation process and
share with class
EDGE™
Concept Generation Process
• Clarify the Problem
– Problem Decomposition
• External Search
–
–
–
–
–
–
Lead Users
Experts
Patents/ Literature
Professional Societies
Standards
Benchmarking
• Internal Search
– Individual Methods
– Group Methods
• Systematic Exploration
– Classification Tree
– Combination Table
– Morphological Tables
• Reflect on the Process
– Continuous Improvement
Karl T. Ulrich and Steven D. Eppinger, 2004, Product Design and Development,
Exhibit 6-3, Chapter 6, 4th Edition, p. 100, Irwin McGraw-Hill
EDGE™
Systematic Exploration:
Concept Combination Table - Hand Held Nailer
Convert Electrical
Energy to
Translational
Energy
Accumulate
Energy
rotary motor w/
transmission
spring
linear motor
moving mass
solenoid
Apply
Translational
Energy to Nail
single impact
multiple impacts
push nail
rail gun
Karl T. Ulrich and Steven D. Eppinger, 2004, Product Design and Development,
Exhibit 6-12, Chapter 6, 4th Edition, p. 117, Irwin McGraw-Hill
EDGE™
Concept Generation Process
• Clarify the Problem
– Problem Decomposition
• External Search
–
–
–
–
–
–
Lead Users
Experts
Patents/ Literature
Professional Societies
Standards
Benchmarking
• Internal Search
– Individual Methods
– Group Methods
• Systematic Exploration
– Classification Tree
– Combination Table
– Morphological Tables
• Reflect on the Process
– Continuous Improvement
Karl T. Ulrich and Steven D. Eppinger, 2004, Product Design and Development,
Exhibit 6-3, Chapter 6, 4th Edition, p. 100, Irwin McGraw-Hill
EDGE™
Rest of the Day….
• Create list of sub-functions AND/OR develop
a functional diagram (refer to Exhibit 6-4)
• Identify and justify critical sub-functions
• Begin external searches of problem solutions
• Internal search of solutions at system and
sub-function levels, include several possible
solutions
• Synthesize possible solution combinations at
the sub-function level (refer to Exhibit 6-9)
EDGE™
By Week 4
Review and submit following deliverables to Team Guide
during week 4:
• Update Overall Project Plan and Schedule
• List of sub-functions AND/OR develop a functional
diagram (refer to Exhibit 6-4)
• Identify and justify critical sub-functions
• Summarize results of external and internal searches
of problem solutions, include several possible
solutions (refer to Exhibit 6-6)
• Synthesize possible solution combinations at the subfunction level (refer to Exhibit 6-9)
• READ Chapter 7 and be prepared for Concept
Selection activities during Week 4 Workshop
EDGE™