SEM Fall 2010 Chapter 4

Engineering Design Methods and Tools

Sahar Idrees

4.1 Conventional Design Practices

For most projects(large or small scale) the basic steps are the same: conceptual design, prelim design, detailed design etc). However, the level of effort & duration for each of these activities as well as the whole project varies depending upon the particular project & scenario. In addition, there are many & varied levels of specialization reqd for each project. As the design progresses, actual definition is accomplished through documentation of plans, specs, procedures, drawings, material parts lists, reports etc. A design may be exquisite, but unless properly documented, its of no use.

4.1 Conventional Design Practices

Documentation: Design Drawings : logic diagrams, schematic diag, piping diag, wiring & cable diag & drawings for assembly, spec control, construction & installation. Material & Parts Lists: Parts lists, material lists, longlead-item lists, bulk item lists, provisioning lists. Analysis Reports: Trade off study reports, supporting design decisions, finite element analysis report, reliability & maintainability analyses & predictions, logistic support analyses records, computer software recommendations.

4.1 Conventional Design Practices

The day to day design activity, esp. for large-scale systems may include generation & processing of hundreds of drawings & drawing-change notices. With a lot of different disciplines involved, these activities become more complex & difficult to follow. In some cases, it might require a month or more to route a single drawing through review steps for approval. Some challenges of these practices of past include:
Unintentional bypassing of procedures Implementation of changes with out proper approval Lack of practice of appropriate configuration control In essence, basic objectives of sys engg havent been followed.

4.2 Analytical Methods

The design engineer is constantly encountered with analysis in one way or the other throughout the design process. Few areas for analysis techniques: Probability Theory & Analysis Topics:Recommended prob. Dist. Models are uniform, binomial, Poisson, exponential, normal, log-normal & Weibull. Where is it reqd: Knowledge in this area is reqd to understand the principles of reliability & maintainability & various process control methods like risk analysis. Economic Analysis Topics: Knowledge of economics, interest & interest formulae, & determining economic equivalence among design alternatives etc. Where is it reqd: reqd in the performance of life cycle cost analysis & related activities.

4.2 Analytical Methods

Optimization Methods Topics: Familiarity with classical optimization theory, constrained & unconstrained optimization, linear & dynamic programming Where is it reqd: reqd to determine optimum sys equip life, equipment replacement policies, equipment packing schemes. Queuing Theory & Analysis Topics: Basic understanding of queuing theory(arrival mech, queue lenth, service mech and associated distribution), single & multi-channel models, Monte Carlo analysis etc Where is it reqd: reqd in design of facilities & functions that process numerous items through channel activity, e.g. establishing appropriate no of logistics & repair channels. Control Concepts & Techniques Statistical Process control tech, control charts, optimum policy control methods, control networks, project scheduling, TQM etc.

4.3 Info Technology, Internet & Emerging Technologies infrastructure that Information Technology: the
fosters, integration of various mechanisms for converting, storing, protecting, processing,transmitting/receiving info. Internet: worldwide network of interconnected computer networks that operates using a standardized set of communication protocols & TCP/IP. Information flows have changes drastically as internet has become widely available & put to use in a variety of models allowing flexibility, distribution of work practices & access to a large volume of online resources. Work flow: is used to describe tasks, organizations, information & tools involved in a business process.

4.4 Current Design Technologies & tools The availability of current design technologies & tools offers three
distinct advantages: 1. Creation of excellent communication networks with PCs at individual workstations connected to a main-frame computer allows rapid parallel processing & transmission of different categories of data. 2. Availability of a variety of efficient software tools like simulation methods, , three dimensional computer models, software to study inter-relationships, space allocations, performance of human task seq. etc. 3. Data handling capabilities allow for acquisition, processing, storage & retrieval of a large variety of data. It is now easier to capture information of drawings plus the generation & distribution of material parts/lists can be done easily.

4.4 Current Design Technologies & tools of Computer Tech. on Sys Engg Methods: Impact
The advent of computer technology can have a very beneficial impact on the system engg process. Specifically, A more in-depth & complete analysis of system reqts can be done at an early stage in design when the impacts on the life-cycle are the greatest. This, in turn, tends to foster more emphasis on a topdown, life-cycle approach in system development. An improved communications process can evolve as a result of a) Being able to disseminate data rapidly & effectively b) Being able to transmit info to multiple individuals & organizations concurrently c) Being able to incorporate design changes expeditiously These improvements in communication help to provide necessary integration of many different disciplinary areas in the design

4.4.1 Use of Simulation

Simulation: is the process of designing & utilizing an operational model of a system to conduct experiments for the purpose of either understanding the behavior of the system or evaluating alternative strategies &/or system design configurations. Objective is to construct a simplified representation of a system or a process in order to facilitate analysis, synthesis, &/or evaluation of the system/process. Its use is particularly appropriate in early stages of system development prior to when the different physical items are available for evaluation(analytical stage). Simulation models can be used to develop 3D system CAD models. Simulation allows for max. visibility in early stages of design.

4.4.2 Use of Rapid Prototyping

Systems in software engg differ from others in that they are mostly one of a kind & not mass produced. The goal is to develop a software that accurately portrays the features desired by the customer; i.e. the user interfaces. If the user does not comprehend & approve of the features as he receives the product, changes are recommended and applied, the cost of which is very high as this process is taking place so late in system life cycle, i.e. after production & utilization. The alternative is:
to develop a prototype early in the system design process design the applicable software involve the user in the operation of prototype identify areas that need improvement

4.4.2 Use of Rapid Prototyping

incorporate changes involve user once again & so on.

This iterative & evolutionary process of software development accomplished throughout prelim & detailed design is called rapid prototyping. This practice is often implemented & is inherent within system engg process, particularly in development of large softwareintensive systems.

4.4.3 Use of Mock-Ups

Although simulation provides a lot of insight into the system, some times it is desirable to construct a 3D scale model or physical mock-up of the system during prelim or detailed design to produce a realistic replica of a proposed config. Mock-ups can bee produced to varying degrees of scale & detail. May be constructed of wood,heavy cardboard,metal or a combo. Can be developed inexpensively & in a short period of time. Applications:
1. Allow design engineer to expt with different facility layouts, packaging schemes, panel displays etc before formal design. 2. Allow the reliability/maintainability/human factors engineers to accomplish a more effective review of a design config. 3. Provide reliability/maintainability/human factors engineers with a tool to use in predictions & detailed task analyses by simulating task seq beforehand & obtaining task seq. & time data.

4.4.3 Use of Mock-Ups

4. Provide the design engineer with a tool to convey the final design approach during a formal design review. 5. Can serve as an excellent marketing tool. 6. Can be employed to facilitate training of operator & maintenance personnel. 7. Are utilized by production & industrial engg personnel in developing fabrication & assembly procedures & in design of factory tooling & associated text fixtures. 8. At a later stage in sys life cycle, they may serve as a tool for verification of a kit design prior to the prep of formal data development of kit hardware.