- Class 21

Report
Concept Generation
Integrated Product and Process Design
ME 475
Fall Schedule
P. 26
Guidebook
2
Fall Assignments
P. 35-62
Guidebook
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?
•4 Summary
Need a BBQ Grill?
Structured Design Process…
Mission
Statement
Identify
Customer
Needs
Establish
Target
Specifications
Generate
Product
Concepts
Select
Product
Concept(s)
Test
Product
Concept(s)
Set
Final
Specifications
Perform Economic Analysis
Benchmark Competitive Products
Build and Test Models and Prototypes
Documentation
Moving forward in the
Design process; from What
to How…
3
Integrated Product and Process Design
Plan
Downstream
Development
Development
Plan
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…..
4
Integrated Product and Process Design
(Speaking of
BBQ’s...)
The Essence of
Engineering is Design…
Apollo 13 Example
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
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….
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?
7
Integrated Product and Process Design
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 subconcepts…
9
Integrated Product and Process Design
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
8
Integrated Product and Process Design
Search
Externally
Explore
Systematically
Reflect on
Process
Concept Generation Process
1. Clarify the problem
•
Problem Decomposition
Clarify
Problem
2. Search externally
•
•
•
•
•
Lead Users
Experts
Patents
Literature
Benchmarking
Search
Internally
Search
Externally
3. Search internally
•
•
Individual Methods
Group Methods
4. Explore Systematically
•
•
Classification Tree
Combination Table
5. Reflect on the Process
10
Integrated Product and Process Design
Explore
Systematically
Reflect on
Process
Clarify the Problem:
Power Nailer Example…
11
Integrated Product and Process Design
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)
- ….
12
Integrated Product and Process Design
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 subfunctions categorized into types…
13
Integrated Product and Process Design
Problem Decomposition:
Function Diagram for Nail Gun
INPUT
OUTPUT
Energy (?)
Energy (?)
Hand-held
nailer
Material (nails)
Signal (tool "trip")
Material (driven nail)
Step 1
Signal (?)
NOTE: verbnoun pattern
Energy
Note 7 subfunctions
Nails
"Trip" of
tool
Store or
acc ept
ext ernal
energy
Conv ert
energy t o
trans lational
energy
Store
nails
Is olate
nail
Sens e
trip
Trigger
tool
Step 2
Apply
trans lational
energy t o nail
14
Integrated Product and Process Design
Driven
nail
Once we note subfunctions (using a
verb noun pattern
of thinking), our
mind will more
readily think of
ways-- “hows”
(sub- concepts) to
accomplish these
sub-functions…
51
18
Integrated Product and Process Design
Function Decomposition: Wheelchair
Note 4
subfunctions
15
Integrated Product and Process Design
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
Sub-Functions and sub-Concepts…
Concept Generation Process
1. Clarify the problem
•
Problem Decomposition
Clarify
Problem
2. Search externally
•
•
•
•
•
Lead Users
Experts
Patents
Literature
Benchmarking
Search
Internally
Search
Externally
3. Search internally
•
•
Individual Methods
Group Methods
4. Explore Systematically
•
•
Classification Tree
Combination Table
5. Reflect on the Process
16
Integrated Product and Process Design
Explore
Systematically
Reflect on
Process
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
17
Integrated Product and Process Design
Capture Innovation from Lead Users:
Utility Light Example
18
Integrated Product and Process Design
Search Externally: Benchmarking
Competitive Products……..
19
Integrated Product and Process Design
Search Externally:
Benchmarking
20
Integrated Product and Process Design
Search Externally:
unrelated/related products
Hardware stores, Sears…….
e.g. gripping
function, etc.
QuickTime™ and a
Photo - JPEG decompressor
are needed to see this picture.
28
Integrated Product and Process Design
Search Externally:
Unrelated Products
Do these products have
anything in common?
29
Integrated Product and Process Design
Both Doors Snap Closed…
The train car
inspired the
cam design that
closes the
battery door on
the Palm Treo
Dock
30
Integrated Product and Process Design
Search Externally: Getting help from
experts…
• Experts in the field
- Within your company
- Other companies (vendors)
• Faculty and researchers at
universities
• Other
21
Integrated Product and Process Design
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)
22
Integrated Product and Process Design
Search Externally
Example:
Bottle Opener
(Patent Search)
24
Integrated Product and Process Design
25
Integrated Product and Process Design
26
Integrated Product and Process Design
Patent Drawings…
27
Integrated Product and Process Design
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
23
Integrated Product and Process Design
“Everyday” Experiences
Learn to use everyday
experiences to generate
ideas…
Search Externally: Web
32
Integrated Product and Process Design
Concept Generation Process
1. Clarify the problem
•
Clarify
Problem
Problem Decomposition
2. Search externally
•
•
•
•
•
Lead Users
Experts
Patents
Literature
Benchmarking
Search
Internally
Search
Externally
3. Search internally
•
•
Individual Methods
Group Methods
4. Explore Systematically
•
•
Classification Tree
Combination Table
5. Reflect on the Process
33
Integrated Product and Process Design
Explore
Systematically
Reflect on
Process
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
34
Integrated Product and Process Design
Concept Generation Process
1. Clarify the problem
•
Problem Decomposition
Clarify
Problem
2. Search externally
•
•
•
•
•
Lead Users
Experts
Patents
Literature
Benchmarking
Search
Internally
Search
Externally
3. Search internally
•
•
Individual Methods
Group Methods
4. Explore Systematically
•
•
Classification Tree
Combination Table
5. Reflect on the Process
48
Integrated Product and Process Design
Explore
Systematically
Reflect on
Process
How do we Synthesize
sub-concepts into Total
Product Concept
Solutions?
- Concept Classification Tree
- Concept Combination Table
- Other
52
Integrated Product and Process Design
Concept Classification Tree…
53
Integrated Product and Process Design
Concept Combination Table
54
Integrated Product and Process Design
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?
55
Integrated Product and Process Design
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
8
Integrated Product and Process Design
Search
Externally
Explore
Systematically
Reflect on
Process
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
Thank You!
48

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