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Bruce Mayer, PE Engineering-11: Engineering Design

Bruce Mayer, PELicensed Electrical & Mechanical Engineer

[email protected]

Engineering 11

Engineering

Design Cycle



PreReq Identify an Opportunity

Idea emerges for an Engineered Product that will likely produce a minimum Return on Investment (RoI)

Described, at a minimum, by a list of Functional Requirements (FR’s)• Technical Function

and Performance• Production Cost Target• Production Time Target



Design Elements Need Schedule

Translate Functional Requirements (FR’s) into Quantitative & Object Design Requirements (DR’s)• e.g., FR = The product output has a

UNIFORMITY of ±3%– DR1 = Temperature controlled 530 °C, ±4°C– DR2 = Pressure controlled to 290 kPa, ±15 kPa– DR3 = etc.



Design Elements Need Schedule BrainStorm Concepts

• Preliminary: Analyze/Rank Concepts– Technical Risk/Feasibility

Search for “Fatal Flaws”– Schedule Risk/Feasibility– Cost Risk/Feasibility

• Final: Evaluate most promising (no more than 3) Concepts– Detailed Calculations and/or Computer Models– SubScale Physical Testing– Cost & Schedule Comparisons

• Select: Determine “best” Concept



Design Elements Need Schedule Conceptual Design

• Explanation of HOW design MEETS the FR’s– Describe “Theory of Operation”

• Form and Fit (LayOut Drawings)• Control System Schematics; e.g.,

Electrical, Plumbing, Optical, Ventilation, etc.– Identify & Describe System-Control Elements

and the associated I/O points

• Identify Suppliers for Critical Components



Design Elements Need Schedule Conceptual Design

• Identify Fabrication Methods for Critical Components

• Identify Critical Infrastructure; e.g., special buildings, machinery, instrumentation, etc.

CONCEPTUAL DESIGN REVIEW• CDR General Presentation Requirements

– Be as detailed as your thoughts or concepts allow.– Clearly state where there are open questions or issues.

• Be prepared for questions. Comments & Queries from the audience are encouraged.




CONCEPTUAL DESIGN REVIEW• CDR Presentation content details

– Define overall design constraints and requirements.

– Describe concept(s) in detail, their features, tradeoffs, and how they will address the performance, cost, schedule, and customer requirements.

– Define the top 3 reliability risks and how they will be mitigated

– Show any test data obtained to date.



Design Elements Need Schedule CONCEPTUAL DESIGN REVIEW

• CDR Presentation content details– Show key project milestones and decisions to

be made between now and start of build.– COST REVIEW: Specific breakdown of cost

estimates, including cost data sources

Detail Design• Fabricated-Part Drawings (BluePrints)

– Material Selection– Material Processing/Finish– Tolerances and other inspection-Criteria




Detail Design• Purchased-Part Specifications

– Supplier: Name & Contact-Information– Supplier Part/Catalog number– Inspection/Test Criteria

• Assembly Drawings and Instructions– Complete Parts List (a.k.a. Bill of Material)– Assembly Processes and Sequence-of-Events

(SoE’s)– Assembly Specifications



Design Elements Need Schedule Detail Design

• Detailed Control-System Schematics– Listing of I/O points– Describe Function of Each I/O point

CRITICAL DESIGN REVIEW• Test Data Supporting the Concept

– C&F data presented where applicable or available

• Design Presentation: How it meets subsystem and system requirements– Describe design, including performance and

operation, critical design or build areas, how the design meets subsystem criteria




CRITICAL DESIGN REVIEW• Functional Engineering BoM, ready for

prototype release– Complete & Accurate BoM using Organization-

Standard Format

• BoM Cost estimate for production build – Purchasing quotes for "Big Hitter" items; std

Company DataBase costs, Supplier quotes, published Catalog-Costs, educated estimates for other items




CRITICAL DESIGN REVIEW• Fab and procurement drawings for

prototype build– All fab drawings and new-component Item

Control Sheet (ICS = Spec Sheet) used in that subassembly

• Updated subsystem requirements table: IO, interfaces, performance & design requirements– Refined requirements that were presented at

CDR, Detailed interface info




CRITICAL DESIGN REVIEW• Listing of manufacturing risks

– Simple statements of risks

• Identification of manufacturing strategy: Make or Buy, Line or Cell, Manual or Automated, etc.– Simple statement attached to BoM components

• Identification of supplier strategy: How/Who will supply components– Simple vendor ID attached to BoM components




CRITICAL DESIGN REVIEW• Identification of inspection strategy:

Supplier or Company inspection, critical areas– Simple statement of who is responsible for

inspection of which critical parts

• Inputs from Safety Engineering to assure compliance with Human-Safety and Ergonomics Standards (UL, CE, NEC, SEMI S2, ASME Pressure-Vessel Code, ANSI Z136 Lasers, etc.)




CRITICAL DESIGN REVIEW• Inputs from Reliability Engineering for your

subsystem: Reliability-Critical Items List (RCIL) compilation, suppliers needing audits or surveys– Simple identification of RCIL and affected

suppliers

• First-cut Identification of Field Replaceable Units (FRUs)– Preliminary FRU identification only




CRITICAL DESIGN REVIEW• SubSystem Test Plans

– Any level of subsystem test plan or subsystem test criteria is acceptable

• Schedule for Open Items– Provide schedule for completion of any open

CrDR deliverables



Design Elements Need Schedule ProtoType Construction & Testing

• Built to CrDR BluePrints and Specifications; Iterate-on– Accuracy/Correctness of Documentation– Fabrication, Inspection, Assembly Process

Improvements• Test & Iterate-on

– Function– Performance– Reliability– SubSystem Testing




ProtoType Construction & Testing• Test & Iterate-on

– Inspection– EveryThing Else

Final Design• 99.99% Accurate (Goal is “Fire & Forget”)

– Fabrication & Assembly BluePrintsDetailed INSTRUCTIONS if needed

– Bill of Materials– Control-System Schematics




Final Design• Finalized

– Test Procedures– Inspection Documents

• First Cut Instruction Manuals– Installation– Operation– Maintenance

Recommended Customer-Site Spare Parts



DilBert BrainStorming



All Done for Today

EngineeringDesign

Pyramid



Bruce Mayer, PERegistered Electrical & Mechanical Engineer

[email protected]

Engineering 11

Appendix



Rules for BrainStorming

Put judgment and evaluation aside temporarily.

Turn imagination loose, and start offering the results.

Think of as many ideas as you can. Seek combination and improvement. Record all ideas in full view. Evaluate at a later session.



SCAMPER BrainStorming

S ≡ substitute C ≡ combine A ≡ adapt M ≡ modify P ≡ put to another use E ≡ eliminate R ≡ reverse

[email protected] engr-11_engineering_design_cycle_details.ppt 1 bruce mayer, pe...

Documents

pe engineering

engineering designprereq

systemcontrol elements

customer requirements

n s j o h n s o n c

minimum return

product output

engineered product