IE201Introduction to Engineering Design

Fall 2006-2007

The Celebration

1- Mostafa Kassem Nagi. 06140802- Ahmed Nafel Alharbee. 0611243

3- Haitham Farook Saied. 06128714- Saieed Ali AlGarnee. 0611276

5- Ali Alomraani. 0150266

This is the introduction for the L3 Assignment, which is about manufacturing to make students in this course know more about manufacturing. it is divided into parts so we can apply what we

have learnt in the course into steps and gradually.The L3 sections:

L3-A about defining the problemL3-B about generating ideas

L3-C about Deciding the course of actionL3-D about implementation.

L3-E about evaluating our work.

Next you will see all the parts of L3.

Introduction

This work is for assignment L-3a, the first part of Capstone design project assignment, which is about defining the

real problem, the first step of heuristic. We followed Fogler and Leblanc book (Strategies for Creative Problem

Solving) to define a problem about students who don’t know enough about manufacturing. We hope that we will be able to define the real problem because it is the most

important step for solving any problem.

The Definition Process:

We applied five techniques to define the problem correctly:

• Gathering Information• Present state /desired state• Dunker Diagram • Statement/Restatement

• Evaluating the five definitions

1.Gathering Information:The first step was to gather information about the problem by one or more of the

four steps in table 3-1 of Fogler and Leblanc book which are collect and analyze data, talk with people familiar with the problem, view the problem first hand and confirm all findings. We chose to talk with people familiar with the problem by talking with engineering faculty members and to view the problem first hand by asking KAAU and high school students about manufacturing and the results was as follows.

What we found out form the Engineering faculty members opinion: The problem is in the student’s life stages from the childhood to the university

stage. Parents, environment, school and university are major affects for the student mentality because if parents encouraged the child to discover the things deeply he will grow up to continue doing that in school stage and as a result will know enough information about manufacturing for university.

The result of KAAU and high school students questionnaire:We found out that almost 8 out of every ten students don’t know any thing about

manufacturing and when we asked why most of them said that they were never asked to get information about manufacturing. And also almost 8 out of every ten students never repair something wasted even their belongs such as cars and mobiles. Asking the teachers showed that the teachers themselves have no information about manufacturing so how can we ask them to teach the students when they need a teachers!.

These information shows that students needs guidance to learn anything not just manufacturing but there are no guiders because parents and teachers needs to learn about the importance of manufacturing and this was a result of not dealing with this problem when they were students and keeping ignoring it since their time as students. So students don’t know enough information about manufacturing because they are not guided to do that as a result student can’t react with out guidance.

2.Present state /desired state:

Discussion: This doesn’t work because enough is kind ambiguous and doesn’t determine the information students should get about manufacturing.

Discussion: This is match and shows that students needs to be educated about the manufacturing before they get start Engineering studies.

Present State Desired state

Students don’t know enough information about manufacturing

Students know enough information about manufacturing.

Present State Desired State

students who wants to study Engineering don’t know about the importance of manufacturing in engineering.

students who wants to study Engineering know about the importance of manufacturing in engineering.

3.Dunker Diagram:

Students know enough about manufacturing.

Ok if students don’t know enough about

manufacturing.

Convince them manufacturing is unimportant.

Put them in their suitable positions

Course in manufacturingParents

encouragement

Search for another faculty for them.

Sections in engineering unrelated to manufacturing.

A high school course about manufacturing.

First year engineering course. Enlighten parents

of manufacturing.

After doing this diagram we found out that the problem is in the house, school and university.

4.Statement/Restatement:Current problem statement: Students do not know enough about manufacturing.

Trigger 3:

How can we make students know nothing about manufacturing?

(By answering this question we found out the reasons for the low level of knowledge about manufacturing in the students.)

Trigger 4:

Students don’t have an enough knowledge about manufacturing for engineering.

(This change opens new thoughts. Why isn’t engineering requirements are not known and announced for students.)

Trigger 5:

The problem statement implies that we obviously want the students to know about manufacturing because it is needed in a lot of engineering fields.

Thus, if the engineering faculty could add to the first year Engineering program a course like IE201, which the student should study an artifact and develop it, the students would get a lot of information about manufacturing.

Maybe not! Maybe they don't want to/need to learn about manufacturing .

Trigger 6:

Students' information of manufacturing = k * Number of manufacturing courses.

The problem definitions we came up with after using the three techniques:

1.Parents and teachers don’t know about the importance of manufacturing.

2.The negative way the community looks at the people who works in manufacturing.

3.There are no teaching about the manufacturing at schools.

4.The students can’t act without guidance.5.Students gets into engineering without knowing

what it really means and requires.

5.Evaluating the five definitions:

Have all the pieces of the problem been identified?

D1:Yes

D2:Yes

D3:Yes

D4:Yes

D5: Yes

Have all constrains been identified? D1:Yes

D2:Yes

D3:Yes

D4:Yes

D5: Yes

What is missing from the problem definition?

D1:Nothing.

D2:Nothing.

D3:Nothing.

D4:Nothing.

D5:Nothing.

What is extraneous to the problem definition?

D1:Nothing.

D2:Nothing.

D3:Nothing.

D4:Nothing.

D5:Nothing.

Have you challenged the assumptions and information you were given to formulate the problem?

D1:Yes

D2:Yes

D3:Yes

D4:Yes

D5: Yes

Have you distinguished fact from opinion?

D1:Yes

D2:Yes

D3:Yes

D4:Yes

D5: Yes

Discussion

We hope that we have done our work completely without any mistakes. This

assignment was really helpful to develop our problem definition skills although it was

really hard because it was our first time defining a real life problem. We have

discovered that not knowing about such a big part of our lives which is manufacturing and we hope that we wouldn’t repeat the same mistakes with our children as ours

did.

Introduction

This is the work we have done in L-3b assignment which is about generating ideas for artifacts to apply what we have learnt about this step in the concept session. I hope we will be able to demonstrate comprehension level of learning about the second step of heuristic.

After we have defined the problem in the previous assignment we are now to generate ideas about the artifact we are going to study and develop and these are the steps we have followed:

First for our first task about the possible artifacts, each member of the team has generated 20 possible artifacts.

Then we used Boggle method to exclude the similarities between our artifacts.

Multi voting was the method to choose our top 10 artifacts.

Then for our second task about the constraints, we brainstormed constraints and we used Osborn checklist at brain drizzling stage.

Also we brainstormed our desires and used random stimulation to increase our desires and we used multi voting to choose our top 4 desires.

Member 1 Member 2 Member 3 Member 4 Member 5

Receiver Toy Car A.C Mobile Stereo

Calculator Toy helicopter Toy airplane Camera Radio

Stereo Printer Car tire Radio Washing machine

Toy Car VCR Watch Receiver Fridge

Microphone Play station Mobile Phone Watch

Watch Lamp Fax machine Bicycle Camera

Alarm clock Remote control Scooter Car House alarm

Television Watch MP3 player Wheel chair Desk chair

A.C Desk chair Lamp Headphone Computer

Robot Clock CD player Computer Printer

Food mixer Car stereo Desk chair Motor cycle Safe

Iron Door Skaters Remote control A.C

VCR Radio Door Watch Television

Telephone Computer mouse Desk VCR Scanner

Remote control Computer keyboard Play station Play station Electronic dictionary

Camera Scanner House alarm Fridge Toy car

Fax machine Bicycle Phone Television Toy airplane

MobileToy helicopter

Computer

A.CTelevision

Washing machine

Toy carPrinterSensor

RobotFan

Coffee maker

RobotTelephone

Mobile

20 13 9 7 2

As you can see from the table 51 artifact from 100 artifact after using boggle method but we need to minimize the number to 10 possible artifacts so it’s time for using multi voting system.

we have divided the total left by 3 to get the number of votes for each member and the result was 17 votes for each member and here is how we did the multi voting.

Sensor.Scooter.Receiver.Car stereo.Wheel chair.Toy helicopter.Robot.A.C.Toy car.Desk chair.

At the brain storming stage we reached to several musts:

The artifact can be dissected into at least ten pieces.The price should not exceed 2000 S.RNo chemical involved.Easy to fix.Easy to move.It can be developed. Shouldn’t cause any damages to people.It is safe for the members to use and develop.It is not kind of any weapon.It should be used daily.

It should be used daily. Adapt? It should help people by making it easier to use it.

It can be developed. Modify? It can be developed to be more expensive.

Shouldn’t cause any damages to people.

Magnify? It doesn’t damage the environment.

No chemical involved. Substitute? No dangerous materials involved.

Easy to move. Rearrange? Its weight should not exceed 10 kg.

We brainstormed our wants and the result was:

Cheap.Electrical.Modern.Easy to develop.Easy to open.Big pieces.Easy to prove it to the instructor.

Here we reached to the brain drizzling stage so we have decided to use random stimulation and we used the table in the book to choose one of the words randomly:

Nice Nice shape

Office It can be used at the office.

High High quality stuff.

So the result were:

Cheap.Electrical.Modern.Easy to develop.Easy to open.Big pieces.Easy to prove it to the instructor.Nice shape.can be used at the office.High quality stuff.

And we used multi voting to choose our top desires.

Our top 6 desires:Cheap.Electrical.Easy to open.Easy to develop.Big pieces.Easy to prove it to the instructor.

Discussion

We hope we generated the ideas in a proper way to be ready to go the third step of the heuristic. In this meeting we were more comfortable together because we know each other well and were viewed our work many times to make sure we have done our work in a good way to show to our instructor that we are developing our problem solving skills.

This is the third part of L3 assignment, L3-C. In this part we will decide the course of action by using the techniques in chapter 5 of Fogler and LeBlanc book. We hope we will

demonstrate a high level of understanding for this step of the heuristic.

After we used KTDA Table we get four alternative

solution from nine.

0

50

100

150

200

250

300

350

400

Receiver ToyHelicopter

Scooter Toy Car

Total

Adverse Consequences:

1. Toy Helicopter Of Occurrence(P) Seriousness(S) PXS

Crashing 5 10 50

Unaccepted by the market

8 8 64

Not to work after developing

7 10 70

184

2. Toy Car Of Occurrence(P) Seriousness(S) PXS

Crashing 8 10 80

Unaccepted by the market.

7 8 56

Not to work after developing.

7 10 70

206

Toy Helicopter:

Toy car:

As you can see from the results above the toy helicopter is the best choice because it has gotten a less number than

the toy car, so after using the techniques in chapter 5, our artifact will be the toy helicopter. And now we will

estimate the cost of our top 2 artifacts.

170

175

180

185

190

195

200

205

210

Toy helicopter Toy car

Total

Cost estimation

The Products The Price

The Toy price 500 SR

The tools for disassembling 10 SR

The Electrical Expert Free

The Developing requirements 300 SR

The Members’ work price 10 SR * 6 Hours *5 members=300 SR

Total 1110 SR

Toy helicopter:

The Products The Price

The Toy price 200 SR

The tools for disassembling 10 SR

The Electrical Expert Free

The Developing requirements 250 SR

The Members’ work price 10 SR * 6 Hours *5 members=300 SR

Total 760 SR

Toy Car:

After these studies we finally settled to one artifact which is the toy helicopter. We hope we have done the work in the right way and we really have chosen the best artifact because if not we are going to face a lot of blocks in the next assignments. We also wish that we showed how our team is working and the level of learning we have

reached to through the concept sessions.

This is the work for the fourth part of L3 assignment, L3-D. Here we will use the fourth step of the heuristic,

implementation, we will use the techniques represented in chapter 6 of Fogler and LeBlanc book such as K.T situation

analysis table, Gantt Chart and we will show the parts of our artifact after dissection process with some explanation

about each part work.

Tasks Timing Trend Impact Process

1.Obtaining the Artifact H H H DA

1.Obtaining the tools for disassembling H H H DA

1.Disassembling the artifact H H H DA/PPA

1.Studying each part M M H PA

1.Numbering each part H H H DA

1.Taking Pictures for each part H H H DA

1.Reassembling the artifact M H H PPA

1.Obtaining Developing requirements M M H PPA

1.Developing Process M M H PPA

1.Presenting the artifact in the celebration M M H PPA

Task Saturday Monday Tuesday Sunday Monday Wednesday

6:30p.m.

7:30 p.m.

6:30p.m.

8:30p.m.

8:30p.m.

10:30p.m.

5:00p.m.

7:00p.m.

6:30a.m.

8:30a.m.

8:30a.m.

9:30a.m.

6:30p.m.

10:30p.m.

11:00a.m.

12:00p.m.

Obtaining the Artifact

(1,2,3,4,5)

Obtaining the tools for disassembling

(12,3,4,5)

Disassembling the artifact

(1,2,3,4,5)

Studying and Numbering each part

(1,4) and(expert)

Taking Pictures for each part

(2,3,5)

Reassembling the artifact

(1,2,3,4,5)

Developing Process

(1,2,3,4,5)

Writing Report(1,4)

Presenting the artifact in the celebration

(1,2,3,4,5)

This is the first and one of the important parts because it is the first thing any one will see in the artifact, it is a ring shaped as you see in figure 1 and it is made of

poly-foam material that’s why it is called poly-foam ring. The reason behind this poly-foam ring is to protect the

artifact from crashing and to give it an attractive and extraordinary shape for the costumers.

These are the four propellers used for flying the toy helicopter and it is very important for the artifact. As you

can see form figure there are two kinds of propellers, one is clockwise propellers for pitching and anti-clockwise for rolling. It is made from plastic to be light for the artifact

and each one is placed in the four rings .

This is the motor used to move the gears to rotate the propellers and there is a small gear at the top of it which is attached to the POM gear. This piece is heavier than the previous pieces because it does a huge part in the

flying process and as you can see from figure 8 it is made of metal. There are 4 motors, one in each ring.

This is the rechargeable battery placed at the bottom of the artifact with a wire to connect it with the artifact by the

electrical board and it is held by a case in. As you can see from figure , it is colored so any one can easily recognize it.

This is the cover for the main board control and all the important pieces that the artifact wouldn’t work without it. It is transparent so anyone can see inside it and as you can see in figure made of strong plastic so it can

protect the pieces and would not be heavy for the helicopter to take it.

This is the case to hold the battery. It is easy to attach to the artifact because of the special place for it in the

artifact. As you can see from the figure it is designed to fit the battery and it is open so the battery is shown and the

weight is less.

These are the gears used to make the propellers rotates because it is attached to the motor in figure 8 that makes

the gear rotate and the propellers rotate because it is placed at the top of the gear. As you can see from figure it is white to recognize it from the other pieces because when we install the propellers we need to put them on the top of the gears and it is made of light plastic to

maintain the lightness for the toy helicopter.

This is the shafts that holds the motor with its house and the POM gears together. It is made form metal and shaped

as you can see form figure with the E-ring that attaches its ends to the pieces.

This is the antenna for transferring the orders from the transmitter to the crystals for rolling and pitching. As you can see from figure it is really thin with a very light weight

and it is made of metal.

This is the stands for the motor house that the shafts is attached with to hold all the parts together. As you can see

from the figure it is small and made from rubber. There are four stands, one in each ring.

This is very small and sensitive parts and it is used to receive the orders from the transmitter by the antenna. It is located under the gyro and the transparent cover and it is connected to the antenna by the electrical circle. It is as you can see in figure really thin , small and has two poles

to insert it into the electric board to receive the signals from the transmitter through the electric board.

This assignment was really helpful to us because we now know our artifact better than before and we determined

how we are going to develop it for the next assignment L3-E. we hope we demonstrated our level of learning for this step of heuristic. Now we are ready

for the next step and we hope we will be able to do it better than this assignment.

This is L3-E assignment, which is the fifth and the last step of L3 assignment. It is about evaluation our final

product from all aspects that we are concerned about. We hope we would evaluate our product very well to

present our real level of learning to our grader.

Part Number Part Name Location in the design

notebook

Quantity Material of the part

(1) Body A.4(4) 1 Poly-foam

(2) Transparent cover A.4(4) 1 Strong plastic

(3) Mechanical Gyro A.4(4) 1 Strong plastic & Iron

(4) Crystal A.4(5) 1 Iron & Cooper

(5) Antenna A.4(5) 1 Aluminum

(6) Propellers A.4(5) 4 Plastic

(7) POM Gears A.4(6) 4 Plastic

(8) Motor A.4(6) 4 Iron & Cooper

(9) Shafts A.4(6) 4 Iron

(10) Rubber Stand A.4(7) 4 Rubber

(11) Battery Pack A.4(7) 1 Iron & Cooper

(12) Case A.4(7) 1 Plastic

Bill Of Materials:

Potential Problem Consequence Possible Cause Preventive action Contingent action

We can’t know how to assemble.

We can’t submit the assignment on

time

Failing to plan a good assembly plan.

Be careful when planning the

assembly plan.

Recording every step in the disassembling

stage.

The approval of the expert about the

plan.

The existence of the expert during the

assembly.

Broken parts. The artifact can’t work.

Didn’t take a good care of the artifact.

Assigning one of the members to look after the artifact.

Use the spare parts that came with the product. .

Buy new artifact.

Loosing small parts. The artifact can’t work.

Not paying attention to them.

Putting them in small bag.

Buy spare parts.

Buy new artifacts

One of the members couldn’t come.

Increasing the work on the other members.

Bad student’s circumstances.

Applying the team norms on him.

Dividing the work on the other members.

Careless student.

We couldn’t develop the artifact.

We can’t submit on time.

The camera couldn’t fit.

Take the expert when we buy the

camera.

Buy another camera.

We couldn’t present the work in the

celebration.

NCE in the assignment.

The electric potential doesn’t fit our

electric devices.

Try out the artifact in the class before the celebration.

Bringing electric wires that fits the room

electricity.

The test of the final assembly plan

We will test our assembly plan by assessing our plan by ourselves and then we let the expert assess it and see what is wrong in it to get his approval, which we

must get before applying the plan.

1. Our assessment is not professional but most of us liked it and said it is pretty clear but member 2 said that it is not detailed enough.

2. The expert assessment took 15 minutes. He saw the KT PPA table, which he liked and said that we used it well and covered most of the holes in the first assembly plan, and the final assembly plan, which he liked too but he said that it needs more improvements in showing the details of each part but its enough for the current situation where we don’t have time.

After this test and the KT PPA table we believe that we came up with a good plan to start with it our developing process to submit out project

on time and properly. Now we will discuss the impacts of our final product after developing.

Environmental Impact

The toy helicopter operates by electricity and the camera also has a receiver, which operates by electricity so that’s one of the factors

that affects the environment by using energy to create electricity which causes air pollution by the produced gases from this process. Electricity

from renewable resources such as solar, geothermal, and wind technologies generally does not contribute to climate change or local air

pollution since no fuels are combusted in these processes.

Social and Cultural Impact:

The toy itself has no remarkable social or cultural impact except that it is a way to entertain the children although it could disturb people because it flies and that’s dangerous to people because it

could hurt them but after installing the camera there will be an additional impacts to those previously mentioned such as that it

would be safer for people if it is used as a security device but at the same time for some people it is unwelcome idea because they

prefer the regular security guy so it is going to create a conflict and change the culture of the security ways.

We hope that we have made our point clearly and our final product was evaluated well by all the techniques we

have studied in this course. After this assignment we believe that our developing idea for the artifact is a good

and useful idea so we hope that it would gain your admiration and the market would accept it as a start for

a whole new security market.

Final cost estimation:

The Products The Price

The Toy price 500 SR

The tools for disassembling 10 SR

The Electrical Expert Free

The Developing requirements 500 SR

The Members’ work price 10 SR * 6 Hours *5 members=300 SR

Total 1310 SR

The Marketing Plane

We will try to make this entertaining toy a more useful product because the camera we have installed in the toy helicopter will give it a whole new

uses such as security device, monitor for wide areas like football play ground and to get to a higher places without getting there. so we believe that our product will hit the market if we have the appropriate financial

support especially at the security market.

This is L3-E assignment, which is the fifth and the last step of L3 assignment. It is about evaluation our final

product from all aspects that we are concerned about. We hope we would evaluate our product very well to

present our real level of learning to our grader.

Part Number Part Name Location in the design

notebook

Quantity Material of the part

(1) Body A.4(4) 1 Poly-foam

(2) Transparent cover A.4(4) 1 Strong plastic

(3) Mechanical Gyro A.4(4) 1 Strong plastic & Iron

(4) Crystal A.4(5) 1 Iron & Cooper

(5) Antenna A.4(5) 1 Aluminum

(6) Propellers A.4(5) 4 Plastic

(7) POM Gears A.4(6) 4 Plastic

(8) Motor A.4(6) 4 Iron & Cooper

(9) Shafts A.4(6) 4 Iron

(10) Rubber Stand A.4(7) 4 Rubber

(11) Battery Pack A.4(7) 1 Iron & Cooper

(12) Case A.4(7) 1 Plastic

Bill Of Materials:

Potential Problem Consequence Possible Cause Preventive action Contingent action

We can’t know how to assemble.

We can’t submit the assignment on

time

Failing to plan a good assembly plan.

Be careful when planning the

assembly plan.

Recording every step in the disassembling

stage.

The approval of the expert about the

plan.

The existence of the expert during the

assembly.

Broken parts. The artifact can’t work.

Didn’t take a good care of the artifact.

Assigning one of the members to look after the artifact.

Use the spare parts that came with the product. .

Buy new artifact.

Loosing small parts. The artifact can’t work.

Not paying attention to them.

Putting them in small bag.

Buy spare parts.

Buy new artifacts

One of the members couldn’t come.

Increasing the work on the other members.

Bad student’s circumstances.

Applying the team norms on him.

Dividing the work on the other members.

Careless student.

We couldn’t develop the artifact.

We can’t submit on time.

The camera couldn’t fit.

Take the expert when we buy the

camera.

Buy another camera.

We couldn’t present the work in the

celebration.

NCE in the assignment.

The electric potential doesn’t fit our

electric devices.

Try out the artifact in the class before the celebration.

Bringing electric wires that fits the room

electricity.

The test of the final assembly plan

We will test our assembly plan by assessing our plan by ourselves and then we let the expert assess it and see what is wrong in it to get his approval, which we

must get before applying the plan.

1. Our assessment is not professional but most of us liked it and said it is pretty clear but member 2 said that it is not detailed enough.

2. The expert assessment took 15 minutes. He saw the KT PPA table, which he liked and said that we used it well and covered most of the holes in the first assembly plan, and the final assembly plan, which he liked too but he said that it needs more improvements in showing the details of each part but its enough for the current situation where we don’t have time.

After this test and the KT PPA table we believe that we came up with a good plan to start with it our developing process to submit out project

on time and properly. Now we will discuss the impacts of our final product after developing.

Environmental Impact

The toy helicopter operates by electricity and the camera also has a receiver, which operates by electricity so that’s one of the factors

that affects the environment by using energy to create electricity which causes air pollution by the produced gases from this process. Electricity

from renewable resources such as solar, geothermal, and wind technologies generally does not contribute to climate change or local air

pollution since no fuels are combusted in these processes.

Social and Cultural Impact:

The toy itself has no remarkable social or cultural impact except that it is a way to entertain the children although it could disturb people because it flies and that’s dangerous to people because it

could hurt them but after installing the camera there will be an additional impacts to those previously mentioned such as that it

would be safer for people if it is used as a security device but at the same time for some people it is unwelcome idea because they

prefer the regular security guy so it is going to create a conflict and change the culture of the security ways.

We hope that we have made our point clearly and our final product was evaluated well by all the techniques we

have studied in this course. After this assignment we believe that our developing idea for the artifact is a good

and useful idea so we hope that it would gain your admiration and the market would accept it as a start for

a whole new security market.

Final cost estimation:

The Products The Price

The Toy price 500 SR

The tools for disassembling 10 SR

The Electrical Expert Free

The Developing requirements 500 SR

The Members’ work price 10 SR * 6 Hours *5 members=300 SR

Total 1310 SR

The Marketing Plane

We will try to make this entertaining toy a more useful product because the camera we have installed in the toy helicopter will give it a whole new

uses such as security device, monitor for wide areas like football play ground and to get to a higher places without getting there. so we believe that our product will hit the market if we have the appropriate financial

support especially at the security market.

This is the end of L3 assignment. In this assignment we have moved a step toward being a successful engineer and we have learnt about manufacturing,

how to work as a team, how to a presentation and how to submit our work as expected. Also we have learnt a lot of things from the whole course such

as the heuristic steps which is very important to us as engineers and humans. For all of that we would like to thank our instructor and father

Dr. Youssef Shatilla, grader Nazeer, Expert Mohammed AlQarny and families for the support and everything they have done for us

during this course.