Testing in Design

James Huff

Learning Objectives

At the end of this session, you will be

able to:

1. Describe at least three ways to test your

projects

2. Describe how prototypes can be used in

testing

3. Categorize potential failures for a design

Testing

How do we know our projects will work?

o When we deliver it?

o For the intended life?

• What is the expected life?

How do we know the project will

function like we want and for the users

intended?

How do we know we are meeting the

right needs?

Testing

Designers have to know that their

design will function

o Plan testing along the way

Tests look at

o Function – does it perform like we intended

• Under what conditions?

o User testing – does it meet needs

• Can people use it as intended

“Fail quickly and cheaply”

Prototyping….rough, quick, very

interative

o IDEO working with Gyrus ACMI to

design new apparatus for

operating on delicate nasal tissues

o Prototype:

http://cataligninnovation.blogspot.com/2008/11/prototyping-foundational-competency-of.html

Think, pair, share….

What questions and/or issues need to

be tested for your current project?

Find one or two others to share your

answers

o Introduce yourself

o Describe your project

o Answer the first question

More discussion

Individually

o What tests need to be done on the project?

Share what you answered for your

project with the same person or pair.

Test plans

Create a test plan for your design

o What tests need to be done?

o What will they measure?

o What are the criteria for success and failure?

Test Plans

What will be

tested

Who and/or

where will it

be done

What will be

measured?

Success or

failure

Test #1

Test #2

Test #3

Test #4

Clearly define what will

be done and by whom

Sample Test Plan Template Sharepoint > Teams > Shared Documents > Templates_Tools > Test Plan Template.docx

1 Description of Product

1.1 Components of interest

1.1.1 Dimensions

1.1.2 Photographs

1.2 Specific, important characteristics

1.2.1 Materials, tolerances, limitations

1.2.2 How close is this test vehicle to the expected final product

2 Objectives of Test

2.1 Overall goal (characterization, optimization, test to failure, e.g.)

2.2 Specific parameters to be measured

2.3 Target values of outputs

2.4 Test Success Criteria Definition

2.4.1 What new knowledge will you have gained

2.4.2 How will you use the new knowledge

2.4.3 Is the comfort/safety of humans interacting with the product compromised

2.5 Is a redesign required

More Template

3 Equipment List, Test Location

3.1 For every output parameter, there should be a way to measure it

3.1.1 Camera should generally be included to photograph/video the set up, test point execution

3.2 Description of test location

4 Test Procedure

4.1 Define conditions

4.1.1 Normal conditions

4.1.1.1 Static or steady cases

4.1.1.2 Dynamic cases

4.1.2 Failure or emergency conditions

More Template 4.2 Define inputs

4.2.1 Controllable inputs, ranges for each

4.2.2 Uncontrollable inputs

4.2.3 Sorted by least risk points being executed first

4.3 Define outputs

4.3.1 Pretest predictions

4.3.1.1 Analytical equations

4.3.1.2 Noted assumptions, unknowns

4.3.2 How to measure the outputs in test

4.3.2.1 Notable stopping points

4.3.2.1.1 increasing risk of damage to test vehicle or persons interacting with test vehicle

4.3.2.1.2 limits of measuring equipment

4.4 Step-by-step procedure for each test point

4.4.1 Equipment set up and calibration

4.4.2 Test vehicle preparation

4.4.3 Initial condition definition, set, measured

4.4.4 Test point execution

4.4.5 Outputs measured

4.4.6 Outputs recorded

4.4.7 Selection of next test point

4.4.7.1 Pass/fail criteria defined

5 Outbrief

5.1 Percentage completion of test points

5.1.1

5.2 New knowledge gained

5.3 Redesign required?

Discussion

In your pairs or groups, identify one test

that was proposed and develop the

who, what, where, why and the success

criteria

Test tips

User testing and prototypes

Component tests

o Small parts that are demonstrated can help

hold the team accountable

Fit and form tests

Simulate usage

o Walked on the Martian surface

Use Cases – software

o Build a case or example of how to use the

design and see if it works correctly

Another example…

Testing in the proper conditions

DFMEA :

Design for

Robustness

Pick one project from your

group for this section

DFMEA Steps

1. Review the design

2. Brainstorm potential failure modes

3. List potential effects of failure

4. Rank failures a) Severity

b) Occurrence

c) Detection

d) RPN = Severity X Occurrence X Detection

5. Develop action plan

6. Implement fixes

7. Revisit potential failure risks

DFMEA Matrix

Failure

mode

Effect of

Failure

Severity Occurrence Detection Rating

Rate failures

Rating

(1 to 10)

Severity How severe are the

consequences to

the failure

Occurrence

How often are the

failures likely to

occur?

Detection How easily are the

failures detected?

DFMEA Calculations

Scores for Severity, Occurrence and

Detection

o 1 to 10

o 1 = Low

o 10 = High

Risk Priority Number (RPN)

o RPN =Severity X Occurrence X Detection

Continue the process

Implement the plan to eliminate the

failure scenario

Revisit other potential failure risks

o Prioritize

o Eliminate failure scenarios

Continue until risks are below

determined thresholds

o Show to the design reviews for

confirmation

Can we get rid of all failures?

All cars have brakes that will eventually

fail

o Potentially catastrophic

o Early warning squealers to notify

Questions/Discussion