Engineering Management Systems Engineering Management MSE607B Chapter 4 Engineering Design Methods and Tools Learning Objectives Briefly highlight some of the recent concepts in design Conventional design practices Analytical methods The role of Electric Commerce (EC) Information Technology (IT) The Internet Current Design Technologies and Tools Simulation Rapid Prototyping Mock-ups Computer Aided Design (CAD) Computer-Aided Manufacturing (CAM) Computer-Aided Support (CAS) Discuss system engineering Objectives as they relate to current design methods 2 1
Conventional Design Practices System development projects include three major steps: Conceptual design Preliminary design Detail design and development Level of effort and duration vary Prime objective: Design system to meet consumer need 3 System Engineering Within the Acquisition Process 4 2
Basic Design Sequence 5 Basic Design Sequence (cont.) Definition accomplished through documentation Plans and specifications Procedures, drawings, Materials and parts lists Reports and analysis, Computerized databases, and so on. Review and approval Before moving to the next step Documentation ensures that others can Understand what is being conveyed Translate the output into a producible entity 6 3
Design Drawings Assembly drawings Specification control drawings Construction drawings Installation drawings Materials and parts lists Parts list Materials list Bulk item list, etc. Analysis reports Trade off study reports Finite element reports Reliability reports Documentation 7 Analytical Methods Probability theory and analysis models Uniform Binomial Poisson Exponential Normal, etc. Economic analysis Break-even Life-cycle cost Optimization methods Queuing theory and analysis Monte Carlo Control concepts and techniques SPC TQM 8 4
The Role of Electronic Commerce (EC), Info. Tech. (IT), and The Internet Electronic Commerce Grown to include all aspects of business and market processes enabled by the Internet and WWW technologies Information Technology The infrastructure fostering the integration of all the mechanisms for transmitting information and data Internet A network of networks and a connecting vehicle for all who have access to a computer Revolutionized and enhanced day-to-day operations and methods of doing business 9 The Role of Electronic Commerce (EC), Info. Tech. (IT), and The Internet (cont.) Benefits: Communication processes Data processing Data storage and retrieval In design area: Greater productivity in less time Networks or customers, contractors, and suppliers Quick data distribution, review and feedback In business process: Business-to-business e-commerce Enterprise resource planning (ERP) Purchasing and marketing-related activities 10 5
Internet Growth Trends 11 The Internet And Other Electronic Communication Internet Intranet Instant messaging Video conferencing Virtual teaming Document management E-learning E-government E-commerce Business-to-business Business-to-customer Website design 12 6
Current Design Technologies and Tools With advancement of computer technology, new tools and techniques have been developed and adapted Mainframe computers Personal computers Software packages Computer models Provided engineers with wide variety of tools to enhance productivity Word processors Graphics packages Spreadsheets Database management packages Analysis routines 13 Advantages of Current Design Technologies and Tools Personal computers (PCs) networks Excellent data communication network Design data exchange Reducing system development time Versatility and variety of software packages/models Many new tools such as simulation, 3-D, and mathematical/statistical models More in-depth analysis Evaluation of design alternatives 14 7
Advantages of Current Design Technologies and Tools (cont.) Data handling capabilities: Acquisition, processing, storage and retrieval Easier and in less time than before, allowing to capture design information on drawings Generation and distribution of parts/materials Automatically produce reports and Technical publications 15 Why Simulate? Common with the availability of quality tools that fit seamlessly with design tools Important with faster operational speeds and higher density requirements Makes it possible to make design changes without costly re-spins and difficult lab work-around Design can be fabricated assuring performance Saves both cost and schedule Improves reliability and quality 16 8
The Use of Simulation Simulation Definition: The process of designing and utilizing an operational model of a system to conduct experiments for understanding and evaluation of Alternative strategies and/or System design configuration Particularly appropriate in the early stages of the system development Examples: Airplane and its components Aircraft cockpit with crew Automobile with driver Manufacturing facility and equipment 17 Simulation Example Effect of Simultaneous Switching Outputs (SSO) Simulation used to determine effect of a bi-directional data bus with 32 simultaneously switching outputs SSO effect observed on data bit and power supply 18 9
The Use of Rapid Prototyping Rapid Prototyping Definition: The use of 3D computer geometry in the production of components using a layer-based build process in condensed time-scales Increasing international competition shortened product lifecycles Demand for faster product development processes to keep up with the competition 19 Prototyping Example Child Utensils 20 10
The Use of Mock-ups Mock-up Definition: Three-dimensional scale model of the system or its elements During the preliminary or detail design phase Provide realistic replica of a proposed equipment/facility configuration Can be produced to any desired scale and detail May be constructed from heavy cardboard, wood, metal, or a combination of materials Can be developed relatively inexpensively and in short time 21 The Benefits of Mock-ups Give opportunity to experiment with different layouts, packaging prior to formal design Provide opportunity to accomplish more effective review Detailed task analysis Simulate operator and maintenance task sequence and time data Provide excellent tool to convey final design approach during design review Serve as an excellent marketing tool Can be employed to facilitate training Allow to develop fabrication and assembly procedures and tooling May serve as a tool for verification of a modification kit design at later stage of system life cycle 22 11
Example: The Use of Mock-ups for Train Development In May and June 2003, a spectacular show for rail transport systems took place on the Champs Élysées in Paris. Siemens Transportation Systems (TS) presented a model of the "Avanto train cart An innovative light rapid transit system that will connect the two Paris suburbs of Aulnay and Bondy from 2005 onwards. General characteristics : Length : 13.5 m Height : 3.5 m Width : 2.45 m Weight : 8 tons Material : - wire chassis, wood frame, glass and epoxy 23 Computer-Aided Design (CAD) CAD Definition: The application of computerized technology to the design process Graphics capabilities Vector and raster graphics Line and bar charts X-y plotting Scatter diagrams Three-dimensional displays Analytical capabilities Mathematical and statistical programs Data management capabilities Storage and retrieval Processing Drafting & Reporting Usually combined in integrated packages 24 12
Example: CAD Models 25 Computer-Aided Manufacturing (CAM) CAM Definition: The application of computerized technology to the manufacturing or production process. Primarily the use of automated methods as they pertain to: Process planning Numerical control (NC) Robotics Production management Will be different for production of multiple quantities versus the construction of a one-of-a-kind Manufacturing tolerances f NC tools and robotics must be consistent with the initial requirements for system design. 26 13
Computer-Aided Support (CAS) CAS Definition: The application of computerized technology to the entire spectrum of logistics and system support activities For years, the consideration of logistics and maintenance support requirements has been relegated to an activity downstream in the system life cycle. Examples to the variety of computer technology applications in the logistics field are: Logistics engineering Supportability analysis (SA) Logistics management information (LMI) Distribution, transportation and warehousing Maintenance and support 27 Major CAD/CAM/CAS Interfaces 28 14
Summary Briefly highlight some of the recent concepts in design Conventional design practices Analytical methods The role of Electric Commerce (EC) Information Technology (IT) The Internet Current Design Technologies and Tools Simulation Rapid Prototyping Mock-ups Computer Aided Design (CAD) Computer-Aided Manufacturing (CAM) Computer-Aided Support (CAS) 29 Interactive Workshop The results of design have generally been conveyed through a combination of the following: a) Design drawings, requirements and analysis reports b) Design drawings, materials and parts lists, and analysis reports c) Requirements, materials and parts lists d) Requirements, materials and parts lists, and analysis reports 30 15
Interactive Workshop Examples of probability and analysis models are: a) Uniform, binomial, and Poisson b) Break-even and life-cycle cost c) Monte Carlo and Poisson d) SPC and TQM 31 Interactive Workshop System engineers use simulation because it allows them to make: a) Mock-up improvements prior to design b) Mock-up improvements prior to production c) Design changes after production d) Design changes prior to production 32 16
Interactive Workshop Process planning and robotics are examples of: a) Computer-aided design (CAD) b) Computer-aided manufacturing (CAM) c) Computer-Aided support (CAS) d) Computer-aided learning (CAL) 33 Interactive Workshop One of the benefits of mock-ups is that they provide excellent tool to: a) Experiment with different packaging during formal design b) Convey final design approach during design review c) Help the engineer complete the design d) Can be employed to facilitate design analysis 34 17
Questions? Comments? 35 18