The Engineering Design Process

1. Comparing the Scientific Method to the Engineering Design Method

Although science and engineering share some common features, there is a difference between the two. The traditional
“scientific method” is not used in engineering design; instead, an engineering design process is used. Although there is
some overlap between the two, they are distinct processes. “Scientists discover the world that exists; engineers create
the world that never was.”

Scientists study how nature works and discover new knowledge about the universe. Engineers on the other hand create
or construct things. This difference in focus results in different objectives and hence approaches. Scientists perform
experiments using a scientific method that is often tried and tested. They rely heavily on evaluation techniques that are
well established to be able to make reliable deductions from their observations. On the other hand, engineers are driven
by creative processes to be able to deliver results that better met a need in society. This is illustrated in figure 1 and 2.

Figure 1: The scientific process

Figure 2: The engineering process

1
© Eng. Dr. Kenneth D. Njoroge
[email protected]
 The Engineering Design Process
2. Engineering Design
There are several different versions of the engineering design process in use today. In this lecture, an 8-step process is
presented. It goes from the identification of the problem, through the design process, ending with a final design. Design
is an iterative problem-solving process. The iterative nature of design arises from the fact that feedback from existing
designs provides information that guides further improvement. The design process is a progression from the abstract to
the concrete.
Figure 3: The engineering design cycle

Identification of
the Problem

Communicate Research the

Final Design Problem –Gather
e.g. Presentation Information

Engineering
Design Process
Refine and Retest Analysis
Model/Prototype of the Problem
- Design Constraints
G

Testing and Brainstorm

Evaluation Alternative Design
Model/Prototype Solutions
Modeling “Best”
Solution

The following sections discuss the 8 steps presented in figure 3.

2.1. Identification of the Problem

In order to solve a problem, we must first identify what the problem is. This is not always a straightforward task as the
challenge/need/concern that is observed may be a secondary challenge resulting from some fundamental problem. It is
also noteworthy that the problem will often present itself as a customer need.

2.2. Research the Problem – Gather Information

The next step in the engineering design process is to understand the problem. This requires research to establish all
relevant information related to the problem. Several questions may be asked and answered:
a) What is the problem that needs to be solved?
b) What is the cause of this problem?
c) What work has been previously undertaken towards solving the problem?
d) How have similar problems been solved?
e) Who will benefit when this problem is solved?

2.3. Analysis of the Problem – Design Constraints

After information about the problem has been obtained, the next step is to perform a preliminary analysis. This stage
focuses on defining design constraints that may be technical issues, economic limitations and time related targets. These

2
© Eng. Dr. Kenneth D. Njoroge
[email protected]
 The Engineering Design Process
constraints will guide the selection of the optimum solution.

The sections 2.1, 2.2 and 2.3 are sometimes referred to as the feasibility study phase.

2.4. Brainstorm - Alternative Design Solutions

At this point the engineer is ready to start developing potential solutions to the problem. This process involves
identifying all possible solutions. At this stage, the solutions are conceptual and lack specific implementation details.
No idea is judged or discarded: all ideas are recorded for use in the next step of the process.

2.5. Modeling “Best” Solution

After listing the possible solutions to the problem, the pros and cons of each possible solution are established, and some
criteria is applied to determine the best solution to the problem. This decision depends in part on the design constraints
and any factors that may constrain the implementation of the solution. The selected solution comprises of an optimum
design and the process necessary to implement the solution. This section can be subdivided into two stages:

 In the first stage referred to as the preliminary design phase, the design concept is detailed to the extent some
level of evaluation is possible.
 In the second stage, the design is developed with sufficient detail to enable its implementation. This is the
detailed design phase.

2.6. Testing and Evaluating - Prototyping

The best way to evaluate a solution is to build the product and test it. As part of the solution, you need to have
developed a test protocol for this purpose. A prototype is then produced. The production process provides feedback on
the ease of implementing the solution. Testing of the prototype serves to establish if it actually solves the problem. If
the prototype does not work as desired, then one returns to the previous stage to select a different solution, and the
evaluation process is repeated.

2.7. Refine and Retest Model/Prototype

The engineering design process rarely yields a complete and final solution with the first prototype. It is more likely that
the design team will take the feedback from the initial testing and revise its solution. A revised - new solution will then
require testing and the process is repeated until a satisfactory prototype has been developed. This step is often the most
time-consuming part of the engineering design process, often taking more time than all the other steps combined.

2.8. Communicate Final Design - Presentation

There are many ways to present the final design, often varying depending on the audience. A presentation to:
 an engineering audience will include circuit diagrams, blueprints, and other technical materials such as operating
manuals.
 a sales team might focus on the capabilities of the final product and how it compares to other products in the
marketplace.
 the general public might emphasize how to use the product, as well as the presentation of marketing materials.

3
© Eng. Dr. Kenneth D. Njoroge
[email protected]
 The Engineering Design Process
3. General design criteria
As indicated in section 2.5, an optimal design solution is required. This is similar to the need to select an optimal
material for a given component. Consequently, the strategies that apply for optimal material selection may be applied to
the selection of an optimal design. The pros and cons for an intuitive approach and a structured approach also apply. To
achieve an optimal choice, a structured approach is recommended. Therefore, a clear definition of the constraint criteria
and salient considerations is required. The following are criteria that would apply in the most general terms:

3.1. Physical realizable

A design should be convertible into material goods or services, i.e. it must be physically realizable. Naturally, designs
that cannot be implemented are of little value.

3.2. Economic worthwhileness.

The products described by a design must be useful to the intended consumer. This value to the consumer must equal or
exceed the sum of the total costs of making it available to him.

3.3. Financial feasibility

The effort for developing, producing and distributing the goods must be financially supportable. This means that such a
design project should be capable for being funded. Several techniques are available for the assessment of the financial
feasibility. These include the 'Net present value' which states that the present worth of cash flows from the project when
added up during the useful life of the product should be greater than the initial investment for the project.

3.4. Optimality
The chosen design concept must be the optimal solution. Optimal design, in theory, strives to achieve the best or
singular point derived by calculus methods. Optimization is guided by constraints that include functional criteria (such
as mechanical strength), minimum weight (reduction in material use) and minimum production cost.

Optimality must be established relative to the design criteria that account for conflicting value judgments of the
consumer, the producer, the distributor, and the designer. Additionally, these designs may be original where new ideas
are implemented, adaptive where a product evolves (e.g. the inclusion of high quality cameras on mobile phones) and
variant where the size of the product changes (scaling).

4
© Eng. Dr. Kenneth D. Njoroge
[email protected]