ENGG 1100 Introduction to Engineering Design

Lecture 2: Engineering Design & Management

Helen Meng
Professor and Chairman
Department of Systems Engineering & Engineering
Management
[email protected]

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 Engineer and Engineering Design
The word engineer has Latin roots in ingeniare (i.e. to contrive,
devise) and ingenium (i.e. cleverness).

An engineer is a professional practitioner of engineering, who has

mathematical and scientific training and can apply such knowledge,
together with ingenuity, to design and build complicated products,
machines, structures or systems and thus develops solutions for
technical problems.

An engineering design pulls together (i.e. synthesizes) something

new or arranges existing things in a new way to satisfy a recognized
need of society. Engineering designs considers the limitations
imposed by practicality, regulation, safety, and cost.

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 Design
Discovery versus Design
Discovery is getting the first knowledge of something
Design is the creation of new things
Science versus Engineering
Science is knowledge based on observed facts and tested truths
arranged in an orderly system that can be validated and
communicated to other people.
Engineering is the creative application of scientific principles
used to plan, build, direct, guide, manage, or work on systems
to maintain and improve our daily lives
Scientists versus Engineers
Scientists see things as they are and ask, WHY?
Engineers see things as they could be and ask, WHY NOT?

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 Challenges of Engineering Design

Creativity: creation of something that has not existed before

Complexity: requires decisions on many variables and
parameters
Choice: requires making choices between many solutions at
all levels, from basic concepts to the smallest detail
Compromise: requires balancing multiple and sometimes
conflicting requirements

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Importance of Engineering Design

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[Source: Dieter & Schmidt 2013]
 Engineering Design Process
Involves analysis and synthesis
Analysis
Decompose problem into manageable parts
Calculate as much about the parts behavior as possible, using
appropriate disciplines in science, engineering and
computational tools, before the part exists in physical form
Synthesis
Identification of the design elements that comprise the product,
how it is decomposed into parts and the combination of the
part solutions into a total workable system
Requires Systems Thinking!

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 Iterative Engineering Design Process
Complex systems can be decomposed into a sequence of design
processes

[Source: Asimov 1962]

Iteration repeated trials

Gives opportunity to improve design on basis of preceding outcome
More knowledgeable team may arrive at acceptable solutions faster
Requires high tolerance of failure
Requires determination to persevere and work out the problem
Often involve tradeoffs and arrive at near-optimal solutions 7
 Problem-solving Methodology for
Engineering Design
1. Defining the problem
o Needs analysis, a difficult task
o True problem not always what it seems at first
o Requires iterative reworking as the problem is better understood
o Problem statement must be as specific as possible
2. Gathering the information
o Understand state of the art
o Many sources of information, unstructured, unordered
o Ask questions
What do I need to find out?
Where can I find it?
How can I get it?
How credible and accurate is the information?
How do I interpret the information for my specific need?
When do I have enough information?
What decisions result from this information? 8
 Problem-solving Methodology for
Engineering Design (cont-1)
3. Generation for alternative solutions / design concepts
o Use of creativity, simulation
o Apply scientific principles, use qualitative reasoning
o Need to generate high-quality alternative solutions
4. Evaluation of alternatives and decision making
o Selecting the best among several concepts
o Often under incomplete information
o May consider simulations
o Very important checking, including mathematical check,
engineering-sense checks (intuition)
o Consider all conditions / situations (e.g. humdity, vibration,
temperature) in selecting optimal solution
5. Communication of the results
o Oral / written communication,
o Engineering drawings, 3D computer models, software, etc.
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 Problem-solving Methodology for
Engineering Design (cont-2)
Iterative nature
Back and forth among the 5 steps
Understanding grows evolve from preliminary to detailed design

Define Problem

Gather Information

Generate Alternative Solutions

Evaluate Alternatives and Make Decision

Communicate Results
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 Problem-solving Methodology for
Engineering Design (cont-2)
Paradox
Design knowledge grows as design freedom diminishes

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[Source: Dieter & Schmidt 2013]
 Considerations of Good Design
Performance Requirements
Functional Requirements for components, sub-assemblies,
assemblies
Aesthetic Requirements shapes, size, touch and feel
Environmental Requirements operations conditions, e.g.
temperature, humidity, dirt, vibration, noise, corrosive
conditions, energy conservation, chemical emissions,
(hazardous) waste production, recycling requirements
Human Factors
Cost, e.g. price-performance considerations
Regulatory and Social Issues
Code of ethics require engineers to protect public health and
safety
Regulating agencies include: Occupation, Safety and Health
Council, Consumer Council, Environmental Protection
Department, etc.
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 Considerations of Good Design (cont)
Design Review
Vital aspect of the design process
Retrospective study of a design up to that point in time
Systematic method to identify problems with the design
determining subsequent courses of action, initiate action to
correct problem areas

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 Computer-Aided Engineering
Engineering drawing, facilitating visualization, supported by
computer graphics and modeling, e.g. AutoCAD, SolidWorks, etc.
Spreadsheets and mathematical tools, e.g. MatLab, Mathematica,
etc.
Enabled concurrent engineering design to minimize time all
aspects of the design and development are represented in a closely
communicating team,

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 Engineering Project Management
Mastery of engineering specialty no longer enough
Project success requires collaboration across technical disciplines,
organizational elements, stakeholder interest
Must think of a project as a cohesive whole and not separate parts!

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 Engineering Project Management (cont)
Initial planning crucial
NASA Rule # 15: a review of most failed project problems
indicates that the disasters were well-planned to happen
from the start. The seeds of the problem were laid down
early. Initial planning is most vital [Madden, 100 Rules of
NASA Project Managers]
Project economics, e.g. NASAs study of software
development projects show that the cost of fixing a defect
increases:
fixing at design phase
fixing at coding phase (10x)
fixing at testing phase (100x)
Lesson
Invest sufficient planning time and effort early because the
cost savings are huge
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 6 Dangerous Planning Mistakes
1. Tolerating vague objectives

2. Ignoring environmental context

3. Using limiting tools and process

4. Neglecting stakeholder interests

5. Mismanaging people dynamics

6. One shot planning

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 4 Fundamental Questions
1. What are we trying to accomplish and why? (Objectives)

2. How will we measure success? (Measures and Verification)

3. What conditions must exist? (Assumptions)

4. How do we get there? (Inputs)

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 Q1. Setting Objectives
Goal: The high level, big picture Objective to which
the project contributes

Purpose: The impact we anticipate by doing the project,

the change expected from producing Outcomes

Outcomes: The specific results that the project team must

deliver by managing Inputs

Inputs: The activities and the resources necessary to produce

Outcomes

If we manage Inputs, then we can produce Outcomes

If we produce Outcomes, then we will achieve the Purpose
If we achieve the Purpose, then we can contribute to the Goal 20
 Setting Objectives Example 1
Goal Ensure smooth operations in disaster recovery

Purpose Recover quickly from a disaster

Outcomes Emergency power systems in place

Data backed up safely

Inputs Install power systems, data backup systems

Test systems
Identify critical data
Backup data in real-time

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 Setting Objectives Example 2
Goal Build a good career. Contribute to society,
enjoy my work, earn good income

Purpose Increase my market value

Outcomes Develop professional skills

Expand professional network

Inputs Do well in school

Read more books related to profession
Attend professional seminars
Be more active in professional community
and society
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 Objective Tree
Goal

Purpose 1 Purpose 2 Purpose 3

Outcome 1 Outcome 2 .. Outcome N

Input 1 Input 2 .. Input M

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 Q2. Measuring Success
Measures and Verification
Quantity
Quality
Time
Customers /Users
Cost

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 Q3. Assumptions
Objectives Assumptions
Goal If and

Purpose If and

Outcomes If and

Inputs If

If Inputs plus valid Assumptions, Then Outcomes

If Outcomes plus valid Assumptions, Then Purpose
If Purpose plus valid Assumptions, Then Goal

NASA's Climate Orbiter was lost September 23, 1999

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[Source: Wikipedia]
 Q4. Inputs
Actions and activities to produce Outcomes
Associated with resources
Time
People
Money
Etc.

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Integration

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[Source: Schmidt 2009]
 Project Scheduling

[Source: Wikipedia]
Gantt Chart
Introduced by Henry Gantt, 1910
Visualizes the project schedule

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 Budget and Resource Planning
Time value of money (TVM)
Capital budgets are essential for supporting project activities
over the project duration; but the value of money changes with
time (because of interest/discount rates) with the concepts of
present value (PV), future value (FV), and discounted cash flow.
The starting time and finishing time of a scheduled project
activity can have a significant impact on budget planning

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 Example: Saving the World
Gods memo: Noah, I have decided to make it rain for 40 days and 40
nights. I want you to build a big ark to hold a pair of all animals on earth,
and people, so you can survive the flood. After the flood, you can restore
life on earth and ensure the long-term survival of human and animal life.
Get everything ready before the big rain starts in six months.

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[Source: Schmidt 2009]
Noahs Ark Project Management

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[Source: Schmidt 2009]
Noahs Ark Project Inputs

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[Source: Schmidt 2009]
Noahs Ark Project Resource Budget Details

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[Source: Schmidt 2009]
 Team Responsibility and Communication
The Confused Project Team
Four people named Everybody, Somebody, Anybody and
Nobody worked together.
An important Outcome needed managing, and Everybody was
sure that Somebody would do it.
Anybody could have done it, but Nobody actually did it.
Somebody got angry because it was really Everybodys job.
Everybody thought that Anybody could do it, but Nobody
realized that Somebody wouldnt.
As it turned out, Everybody blamed Somebody when Nobody
did what Anybody could have done!

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[Source: Schmidt 2009]
 Noahs Ark Responsibility Chart
R: Responsible (may delegate), P: Participants,
C: may be Consulted, A: Approves, I: must be informed

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[Source: Schmidt 2009]
 Project Reporting
Clearly tell others
Your Objectives
What you have done
Why decisions are taken
Lessons learned
Results
Future opportunities

Use proper quotations, citations and references

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 Engineering Ethics
Order of the Engineer: association for graduate and
professional engineers in North America emphasizing the
pride and responsibility in the engineering profession
Code of ethics called The Obligations of an Engineer
The Engineers Ring

Quebec Bridge: Wreckage of the 1907 collapse

[Source: Wikipedia] 37
 Engineering Ethics (cont)
Code of ethics: The Obligations of an Engineer
I am an engineer, in my profession I take deep pride.
To it I owe solemn obligations.
Since the stone age, human progress has been spurred by the engineering genius.
Engineers have made usable nature's vast resources of material and energy for humanity's
benefit.
Engineers have vitalized and turned to practical use the principles of science and the means
of technology.
Were it not for this heritage of accumulated experience, my efforts would be feeble.
As an engineer, I pledge to practice integrity and fair dealing, tolerance, and respect, and to
uphold devotion to the standards and the dignity of my profession, conscious always that my
skill carries with it the obligation to serve humanity by making the best use of Earth's
precious wealth.
As an engineer, I shall participate in none but honest enterprises.
When needed, my skill and knowledge shall be given without reservation for the public good.
In the performance of duty and in fidelity to my profession, I shall give the utmost.
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 References
M. Asimov, Introduction to Design, Prentice-Hall, Englewood Cliffs,
NJ. 1962.
C.S. Park, Contemporary Engineering Economics, Prentice Hall, 2002
C. L. Dym, P. Little, E. J. Orwin, and R. Erik Spjut, Engineering
Design: A Project-Based Introduction, Third Edition, Wiley, 2009.
T. Schmidt, Strategic Project Management Made Simple, Wiley
2009.
E. A. Stephan, D. R. Bowman, W. J. Park, B. L. Sill, and M. W. Ohland,
Thinking Like an Engineer: An Active Learning Approach, Pearson,
2012.
G. Dieter and L. Schmidt, Engineering Design, 5/e, McGraw Hill,
2013.
IET publication: A Guide to Technical Report Writing, online
www.theiet.org
Personal communication, Dr. Dorbin Ng, CUHK SEEM 39
END

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 Importance of Engineering Design

1. Design costs very little in terms of the overall product cost but its
decisions has major event on the overall cost
2. Defects introduced in the design phase cannot be compensated in the
manufacturing phase
3. Design process should be conducted to develop quality, cost-competitive
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products in the shortest time possible
 Problem-solving Methodology for
Engineering Design (cont-2)
Paradox
Design knowledge grows, design freedom diminishes
Sometimes have forced decisions, e.g. long lead time equipment

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[Source: Dieter & Schmidt 2013]
 Design Process as a Process of Questioning
Suppose your client wants you to design a safe ladder.

There will be a lot of questions arising:

Why do you want another ladder?
How will it be used?
How much can it cost?
What do you mean by safe?
.
Similar sets of questions arise if I simply ask you to design an
automated guided vehicle (AGV), without further specifications.

The designers first task is to clarify what the client wants so as to

be able translate wishes into meaningful objectives and
constraints.
 Example: Design a Safe Ladder
Questions like
Why do you want another ladder?
How will it be used?
How much can it cost?
help clarify and establish the clients
objective.
Questions like
What does safe mean?
Whats the most youre willing to spend?
help identify the constraints that govern the
design.