Introduction to

Engineering Design

Notes of S. Takagaki, H. P. Huang, S. Ramaswamy

Fall 2019
 Foundational Questions
What is an engineer?
What is engineering design?
Difference between engineering analysis and engineering design
What is the difference between product and process design?
What is the context of the design process?
Engineering design vs. design in other academic disciplines?
Why design?

Notes of S. Takagaki, H. P. Huang, S. Ramaswamy

Fall 2019
 What is engineering?
“…the purposive adaptation of means to reach a pre-conceived end…” E.T. Layton, Jr.
“Technological activity to solve problems”

Notes of S. Takagaki, H. P. Huang, S. Ramaswamy

Fall 2019
 Human creativity
Engineering as a “Thinking-Making” Activity
The use of technology to make products and systems
for societal benefit.

Notes of S. Takagaki, H. P. Huang, S. Ramaswamy

Fall 2019
 Historical Questions
What role of engineers in history?
Irrigation and farming equipment, dam projects, water and wind mills building construction,
the Pyramids, the Great Wall, Leonardo’s contraptions, the printing press, the Wright brothers’
aircraft, fermented beverages, nuclear power, the Space Shuttle, Tacoma Narrows Bridge,
electric appliances, petroleum products, pharmaceuticals.

When did the engineering disciplines begin?

3000 BC Civil
1000 BC Military
AD 1700 Mechanical
AD 1800 Materials
Agricultural
Electrical
AD 1900 Chemical
Aerospace
AD 1950 Computer, Nuclear, Biochemical
Biomedical
[ Holtzapple, M. T., Reece, W. D. (2005) ]

Notes of S. Takagaki, H. P. Huang, S. Ramaswamy

Fall 2019
 Product Realization Process
(PRP)
• Engineering design • Environmental assessment
• Industrial design • Stakeholder involvement
• Production planning • Engineering design
• Manufacturing • Construction planning
• Distribution • Construction
• Sales • Effectiveness monitoring,
• Marketing control, and maintenance
• Service
• Disposal

Notes of S. Takagaki, H. P. Huang, S. Ramaswamy

Fall 2019
Notes of S. Takagaki, H. P. Huang, S. Ramaswamy
Fall 2019
 Problem solution
Engineering as Problem Solving

Problem identification
Synthesis Orderly stepwise approach
Analysis
Qualitative/general
Application  quantitative/detailed

Comprehension
[ Holtzapple, M. T., Reece, W. D. (2005) ]

Solution
Notes of S. Takagaki, H. P. Huang, S. Ramaswamy
Fall 2019
 Process of Engineering

Think Think Math Politics

Analysis
Sketch Sketch Physics Law
Make Make
Chemistry
Show Show Ethics
Use Use Biology
Environmental

Economy

Notes of S. Takagaki, H. P. Huang, S. Ramaswamy

Fall 2019
 Process of Engineering
Need

Analysis of Problem

Statement of Problem Brainstorming

Rule : There are
Conceptual Design
no stupid ideas
in a brainstorm
Selected Schemes

Embodiment of Schemes

Detailing

Working drawings, etc.. [ Ferguson, E. S. , (1992) ]

Notes of S. Takagaki, H. P. Huang, S. Ramaswamy

Fall 2019
• What is a product or process?
Object produced, substance, material, arrangement, service, step sequence,
manufactured good, transformation of something, system, organization.
Example 1 : Water bottle made of biodegradable plastic
Example 2 : Biorefinery for ethanol production from biomass
Example 3 : Bio-repellant coatings
Example 4 : Flood control structures
Example 5: Contaminant/pollutant removal systems
Example 6: Structures for wildlife migration

Notes of S. Takagaki, H. P. Huang, S. Ramaswamy

Fall 2019
Notes of S. Takagaki, H. P. Huang, S. Ramaswamy
Fall 2019
 Examples in bio-based products
Materials and Chemicals
- Wood
- Wood-based
- Paper
- Biodiesel fuel
- Bio-based plastics
- Biodegradable plastics (e.g. drink bottles)
- Ethanol (bio-based)
-
-

Notes of S. Takagaki, H. P. Huang, S. Ramaswamy

Fall 2019
 Examples in bioprocessing
Utilization of living cells or their components to obtain
desired products
- Ethanol fermentation from corn
- Antibody production via fungal fermentation
- Anaerobic digestion to treat wastewater
- Biodegradable plastics (e.g. PLA) production from corn
- Enzymatic hydrolysis to produce sugar from cellulose
-
-

Notes of S. Takagaki, H. P. Huang, S. Ramaswamy

Fall 2019
 What is engineering design?
• Engineering design is the set of decision-making processes
and activities used determine the form of an object given the
functions desired by the customer. (Gov of MA)
• Engineering design is the process of devising a system,
component, or process to meet desired needs. It is a decision-
making process (often iterative), in which the basic science
and mathematics and engineering sciences are applied to
convert resources optimally to meet a stated objective. Among
the fundamental elements of the design process are the
establishment of objectives and criteria, synthesis, analysis,
construction, testing and evaluation. (ABET)

Notes of S. Takagaki, H. P. Huang, S. Ramaswamy

Fall 2019
 Product Design
• New products are critical for corporate
prosperity
• Approximately 33% of revenues come from
products that did not sell 5 years ago
• Successful new products are profitable
– Median achieve 33% ROI or better
– Median have payback of 2 years or less
– Median achieve market share of 35%

• Significant R&D expenditures and investment

Notes of S. Takagaki, H. P. Huang, S. Ramaswamy

Fall 2019
 Manufacturing of Chemical Products

Notes of S. Takagaki, H. P. Huang, S. Ramaswamy

Fall 2019
 Process Engineering Design

Notes of S. Takagaki, H. P. Huang, S. Ramaswamy

Fall 2019
 Environmental Design
• Changing human needs mean the need
for the design of new infrastructures
• Design with a focus on natural processes
• Designs should mimic nature – i.e., self-
adaptive, self-sustaining, and resilient

Notes of S. Takagaki, H. P. Huang, S. Ramaswamy

Fall 2019
 Engineering Design vs Engineering Analysis

• Engineering analysis: Predicted behavior is the solution

to an analysis problem
– Formulating
– Solving
– Checking

• Engineering design:
– Formulating
– Generating
– Analyzing
– Evaluating

Notes of S. Takagaki, H. P. Huang, S. Ramaswamy

Fall 2019
 Design Step

Notes of S. Takagaki, H. P. Huang, S. Ramaswamy

Fall 2019
Process of Engineering

Map

[ SSL (2004) ]

Notes of S. Takagaki, H. P. Huang, S. Ramaswamy

Fall 2019
Process of Engineering (cont.)

Map

[ SSL (2004) ]

Notes of S. Takagaki, H. P. Huang, S. Ramaswamy

Fall 2019
 Issues in design
Utility and cost
Single and multi-functionality
Batch or mass production
Patents
Aesthetics
Integrity of product (wholeness)
Whole life-cycle planning
Health effects and safety
Recycling and disposal
End of product life and replacement issues
Failure modes
Effects on society

Notes of S. Takagaki, H. P. Huang, S. Ramaswamy

Fall 2019
 Ethical issues design
Philosophical and practical ethics
Codes of Ethics

- Health and welfare of humans and nature

- Informing client/employers of consequences
- Statements and information in truthful manner
- Treating people fairly (avoiding conflict of interest)
- Limits of professional competence
- Building professional reputations according to merits
- Continuing professional development
- Issues with intellectual property. [ SSL (2004) ]

Issues
Life systems preservation
Maintenance of quality of life
Maintaining high standards of personal and professional conduct
Managing intra-professional customs, identifiers, habits, and limits.

Notes of S. Takagaki, H. P. Huang, S. Ramaswamy

Fall 2019
 Economic analysis
What is the relevance of economic analysis to design?

Economic assumption : Measure of value is “monetary”

Process cost in context of the company
Reporting costs, financial status, and transactions.
Value today, value tomorrow.
Material cost, labour cost, indirect cost
Manufacturing cost, storage cost, transport cost
Product cost scaling and correction factors

Notes of S. Takagaki, H. P. Huang, S. Ramaswamy

Fall 2019
 Statistical analysis
What relevance is statistics to design?

Statistical focus : “The one and the many”

Measures of central tendency
Measures of variation
Probability
Uncertainty analysis
Linear regression
Six sigma quality concept
Optimization and development of designs
Statistics in process control for quality
Notes of S. Takagaki, H. P. Huang, S. Ramaswamy
Fall 2019
 AspenTech HYSYS Modeling Code
• Menu driven, Mouse driven.
• Flowsheets, Modular units.
– Mixers, Reactors, Flash separators,
Distillation units, Heat exchangers.
• Reaction databases.
• Chemical property calculations.
• Species, Mass, Momentum, Heat Balances.
• Equipment Sizing.
• Economic calculations.
• Optimization.

Notes of S. Takagaki, H. P. Huang, S. Ramaswamy

Fall 2019
 CAD, MAPWindow/ArcGIS, WAM,
HEC-RAS
• CAD – develop engineering drawings
• MAPWindow/ArcGIS – work with mapping
systems for various geographical analyses
• WAM – one of many models for watershed
assessments
• HEC-RAS – a model for water flow in open
channels

Notes of S. Takagaki, H. P. Huang, S. Ramaswamy

Fall 2019
 References
deCamp, L. Sprague, (1963) The Ancient Engineers, Bantam books
Ferguson, E. S. , (1992) Engineering and the Mind’s Eye, MIT Press, Cambridge.
Cussler, E.L., Moggridge, G.D. (2001) Chemical Product Design, MIT Press, Cambridge
Holtzapple, M. T., Reece, W. D. (2008) Concepts in Engineering, 2nd Edition, McGraw-
Hill.
also Holtzapple, M. T., Reece, W. D. (2005) Concepts in Engineering, McGraw-Hill.
Kangas, P.C., Ecological Engineering, Principles and Practice, Lewis Publishers, 2004

Ogot, M. G. Okudan-Kremer, Engineering design: a practical guide, Togo Press, LLC.

2004, 544 pages.

Seider, W. D., Seader, J. D., Lewin, D. R. (2004) Product and Process Design Principles,
Second Edition, Wiley.

Smith, R. (2005) Chemical Process, Wile y.

Notes of S. Takagaki, H. P. Huang, S. Ramaswamy

Fall 2019