1. EAS 140 Engineering Solutions Lecture #11 New Design Strategies

2. Chemical  Civil  Computer  Industrial  Electrical  Mechanical EAS 140: Engineering Solutions Outline  Need for Innovative Design Processes  New Design Strategies

3. Chemical  Civil  Computer  Industrial  Electrical  Mechanical EAS 140: Engineering Solutions Need for Innovative Design Processes  Traditional design approach has been successful, but….  What problems do you see with the traditional design process?

4. Chemical  Civil  Computer  Industrial  Electrical  Mechanical EAS 140: Engineering Solutions Need for Innovative Design Processes Problems include:  Long design time - sometimes called “throw-it-over-the-wall” design –Engineering dept designs product –Throw design over the wall of the cubicle to marketing dept –Marketing changes the design –Throws revised design back to engineering Example: Every blueprint page of a Boeing aircraft is revised 4.5 times on average – they design 4.5 airplanes for every model built!

5. Chemical  Civil  Computer  Industrial  Electrical  Mechanical EAS 140: Engineering Solutions Need for Innovative Design Processes Other problems include:  No incentive to make products easy to: –manufacture/assemble –service/maintain/support  No incentive to minimize environmental impact of products

6. Chemical  Civil  Computer  Industrial  Electrical  Mechanical EAS 140: Engineering Solutions New Design Strategies To address these problems, engineers have developed new design strategies, including:  Concurrent Engineering (CE)  Reverse Engineering  Reengineering/redesign

7. Chemical  Civil  Computer  Industrial  Electrical  Mechanical EAS 140: Engineering Solutions Concurrent Engineering  Idea: Systematic approach Consider all elements of product lifecycle, including: End user requirements Manufacturing User support Quality control Product disposal  Key elements: Design for manufacturing (DFM) Design for assembly (DFA) Design for environment (DFE, also called Green Engineering)

8. Chemical  Civil  Computer  Industrial  Electrical  Mechanical EAS 140: Engineering Solutions DFM Example  Example: Mattel toy: Color Spin Child rotates red ball, other balls spin For children for 6 mo - 3 years old

9. Chemical  Civil  Computer  Industrial  Electrical  Mechanical EAS 140: Engineering Solutions DFM Example  Background: Mattel purchased rights to toy from Japanese manufacturer Toy is too expensive for US market

10. Chemical  Civil  Computer  Industrial  Electrical  Mechanical EAS 140: Engineering Solutions DFM Example  Potential savings are huge –Mattel saves $0.5 million dollars for every 1 penny savings on manufacture of Barbie  How can Mattel design to save money? What costs money to make the Color Spin toy?

11. Chemical  Civil  Computer  Industrial  Electrical  Mechanical EAS 140: Engineering Solutions DFM Example Main expenses in Color Spin toy:  Number of parts –originally, 55 parts  Materials –originally, made of expensive plastics  Manufacturing process –New goals: Reduce the number of fasteners Use standardized parts Use unidirectional assembly

12. Chemical  Civil  Computer  Industrial  Electrical  Mechanical EAS 140: Engineering Solutions DFM Example  Example: Replaced 10 screws with ultrasonic welding

13. Chemical  Civil  Computer  Industrial  Electrical  Mechanical EAS 140: Engineering Solutions Design for Manufacturing  Example: Created symmetric roller drive - 4 less parts and interchangeable parts

14. Chemical  Civil  Computer  Industrial  Electrical  Mechanical EAS 140: Engineering Solutions DFM Example Overall impact:  Number of parts reduced from 55 to 27 (49% reduction)  Reduction in factory costs: 38%  Annual savings: $700,000/yr

15. Chemical  Civil  Computer  Industrial  Electrical  Mechanical EAS 140: Engineering Solutions Reverse Engineering  Idea: Take apart an object or system to see how it works  Uses: New ideas from competitors Fabricate copies of old parts, machinery for legacy equipment Reuse computer code

16. Chemical  Civil  Computer  Industrial  Electrical  Mechanical EAS 140: Engineering Solutions Reverse Engineering  Example: Saturn automotive engineers dismantle other cars to look for design ideas (worksheet below):

17. Chemical  Civil  Computer  Industrial  Electrical  Mechanical EAS 140: Engineering Solutions Reengineering/Redesign  Idea: Fundamental rethinking and radical redesign of a system  Applications: Engineering Computer software Business systems

18. Chemical  Civil  Computer  Industrial  Electrical  Mechanical EAS 140: Engineering Solutions Reengineering/Redesign  Examples: Power Mac G4 Cube Boeing 777 designe d using 3DCAD see text for details orhttp://bits.me.berkeley.edu/develop/b777/ Microso ft.NET net- basedsoftwaredevelopment (but production suspended)

19. Chemical  Civil  Computer  Industrial  Electrical  Mechanical EAS 140: Engineering Solutions Reengineering/Redesign  Examples continued: Boeing 777 designed using 3D CAD 2,200 workstations, 3x10 12 bytes of data (3 terabytes) see text for details or http://bits.me.berkeley.edu/develop/b777/ Microsoft.NET net-based software development Boeing 777 designe d using 3DCAD see text for details orhttp://bits.me.berkeley.edu/develop/b777/ Microso ft.NET net- basedsoftwaredevelopment