STEM Project Design Science Technology Engineering and Math STEM Service-Learning Summer institute Sacramento State University August 5-7, 2009

Many Definitions of Design Design as art Design as problem solving Design activity as applying scientific and other organized knowledge to practical tasks Design as a social process in which individual worlds interact and parameters are negotiated Source: Dr. Robin Adams ENE 696G course notes

Design Process Few Specifications » » Many Specifications Most Influential Choices » » Least Influential Choices Infinite Variety of Designs » » One Design Design is done by many disciplines

Multiple Valid Solutions Examples: Cell PhonesComputers

STEM Balance Service-learning is a balance of the learning of design and the service we contribute to the communities through completed designs and support Service To our partners, meeting needs in the community Learning Becoming good designers, professionals and active learners Complimentary goals that enhance each other

Design Process and Project Mgmt. Many models and tools Design Process Mechanical Engineering Ullmans - 6 steps Service Learning PARDE Model – key elements Different Companies use different models They all use some process Avoid hobbyist approach and inefficient project progress Design needs to combine STEM and Service-Learning

EPICS * Design Process Six Phases 1. Problem Identification 2. Specification Development 3. Conceptual Design 4. Detailed Design 5. Production 6. Service/Maintenance 7. Redesign or retirement *EPICS High–Engineering Projects in Community Service-Learning, Purdue University

The EPICS Design Cycle Specification Development Detailed Design Production Service Maintenance Redesign Retirement Problem Identification Conceptual Design Disposal

Problem Identification Tasks Identify problem Determine project objectives Determine motivation for project Identify outcomes or deliverables Determine duration of the project Identify community partner contact Identify stakeholders Deliverables Project Charter

Specification Development Tasks Complete users and beneficiaries analysis Define the customer requirements Evaluate design constraints Develop engineering specifications Compare to benchmark products (prior designs) Determine design targets Deliverables Project Specification Document

Conceptual Design Tasks Complete Functional Decomposition of project Complete Decision Matrix of requirements Define how users will interact with project Analyze/evaluate potential solutions Choose best solution Deliverables Project Conceptual Design Report

Detailed Design Tasks Complete top down specification/ bottom-up implementation (freeze interfaces) Analysis/evaluation of project, sub-modules and/or components Prototyping/proof-of-concept of project, sub-modules and/or components Field test prototype/get feedback from users Complete DFMEA* analysis of project Bill of materials Determine what user training is necessary Deliverables Project Detailed Design Report Prototype version of project *DFMEA -Design for Failure Mode and Effect Analysis

Production Tasks Complete production version of the project Complete user manuals/training material Complete delivery review Deliverables Delivered project Project Delivery Report Delivery checklist User manuals

Service/Maintenance Tasks Evaluate performance of fielded project Determine what resources are necessary to support and maintain the project Deliverables Fielded Project Report Redesign or Retirement Decisions

The EPICS Design Cycle Specification Development Detailed Design Production Service Maintenance Redesign Retirement Problem Identification Conceptual Design Disposal

Iterations in the Design Process Disposal Specification Development Detailed Design Production Service Maintenance Redesign Retirement Problem Identification Conceptual Design

Iterations in the Design Process Disposal Specification Development Detailed Design Production Service Maintenance Redesign Retirement Problem Identification Conceptual Design

Iterations in the Design Process Disposal Specification Development Detailed Design Production Service Maintenance Redesign Retirement Problem Identification Conceptual Design

Seeking and Selecting Each phase of the design process has divergent (creative) components where ideas are sought and a convergent component where options are selected Diverge - Seek Possibilities Converge - Narrow Choices Problem Identification Specification Development Converge - Narrow Choices Diverge - Seek Possibilities

EPIC Projects and Design Four Broad Areas Human Services Access and Abilities Environmental Education Outreach Design Process Often Same Can be STEM rich

Design Tools Group Activities Engineering Specifications

Specifications Development What does your project partner need? Dont rely on what they want, find out what they need. Understand the problems and issues you are addressing Who will use the product? Who will benefit from the product? Gather Data Talk to project partner and others impacted Research

Specifications Development (cont.) How will the problem be worked? Criteria for design teams How will teams be integrated? Who will use the product? Transition plans for multiple semesters Gather input from project partner on specifications Develop a specifications document Share and modify specifications

Customer Requirements Types of customer requirements Functional performance Human factors Physical Time Cost Standards Test methods Service and maintenance

Customer Requirements For a cell phone, make a list of ten customer requirements Or For an energy audit of a school, make a list of ten customer requirements

Engineering Specifications Answer the how question Quantified Should be able to measure whether you meet it Objective quantities A set of units should be associated with each specification Forms the basis for your specifications document

Engineering Requirements Starting with the customer requirements for a cell phone or energy audit, make a list of engineering requirements

Defining Requirements Benchmarks What is available? Make comparisons Why did they use their approach? Patent searches (avoid infringement) Are we smarter than everyone else? Did we miss something?

Design Targets Set standards to meet with your design How good is good? Should be a living document Dont compromise on goals Refine as the design progresses Make design trade-offs if needed Communication with project partner Design decisions

Design Tools Defining the System

Functional Decomposition Breaking tasks or functions of the system down to the finest level Create a tree diagram starting at the most general function of your system What is the purpose of your system Action word (verb) and object (noun) Break this function down into simpler subtasks or sub functions Continue until you are at the most basic functions or tasks Consider What, not How

Sample FD – Bike Fender Protect rider from water and dirt off wheel Shield rider Steers water away from rider Supports other items Attach reflector Attach splashguard

Create a functional decomposition diagram for a cell phone, energy audit or mechanical pencil (wont be complete)

Generating Ideas - Brainstorming Pick a facilitator Define the problem Small group Explain the process Record ideas in a visible way Everyones involved No evaluating Eliminate duplicates Pick three

In the same group – Brainstorm ways to implement one of the functions on your diagram and select the best alternative

Decision Matrix Table with alternatives Quantify categories and score alternatives Use judgment to do reality checks Leaves documentation of thought process of design Can be shared in design reviews

Decision Matrix Example: Seeking a Job CriteriaWts.Co. ACo. BCo. C Location5 Salary4 Bonus2 Job4 Training2 Boss3 Totals

Testing for Failures –DFMEA * Steps Review the design Brainstorm potential failure modes List potential effects of failure Rank Failures Severity Occurrence Detection Develop action plan Implement fixes Revisit potential failure risks *Design for Failure Mode and Effective Analysis

In a group, Identify one project to use as an example for this exercise Describe the project so the whole group understands it

Brainstorm Failures What could go wrong? What could break? Are there systems your design relies upon? Are there things that could fail over time?

Brainstorm a list of potential failures for the project

Rate Failures Rating SeverityHow severe are the consequences to the failure? OccurrenceHow often are the failures likely to occur? DetectionHow easily are the failures detected

Failure Action Plan Identify the failure scenario that should be addressed first Develop an action plan to address the failure scenario

Final Design Tasks Production Service and Maintenance Retirement or Redesign

STEM Project Design Questions/Discussions