Functional Decomposition and Concept Generation MSD I Workshop

Functional Decomposition and Concept Generation MSD I Workshop 3 prepared by Prof. Margaret Bailey (ME) Copyright © 2007 Rochester Institute of Technology All rights reserved. EDGE™

Today’s Workshop Overview • 10 – 11: 30 AM • • • 11: 30 – 12: 30 Noon - 2 PM 2 - 3: 30 PM • 3: 30 – 4 PM • By 4: 30 PM Interactive Exercise on Functional Decomposition and Concept Generation Team Work Session Lunch and Activity Hour Break Functional Decomposition and Concept Generation on Project Create Summary of Workshop Activities Review Team Concept Generation Activities with Guide EDGE™

Morning Session Overview • Introduce Concept Generation • Explore Five-Step Concept Generation Method • Demonstrate Above Steps on Various Examples • Discuss Common Dysfunctions and Tips • Apply Concept Generation Steps to Team MSD I Project EDGE™

Concept Development Process Mission Statement Identify Customer Needs Establish Target Specifications Generate Product Concepts Select Product Concept(s) Test Product Concept(s) Set Final Specifications Plan Downstream Development Perform Economic Analysis Benchmark Competitive Products Build and Test Models and Prototypes Karl T. Ulrich and Steven D. Eppinger, 2004, Product Design and Development, Exhibit 6 -2, Chapter 6, 3 rd Edition, Irwin Mc. Graw-Hill EDGE™ Development Plan

Concept Generation "Fail Often, Fail Fast, Fail Cheap" Customer Needs Target Specifications Concept Generation Phase SET of Possible Concepts Goal: By the end of this phase, your team should feel confident that the full spectrum of options has been explored. EDGE™

Concept Generation Process • Clarify the Problem – Problem Decomposition • External Search – – – Lead Users Experts Benchmarking Patents/ Literature Professional Societies Standards • Internal Search – Individual Methods – Group Methods • Systematic Exploration – Classification Tree – Combination Table • Reflect on the Process – Continuous Improvement Karl T. Ulrich and Steven D. Eppinger, 2004, Product Design and Development, Exhibit 6 -3, Chapter 6, 3 rd Edition, Irwin Mc. Graw-Hill EDGE™

Clarify the Problem • Decompose or divide a complex problem into simpler problems that can more easily be solved in a focused manner. • Several “decomposition” methods available, such as: – Sequence of User Actions – Key Customer Needs – FUNCTIONS, known as Functional Decomposition • Division process occurs until sub-functions can be worked on easily • Function diagram useful for documenting but they are not unique; several decompositions may be found for a given problem • A simple list of sub-functions (without connections shown) is also acceptable EDGE™

Function Diagram: Hand Held Nailer Karl T. Ulrich and Steven D. Eppinger, 2004, Product Design and Development, Exhibit 6 -4, Chapter 6, 3 rd Edition, Irwin Mc. Graw-Hill EDGE™

Review Functional Decomposition on MSD I Project • Develop function diagram (showing connections or flows) and/or list of subfunctions for your MSD I project • Identify sub-functions that could be considered critical – Most critical to the success of the product – Most likely to benefit from novel or creative solutions EDGE™

Concept Generation Process • Clarify the Problem – Problem Decomposition • External Search – – – Lead Users Experts Benchmarking Patents/ Literature Professional Societies Standards • Internal Search – Individual Methods – Group Methods • Systematic Exploration – Classification Tree – Combination Table • Reflect on the Process – Continuous Improvement Karl T. Ulrich and Steven D. Eppinger, 2004, Product Design and Development, Exhibit 6 -3, Chapter 6, 3 rd Edition, Irwin Mc. Graw-Hill EDGE™

Patents/Literature • US Patent and Trademark Office Web Site – – http: //www. uspto. gov/web/offices/com/iip/index. htm • European Patent Office – http: //www. european-patent-office. org/online/ • Academic Journals – Database tools such as web of science, engineering index, compendex, science citations index, etc. • Conference Proceedings • Internet Resources – Search engines: Google, Metacrawler, … – Government Web Site (Foreign and Domestic) – DO NOT rely exclusively on internet search resources. They are often good, but they are also often WRONG and INCOMPLETE EDGE™

Professional Societies • • Project Management Institute (PMI) Institute of Electrical and Electronics Engineers (IEEE) The technical objectives of the IEEE focus on advancing theory and practice of electrical, electronics and computer engineering and computer science. Software Engineering Institute The SEI mission is to provide leadership in advancing the state of the practice of software engineering to improve the quality of systems that depend on software. The International Society for Optical Engineering (SPIE) The society's fundamental mission is to provide world-class education and information services that enhance and promote the profession and field of optical engineering and that add quality and value to the careers of the members it serves. Society of Automotive Engineers (SAE) SAE provides technical information and expertise used in designing, building, maintaining, and operating self-propelled vehicles for use on land or sea, in air or space. American Society for Testing and Materials (ASTM) The society promotes public health and safety, and the overall quality of life; contributes to the reliability of materials, products, systems and services. Society of Manufacturing Engineers (SME) The society is dedicated to serving its members and the manufacturing community through the advancement of professionalism, knowledge, and learning. EDGE™

Standards • Private Companies & Organizations – – – Underwriter’s Laboratory International Organization for Standards (ISO) European Environment Agency – – – Occupational Safety & Health Administration MIL standards Codes • Government • Societies – Design standards – Accepted practices EDGE™

Develop External Search Strategy for MSD I Project • Identify lead users and experts • Create benchmarking plan – Closely related products – Functionally related products • Discuss usefulness of patent/literature search for various subfunctions EDGE™

Concept Generation Process • Clarify the Problem – Problem Decomposition • External Search – – – Lead Users Experts Patents/ Literature Professional Societies Standards Benchmarking • Internal Search – Individual Methods – Group Methods • Systematic Exploration – Classification Tree – Combination Table • Reflect on the Process – Continuous Improvement Karl T. Ulrich and Steven D. Eppinger, 2004, Product Design and Development, Exhibit 6 -3, Chapter 6, 3 rd Edition, Irwin Mc. Graw-Hill EDGE™

Tips for Idea Generation • • Focus on generating a large QUANTITY of ideas Do not criticize individuals, ideas, or suggestions Do not pass judgment on the statements made Do not evaluate the merits of an idea – welcome ideas that may first appear infeasible Set goals – either fixed number of ideas in a session, or maximum ideas in a fixed length of time Analogies – What other devices solve related problem? Wish and wonder – Consider new possibilities Related stimuli – Work on your neighbor’s idea list EDGE™

More Tips for Idea Generation • Balance Individual and Group Search • Individuals generate ideas more quickly than groups – Analogies – What other devices solve related problem? – Wish and wonder – Consider new possibilities • Group interaction is critical for refinement, combination, and critique of the solutions – Group sessions build team consensus that solution space has been adequately explored – Gallery Method – Display many concepts created by various individuals at once (via post-its, etc. ) • Explain • Improve/refine • Identify related concepts EDGE™

Begin Internal Search Process for MSD I Project • Focus on generating a large QUANTITY of ideas for a critical subfunction • Use individual and group techniques • Record concept generation process and share with class EDGE™

Concept Generation Process • Clarify the Problem – Problem Decomposition • External Search – – – Lead Users Experts Patents/ Literature Professional Societies Standards Benchmarking • Internal Search – Individual Methods – Group Methods • Systematic Exploration – Classification Tree – Combination Table – Morphological Tables • Reflect on the Process – Continuous Improvement Karl T. Ulrich and Steven D. Eppinger, 2004, Product Design and Development, Exhibit 6 -3, Chapter 6, 3 rd Edition, Irwin Mc. Graw-Hill EDGE™

Systematic Exploration: Concept Combination Table - Hand Held Nailer Karl T. Ulrich and Steven D. Eppinger, 2004, Product Design and Development, Exhibit 6 -12, Chapter 6, 3 rd Edition, Irwin Mc. Graw-Hill EDGE™

Concept Generation Process • Clarify the Problem – Problem Decomposition • External Search – – – Lead Users Experts Patents/ Literature Professional Societies Standards Benchmarking • Internal Search – Individual Methods – Group Methods • Systematic Exploration – Classification Tree – Combination Table – Morphological Tables • Reflect on the Process – Continuous Improvement Karl T. Ulrich and Steven D. Eppinger, 2004, Product Design and Development, Exhibit 6 -3, Chapter 6, 3 rd Edition, Irwin Mc. Graw-Hill EDGE™

Rest of the Day…. • Create list of sub-functions AND/OR develop a functional diagram (refer to Exhibit 6 -4) • Identify and justify critical sub-functions • Begin external searches of problem solutions • Internal search of solutions at system and sub -function levels, include several possible solutions • Synthesize possible solution combinations at the sub-function level (refer to Exhibit 6 -9) EDGE™

Week 4 Review and submit following deliverables to Team Guide during week 4: • Update Overall Project Plan and Schedule • List of sub-functions AND/OR develop a functional diagram (refer to Exhibit 6 -4) • Identify and justify critical sub-functions • Summarize results of external and internal searches of problem solutions, include several possible solutions (refer to Exhibit 6 -6) • Synthesize possible solution combinations at the subfunction level (refer to Exhibit 6 -9) • READ Chapter 7 and be prepared for Concept Selection activities during Week 4 Workshop EDGE™