STEM Project Design

Science Technology Engineering and Math

STEM Service-Learning Summer instituteSacramento 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 Phones Computers

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

ServiceTo our partners, meeting needs in the community

LearningBecoming 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 Ullman’s - 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 Phases1. Problem Identification2. Specification Development 3. Conceptual Design4. Detailed Design5. Production6. Service/Maintenance7. Redesign or retirement

*EPICS High–Engineering Projects in Community Service-Learning, Purdue University

The EPICS Design Cycle

Specification Development

Detailed Design

Production

ServiceMaintenance

Redesign

Retirement

Problem Identification

ConceptualDesign

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

ServiceMaintenance

Redesign

Retirement

Problem Identification

ConceptualDesign Disposal

Iterations in the Design Process

Disposal

Specification Development

Detailed Design

Production

ServiceMaintenance

Redesign

Retirement

Problem Identification

ConceptualDesign

Iterations in the Design Process

Disposal

Specification Development

Detailed Design

Production

ServiceMaintenance

Redesign

Retirement

Problem Identification

ConceptualDesign

Iterations in the Design Process

Disposal

Specification Development

Detailed Design

Production

ServiceMaintenance

Redesign

Retirement

Problem Identification

ConceptualDesign

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? Don’t 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

Don’t 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 riderSteers wateraway from

rider

Supportsother items

Attach reflectorAttach

splashguard

Create a functional decomposition diagram for a cell phone, energy audit or

mechanical pencil(won’t be complete)

Generating Ideas - Brainstorming

Pick a facilitator Define the problem Small group Explain the process Record ideas in a visible way Everyone’s 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

Criteria Wts. Co. A Co. B Co. C

Location 5

Salary 4

Bonus 2

Job 4

Training 2

Boss 3

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

Severity How severe are the consequences to the failure?

Occurrence How often are the failures likely to occur?

Detection How 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