Design Engineering and Science

Design Engineering and Science teaches the theory and practice of axiomatic design (AD). It explains the basics of how to conceive and deliver solutions to a variety of design problems. The text shows how a logical framework and scientific basis for design can generate creative solutions in many fields, including engineering, materials, organizations, and a variety of large systems. Learning to apply the systematic methods advocated by AD, a student can construct designs that lead to better environmental sustainability and to increased quality of life for the end-user at the same time reducing the overall cost of the product development process. Examples of previous innovations that take advantage of AD methods include: • on-line electric vehicle design for electric buses with wireless power supply; • mobile harbors that allow unloading of large ships in shallow waters; • microcellular plastics with enhanced toughness and lower weight; and • organizational changes in companies and universities resulting in more efficient and competitive ways of working. The book is divided into two parts. Part I provides detailed and thorough instruction in the fundamentals of design, discussing why design is so important. It explains the relationship between and the selection of functional requirements, design parameters and process variables, and the representation of design outputs. Part II presents multiple applications of AD, including examples from manufacturing, healthcare, and materials processing. Following a course based on this text students learn to create new products and design bespoke manufacturing systems. They will gain insight into how to create imaginative design solutions that satisfy customer needs and learn to avoid introducing undue complexity into their designs. This informative text provides practical and academic insight for engineering design students and will help instructors teach the subject in a novel and more rigorous fashion. Their knowledge of AD will stand former students in good stead in the workplace as these methods are both taught and used in many leading industrial concerns. Preface On the Role of Computers and Software in the Field of Design In Conclusion Acknowledgments Contents 1 Introduction to Design Abstract 1.1 Human Creativity and Design 1.2 Design: A Basic Human Intellectual Instinct 1.3 Importance of Knowing How to Define the Problem Based on Design Goals 1.3.1 Invention of the Steam Engine by James Watt Changed the History of Humanity and Created the Science of Thermodynamics 1.3.2 Design as a Common Human Activity in Many Fields 1.3.3 Two Different Solutions for the Same Problem 1.4 Designing Without Explicit Goals and Problem Identification is Analogous to Sailing a Sailboat Without a Rudder 1.5 A Summary of the Creative Process 1.6 Importance of Design and Design Thinking 1.7 What is the Most Difficult Aspect of Learning Axiomatic Design? 1.8 List of Example Problems 1.9 Definition of Systems 1.10 Fundamental Principles of Design 1.11 Principle of Similitude of Systems 1.12 Importance of Knowing the Basic Laws and Principles of Science and Engineering 1.13 The Inverse Problem in Design: Extraction of Functional Requirements from Many Design Parameters 1.14 Optimization of an Existing System Versus Design of a New System 1.15 Scope of the Book 1.16 Conclusions References Further Reading 2 What Is Design? Abstract 2.1 Introduction 2.1.1 Why Design Theory (DT)? 2.1.2 Think in Solution-Neutral Environment! 2.1.3 Design Theory: Should It Be Axiomatic or Algorithmic? 2.2 Design: Transformational Process to Create Human-Inspired Systems 2.2.1 Definition of Key Words: Design, Goals, and Domains 2.2.2 The Concept of Four Domains 2.2.3 Goals 2.2.4 Mapping from Domain to Domain: Functional Requirements, Design Parameters, and Process Variables 2.2.5 Design Axioms 2.2.6 Design Matrix [DM] 2.2.7 Design Equation 2.2.8 Decomposition of Functional Requirements, Design Parameters, and Process Variables Through Zigzagging Between the Domains 2.3 Design Process in Creating Various Systems 2.3.1 Revisiting the Water Faucet Design 2.3.2 Design of a System for Salary Raise 2.4 Role of System Architect in Managing Large System Development 2.5 Uncertainty and the Information Axiom 2.6 On Design of Machines that Can Design 2.7 Conclusions Bibliography Further Reading 3 How Do We Design? Abstract 3.1 Universal Nature of Design Tasks 3.2 Some Useful and Simple Corollaries and Theorems 3.3 Lesson on “Design It Right, i.e., No Coupled Design!” 3.4 Mathematical Optimization and Design 3.5 Design of Technological Products 3.5.1 Design of Easy Open Beverage Can 3.5.2 Removal of Kidney Stone with a Robot 3.5.3 Ash Tray in Automobiles 3.5.4 Design of a Collapsible Steering Column for Automobiles 3.5.5 Design of a Technology that Reduces Material Consumption 3.5.6 Wireless Electric Power Transmission System to a Bus in Motion 3.5.7 Design of Ultra-Precision Lithography Machine 3.6 Design of Organizations 3.6.1 Design of a Government Organization 3.6.2 Design of High-Technology Industrial Firms 3.7 Conclusions Appendix Bibliography Further Reading 4 Design Representations Abstract 4.1 Introduction: Design Representations and Their Purposes 4.2 Design Representations for Applying the Axioms 4.2.1 Axiom 1, Maintaining Independence, Function–Physical Representations, and Module Junction Diagram and Flow Diagram 4.2.2 Axiom 2, Minimizing Information Content and the Concept of Tolerances 4.2.3 V-Model, Design Process Representation to Guide a Structured Design Process 4.3 Examples of Design Representations in Industrial Environment 4.3.1 Mechanical Product Design: From the Design Matrix to the Mechanical Drawing 4.3.1.1 Mechanical Drawing General Rules 4.3.2 Industrial Environment: Piping and Instrumentation Diagram (P&ID) 4.4 Case Study: Design and Manufacture of Mechanical and Chemical Polishing Machine (CMP) by Four Graduate Students 4.5 Software Design 4.5.1 Operational Context 4.5.2 Software Representation—UML 4.5.3 Equivalence Between Forms of Representation 4.5.4 Example of a Software Representation References Further Reading 5 Problem Definition Abstract 5.1 Problem Definition in Engineering Design 5.1.1 Characteristics of Problem Definition 5.1.2 Good Problem Definition Leads to Design Innovation 5.2 Definition of Customer Need 5.2.1 Who Are the Target Customers and Relevant Stakeholders? 5.2.2 How to Solicit Customer Voices? 5.2.3 Understand Customer Voices to Capture Innovation Opportunity 5.3 Definition of Functional Requirement 5.3.1 How to Represent Functional Requirements? 5.3.2 How to Extract Functional Requirements from Existing “Things” 5.3.3 How to Classify Functional Requirements into Different Categories? 5.3.4 How to Structure Functional Requirements? 5.4 Definition of Design Constraint 5.4.1 What Is Design Constraint? 5.4.2 Examples of Design Constraint 5.5 Definition of Problem Context 5.5.1 What Is Design Context? 5.5.2 Example of Design Context 5.6 Examples of Problem Definition 5.7 Summary and Conclusion References Further Reading 6 How Should We Select Functional Requirements? Abstract 6.1 Importance of “Solution-Neutral Environment” in Selecting Functional Requirements 6.2 Functional Requirements and Zigzagging between Domains to Generate Lower Level Functional Requirements through Decomposition 6.3 Role of Broad Knowledge Base/Data Base in Formulating Functional Requirements 6.4 On Selection of a Right Set of Functional Requirements—Need to Review Functional Requirements from Time to Time 6.5 On Reverse Engineering to Determine the Functional Requirements of Existing Products 6.6 Minimum Number of Functional Requirements 6.7 No Relative Ranking of the Importance of Functional Requirements 6.8 Interdisciplinary Background and Choice of Functional Requirements 6.9 Importance of Design Matrix and the System Architecture 6.10 Conclusions Bibliography Further Reading 7 How Should We Select Design Parameters? Abstract 7.1 Introduction 7.2 Criteria for Selection of Design Parameters 7.3 Ideal Design 7.4 Generation and Selection of Design Parameters 7.5 Integration of Design Parameters in a System 7.6 Case Studies 7.7 Use of Artificial Intelligence (AI) in Axiomatic Design 7.7.1 Thinking Design Machine (TDM) 7.7.2 Physical Laws and Thinking Design Machine 7.8 Guidelines for Choosing Design Parameters and Process Variables 7.9 Conclusions Appendix 7.1 Algorithm for Changing the Order of {FRs} and {DPs} References Further Reading 8 How Should We Select Process Variables? Abstract 8.1 Introduction 8.2 Precision Engineering 8.3 Designing a Manufacturing Process for a Difficult-to-Machine Material 8.4 Mass Production of Microcellular Plastics 8.5 3D Printing: Layered Manufacturing 8.6 Process Variables in Organizational Design 8.7 Conclusions References 9 Mapping in Design Abstract 9.1 Introduction 9.2 The Role of Optimization 9.3 Hints for Defining the Functional Requirements 9.4 The Decomposition Process 9.5 The Zig 9.6 The Zag 9.7 Decomposition and Concurrent Engineering 9.8 Conclusion References Further Reading 10 Redundant Designs Abstract 10.1 Introduction 10.2 Redundancy in Nature 10.3 The Theorem of Redundancy 10.4 Reliability-Motivated Redundancy 10.5 Functionally Related Redundancy 10.6 More Theorems on Redundancy 10.7 Solving Coupled Designs 10.8 Conclusions References Further Reading 11 The Information Axiom and Robust Design Abstract 11.1 Introduction 11.2 The Information Axiom 11.3 Independence and Information Content 11.4 The Computation of Information Content of Decoupled Designs Through Graphical Methods 11.5 Information Content and Robustness 11.6 Summary References 12 Complexity in Axiomatic Design Abstract 12.1 Motivation for the Complexity Theory in Axiomatic Design 12.1.1 Applying a Complexity Theory to Real Problems 12.1.2 What is Complexity 12.2 Theory of Complexity, Periodicity, and the Design Axioms 12.2.1 Time-Independent Complexity in Axiomatic Design 12.2.2 Time-Dependent Complexity 12.2.3 Limiting Behavioral Options by Banning Irregularities from the Design 12.2.4 Known and Unknown Kinds of Time-Independent Complexity 12.2.5 Overview of All Kinds of Time-Independent Complexity 12.3 Graphical Representation of Complexity 12.3.1 The Functionality Diagram 12.3.2 Presumed and Legitimate Position in the Functionality Diagram 12.3.3 Ideal Development Path for Product Design 12.3.4 Examples of Typical Errors 12.3.5 Summary of the Application of Complexity in Functionality Diagrams 12.4 Conclusions of This Chapter References 13 Axiomatic Design Application to Product Family Design Abstract 13.1 Axiomatic Design Application for Product Family Design 13.1.1 Design Concept Description as the First Step in Axiomatic Design 13.1.2 Axiomatic Design Application with Proper Functional Requirements 13.1.3 Axiomatic Design Application with Many Functional Requirements 13.1.4 Creating New Design Using Axiomatic Design 13.2 Product and Product Family Design Cases Using Axiomatic Design 13.2.1 Automatic Driving 13.2.2 Fan Design 13.2.3 Entrance Exam Administration 13.2.4 Umbrella that Follows the Owner 13.2.5 Stirling Engine 13.2.6 CurcurPlate for Managing Peoples in a Building 13.2.7 Tool for Brushing the Back of Teeth 13.3 Conclusions References 14 Design of Large Engineering Systems Abstract 14.1 Introduction 14.1.1 Motivation 14.1.2 Chapter Contribution 14.1.3 Chapter Outline 14.2 Axiomatic Design of Large Fixed Engineering Systems 14.2.1 What Are Large Fixed Engineering Systems? 14.2.2 Divide and Conquer: Decomposition of System Hierarchy 14.2.3 Allocation of Function to form—the Zigzagging Process 14.3 Examples 14.3.1 Axiomatic Design of the Mount Type Air Conditioning System 14.3.2 Automobile Cooling System 14.3.3 Automobile Suspension System 14.3.4 Mobile Harbor 14.3.5 The Online Electrical Vehicle 14.4 Axiomatic Design of Large Flexible Engineering Systems 14.5 Conclusion References Further Reading 15 Complexity in the Kitchen 15.1 Introduction 15.1.1 Axiomatic Design in Other Words 15.1.2 Complexity Theory 15.1.3 Cooking Science 15.2 Cooking Axioms 15.3 Cooking a Turkey 15.3.1 Why Does US Thanksgiving Mean Eating a Turkey? 15.3.2 Bringing the Bird to the Table 15.3.3 How Do People Really Cook a Turkey? 15.4 Baking an Apple Pie 15.5 The Complexity of Reverse Engineering a Recipe 15.5.1 Reproduction of Braised Lamb Ribs 15.5.2 Reproduction of Scottish Haggis 15.5.3 Reproduction of Swiss Hay Soup 15.6 Achieving Functional Requirements with Less Waste 15.7 Conclusion 16 Design of Organizations Abstract 16.1 Why Design an Organization? 16.2 How Should We Design an Organization? 16.3 Operation of Organizations 16.4 Design and Decision-Making in an Organization 16.5 Typical Organizational Design 16.6 When Should an Organization Be Re-designed? 16.7 Institutional Development: The S-Curve, S-Gap, and Vector Delta (δ) 16.8 Concluding Remarks Reference Further Reading 17 Application of Axiomatic Design for the Design of Flexible and Agile Manufacturing Systems Abstract 17.1 Introduction 17.2 Use of Axiomatic Design in Manufacturing System Design 17.3 Case Study 1: Design of Flexible and Changeable Manufacturing Systems 17.4 Case Study 2: Design of a Smart Shopfloor Management System 17.5 Case Study 3: Design of Collaborative Human–Robot Assembly Workplaces 17.6 Case Study 4: Design of a Learning Factory for Industry 4.0 17.7 Case Study 5: Design of a Demonstrator for a Flexible and Decentralized Cyber-Physical Production System (CPPS) 17.8 Conclusions References 18 Design of the Assembly Systems for Airplane Structures Abstract 18.1 Introduction 18.2 Case Study: Airplane Fuselage Panel Assembly with Axiomatic Design Principles 18.3 Assembly System Design Alternatives Simulation Results 18.4 Conclusion References 19 Healthcare System Design Abstract 19.1 Introduction 19.1.1 Motivation 19.1.2 Chapter Outline 19.2 Defining a Healthcare System 19.2.1 Healthcare System Boundary, Scope, and Scale 19.2.2 Healthcare System Function and System Form 19.2.3 Variations of Healthcare System Function and System Form Across Cultures and Regions 19.3 Challenges Specific to the Design of Healthcare Systems 19.3.1 Healthcare is a Socio-Technical System 19.3.2 Healthcare Delivery Heterogeneity 19.3.3 Complexity and Interoperability 19.3.4 Healthcare as a Legacy System 19.4 Key Takeaways and Conclusion References Further Reading 20 Functional Periodicity, “Function Clock,” and “Solar Time Clock” in Design Abstract 20.1 Introduction to Functional Periodicity and Re-initialization 20.2 “Function Clock” Versus “Time Clock” 20.3 Pros and Cons of “Function Clock” Versus “Time Clock” 20.4 Periodicity and Re-initialization of Airline Scheduling 20.5 Periodicity and Re-initialization of Biological Systems: Cell Division and Mitosis of Cells 20.6 Periodicity and Re-initialization in Manufacturing System Design 20.6.1 Functional Periodicity in Design of a Simple Manufacturing Operation 20.6.2 Functional Periodicity in Job Shop Scheduling 20.7 Periodicity and Re-initialization of Political Systems 20.8 Functional Periodicity and Re-initialization of Educational Systems 20.8.1 Academic Calendar 20.8.2 Research Universities 20.9 Conclusions Reference Further Reading 21 Artificial Intelligence in Design: A Look into the Future of Axiomatic Design Abstract 21.1 Introduction 21.2 Artificial Intelligence—The Next Hype? 21.3 Examples of Artificial Intelligence Applications in Engineering 21.4 Axiomatic Design Knowledge Database as Basis for Artificial Intelligence in Axiomatic Design 21.5 Vision of Combining Artificial Intelligence and Axiomatic Design 21.6 Artificial Intelligence-Assisted Design of Complex Systems 21.7 Artificial Intelligence-Assisted Re-design of Complex Systems 21.8 Impact and Advantages of Artificial Intelligence in Axiomatic Design References 22 Axiomatic Cloud Computing Architectural Design Abstract 22.1 Introduction 22.2 History of Cloud Computing 22.3 Socio-Technical Stigmergy 22.4 Complex Adaptive System (CAS) 22.5 Knowledge Hierarchy/Heterarchy 22.6 Power Law Versus Gaussian Distribution 22.7 Axiomatic Trace 22.8 Cynefin 22.9 Cloud OODA 22.10 Iterative Axiomatic Maturity Diagram (AMD) Ensembles 22.11 Non-Functional Requirements from a Complex Adaptive System Perspective 22.12 Security of Cloud Computing 22.13 Econo-Complex Adaptive System Strategy in the Cloud 22.14 Weickian Versus Axiomatic Adaptive Coupling in Complex Adaptive System Architectures 22.15 Conclusions References 23 Future Design Challenges Abstract 23.1 Introduction: Continuing Human “Saga” 23.2 A Challenging Design Problem: Creating Forest in North Africa 23.3 Design Challenges Related to Renewable Energy 23.4 Design Problems Related to Transportation 23.5 Design Problems Related to CO2 and Methane Gas (CH4) Emission 23.6 Future Roles of Artificial Intelligence (AI) and Quantum Computing in Design 23.7 Design and Large Databases 23.8 Design Issues Related to De-Salination 23.9 Design of Software 23.10 Control of the Weather Pattern 23.11 Design of a Better Educational System 23.12 Design of a Democratic and Transparent Government 23.13 Design of Improved Health Delivery Systems 23.14 Design of a Peaceful World 23.15 Design of Better Drugs for Brains 23.16 Design of Computer Assisted Brains (I.E., Supplementary Brain) 23.17 Recycling of Materials 23.18 Design Problems Related to Self-Driving Cars 23.19 Concluding Remarks Index