Engineering 11
Engineering
Design Cycle
Bruce Mayer, PE
Licensed Electrical & Mechanical Engineer
BMayer@ChabotCollege.edu
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Engineering_Design_Cycle_Details.ppt
PreReq  Identify an Opportunity
 Idea emerges for an Engineered
Product that will likely produce a
minimum Return on Investment (RoI)
 Described, at a minimum, by a list of
Functional Requirements (FR’s)
• Technical Function
and Performance
• Production Cost Target
• Production Time Target
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Engineering_Design_Cycle_Details.ppt
Design Elements  Need Schedule
 Translate Functional Requirements
(FR’s) into Quantitative & Object Design
Requirements (DR’s)
• e.g., FR = The product output has a
UNIFORMITY of ±3%
– DR1 = Temperature controlled 530 °C, ±4°C
– DR2 = Pressure controlled to 290 kPa, ±15 kPa
– DR3 = etc.
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Engineering_Design_Cycle_Details.ppt
Design Elements  Need Schedule
 BrainStorm Concepts
• Preliminary: Analyze/Rank Concepts
– Technical Risk/Feasibility
 Search for “Fatal Flaws”
– Schedule Risk/Feasibility
– Cost Risk/Feasibility
• Final: Evaluate most promising (no more
than 3) Concepts
– Detailed Calculations and/or Computer Models
– SubScale Physical Testing
– Cost & Schedule Comparisons
• Select: Determine “best” Concept
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Engineering_Design_Cycle_Details.ppt
Design Elements  Need Schedule
 Conceptual Design
• Explanation of HOW design MEETS the
FR’s
– Describe “Theory of Operation”
• Form and Fit (LayOut Drawings)
• Control System Schematics; e.g.,
Electrical, Plumbing, Optical, Ventilation,
etc.
– Identify & Describe System-Control Elements
and the associated I/O points
• Identify Suppliers for Critical Components
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Engineering_Design_Cycle_Details.ppt
Design Elements  Need Schedule
 Conceptual Design
• Identify Fabrication Methods for Critical
Components
• Identify Critical Infrastructure; e.g., special
buildings, machinery, instrumentation, etc.
 CONCEPTUAL DESIGN REVIEW
• CDR General Presentation Requirements
– Be as detailed as your thoughts or concepts allow.
– Clearly state where there are open questions or issues.
• Be prepared for questions. Comments & Queries
from the audience are encouraged.
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Engineering_Design_Cycle_Details.ppt
Design Elements  Need Schedule
 CONCEPTUAL DESIGN REVIEW
• CDR Presentation content details
– Define overall design constraints and
requirements.
– Describe concept(s) in detail, their features,
tradeoffs, and how they will address the
performance, cost, schedule, and customer
requirements.
– Define the top 3 reliability risks and how they
will be mitigated
– Show any test data obtained to date.
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Engineering_Design_Cycle_Details.ppt
Design Elements  Need Schedule
 CONCEPTUAL DESIGN REVIEW
• CDR Presentation content details
– Show key project milestones and decisions to
be made between now and start of build.
– COST REVIEW: Specific breakdown of cost
estimates, including cost data sources
 Detail Design
• Fabricated-Part Drawings (BluePrints)
– Material Selection
– Material Processing/Finish
– Tolerances and other inspection-Criteria
Bruce Mayer, PE
Engineering-11: Engineering Design
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BMayer@ChabotCollege.edu • ENGR-11_Engineering_Design_Cycle_Details.ppt
Design Elements  Need Schedule
 Detail Design
• Purchased-Part Specifications
– Supplier: Name & Contact-Information
– Supplier Part/Catalog number
– Inspection/Test Criteria
• Assembly Drawings and Instructions
– Complete Parts List (a.k.a. Bill of Material)
– Assembly Processes and Sequence-of-Events
(SoE’s)
– Assembly Specifications
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Engineering_Design_Cycle_Details.ppt
Design Elements  Need Schedule
 Detail Design
• Detailed Control-System Schematics
– Listing of I/O points
– Describe Function of Each I/O point
 CRITICAL DESIGN REVIEW
• Test Data Supporting the Concept
– C&F data presented where applicable or
available
• Design Presentation: How it meets
subsystem and system requirements
– Describe design, including performance and
operation, critical design or build areas,
how the design meets subsystem criteria
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Engineering_Design_Cycle_Details.ppt
Design Elements  Need Schedule
 CRITICAL DESIGN REVIEW
• Functional Engineering BoM, ready for
prototype release
– Complete & Accurate BoM using OrganizationStandard Format
• BoM Cost estimate for production build
– Purchasing quotes for "Big Hitter" items; std
Company DataBase costs, Supplier quotes,
published Catalog-Costs, educated estimates for
other items
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Engineering_Design_Cycle_Details.ppt
Design Elements  Need Schedule
 CRITICAL DESIGN REVIEW
• Fab and procurement drawings for
prototype build
– All fab drawings and new-component Item
Control Sheet (ICS = Spec Sheet) used in that
subassembly
• Updated subsystem requirements table:
IO, interfaces, performance & design
requirements
– Refined requirements that were presented at
CDR, Detailed interface info
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Engineering_Design_Cycle_Details.ppt
Design Elements  Need Schedule
 CRITICAL DESIGN REVIEW
• Listing of manufacturing risks
– Simple statements of risks
• Identification of manufacturing strategy:
Make or Buy, Line or Cell, Manual or
Automated, etc.
– Simple statement attached to BoM components
• Identification of supplier strategy:
How/Who will supply components
– Simple vendor ID attached to BoM components
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Engineering_Design_Cycle_Details.ppt
Design Elements  Need Schedule
 CRITICAL DESIGN REVIEW
• Identification of inspection strategy:
Supplier or Company inspection,
critical areas
– Simple statement of who is responsible for
inspection of which critical parts
• Inputs from Safety Engineering to assure
compliance with Human-Safety and
Ergonomics Standards (UL, CE, NEC,
SEMI S2, ASME Pressure-Vessel Code,
ANSI Z136 Lasers, etc.)
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Engineering_Design_Cycle_Details.ppt
Design Elements  Need Schedule
 CRITICAL DESIGN REVIEW
• Inputs from Reliability Engineering for your
subsystem: Reliability-Critical Items List
(RCIL) compilation, suppliers needing
audits or surveys
– Simple identification of RCIL and affected
suppliers
• First-cut Identification of Field Replaceable
Units (FRUs)
– Preliminary FRU identification only
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Engineering_Design_Cycle_Details.ppt
Design Elements  Need Schedule
 CRITICAL DESIGN REVIEW
• SubSystem Test Plans
– Any level of subsystem test plan or subsystem
test criteria is acceptable
• Schedule for Open Items
– Provide schedule for completion of any open
CrDR deliverables
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Engineering_Design_Cycle_Details.ppt
Design Elements  Need Schedule
 ProtoType Construction & Testing
• Built to CrDR BluePrints and
Specifications; Iterate-on
– Accuracy/Correctness of Documentation
– Fabrication, Inspection, Assembly Process
Improvements
• Test & Iterate-on
– Function
– Performance
– Reliability
– SubSystem Testing
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Engineering_Design_Cycle_Details.ppt
Design Elements  Need Schedule
 ProtoType Construction & Testing
• Test & Iterate-on
– Inspection
– EveryThing Else
 Final Design
• 99.99% Accurate (Goal is “Fire & Forget”)
– Fabrication & Assembly BluePrints
 Detailed INSTRUCTIONS if needed
– Bill of Materials
– Control-System Schematics
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Engineering_Design_Cycle_Details.ppt
Design Elements  Need Schedule
 Final Design
• Finalized
– Test Procedures
– Inspection Documents
• First Cut Instruction Manuals
– Installation
– Operation
– Maintenance
 Recommended Customer-Site Spare Parts
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Engineering_Design_Cycle_Details.ppt
DilBert BrainStorming
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Engineering_Design_Cycle_Details.ppt
All Done for Today
Engineering
Design
Pyramid
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Engineering_Design_Cycle_Details.ppt
Engineering 11
Appendix
Bruce Mayer, PE
Registered Electrical & Mechanical Engineer
BMayer@ChabotCollege.edu
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Engineering_Design_Cycle_Details.ppt
Rules for BrainStorming
 Put judgment and evaluation aside
temporarily.
 Turn imagination loose, and start
offering the results.
 Think of as many ideas as you can.
 Seek combination and improvement.
 Record all ideas in full view.
 Evaluate at a later session.
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Engineering_Design_Cycle_Details.ppt
SCAMPER BrainStorming







S ≡ substitute
C ≡ combine
A ≡ adapt
M ≡ modify
P ≡ put to another use
E ≡ eliminate
R ≡ reverse
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Engineering_Design_Cycle_Details.ppt