STEM Project Design
Science Technology Engineering and Math
STEM Service-Learning Summer institute
Sacramento State University
August 5-7, 2009
Many Definitions of Design
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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
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.
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Many models and tools
Design Process
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Mechanical Engineering
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Service Learning
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PARDE Model – key elements
Different Companies use different models
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Ullman’s - 6 steps
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
Problem Identification
Specification
Development
Redesign
Retirement
Conceptual
Design
Disposal
Detailed
Design
Service
Maintenance
Production
Problem Identification
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Tasks
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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
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Project Charter
Specification Development
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Tasks
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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
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Project Specification Document
Conceptual Design
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Tasks
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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
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Project Conceptual Design Report
Detailed Design
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Tasks
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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
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Project Detailed Design Report
Prototype version of project
*DFMEA -Design for Failure Mode and Effect Analysis
Production
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Tasks
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Complete production version of the project
Complete user manuals/training material
Complete delivery review
Deliverables
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Delivered project
Project Delivery Report
Delivery checklist
User manuals
Service/Maintenance
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Tasks
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Deliverables
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Evaluate performance of fielded project
Determine what resources are necessary to
support and maintain the project
Fielded Project Report
Redesign or Retirement Decisions
The EPICS Design Cycle
Problem Identification
Specification
Development
Redesign
Retirement
Conceptual
Design
Disposal
Detailed
Design
Service
Maintenance
Production
Iterations in the Design Process
Problem Identification
Specification
Development
Redesign
Retirement
Conceptual
Design
Disposal
Detailed
Design
Service
Maintenance
Production
Iterations in the Design Process
Problem Identification
Specification
Development
Redesign
Retirement
Conceptual
Design
Disposal
Detailed
Design
Service
Maintenance
Production
Iterations in the Design Process
Problem Identification
Specification
Development
Redesign
Retirement
Conceptual
Design
Disposal
Detailed
Design
Service
Maintenance
Production
Seeking and Selecting
Diverge Seek Possibilities
Problem
Identification
Converge Narrow Choices
Diverge Seek Possibilities
Specification
Development
Converge Narrow Choices
Each phase of the design process has divergent
(creative) components where ideas are sought and a
convergent component where options are selected
EPIC Projects and Design
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Four Broad Areas
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Human Services
Access and Abilities
Environmental
Education Outreach
Design Process
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Often Same
Can be STEM rich
Design Tools
Group Activities
Engineering
Specifications
Specifications Development
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What does your project partner need?
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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
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Talk to project partner and others impacted
Research
Specifications Development (cont.)
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How will the problem be worked?
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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
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Develop a specifications document
Share and modify specifications
Customer Requirements
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Types of customer requirements
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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
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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
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Engineering Requirements
Starting with the customer
requirements for a cell
phone or energy audit,
make a list of engineering
requirements
Defining Requirements
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Benchmarks
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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?
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Design Targets
Set standards to meet with your design
 How good is good?
 Should be a living document
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Don’t compromise on goals
Refine as the design progresses
Make design trade-offs if needed
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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
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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
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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
(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
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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
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Decision Matrix
Example: Seeking a Job
Criteria
Wts.
Location
5
Salary
4
Bonus
2
Job
4
Training
2
Boss
3
Totals
Co. A
Co. B
Co. C
Testing for Failures –DFMEA* Steps
Review the design
 Brainstorm potential failure modes
 List potential effects of failure
 Rank Failures
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Severity
Occurrence
Detection
Develop action plan
 Implement fixes
 Revisit potential failure risks
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*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?
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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
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Final Design Tasks
Production
 Service and Maintenance
 Retirement or Redesign
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STEM Project Design
Questions/Discussions