Ohio University Mechanical Engineering Sr. Design Web-Book
Design Process Resources, Design Report Guidelines, Development Activities, and Tollgates

Design Process Resources Link to Phases: 1, 2, 3, 4, 5, 6	Design Report Guidelines* * Guidelines provide a suggested format – adapt them for your project Citation format : Chicago Style Editing Notes: OHIO_ME_TechComm Website	Development Activities Teamwork and Professional Skills
Phase 1 – Problem Definition * Design Process Overview (pdf presentation file) * Video of design process produced by TIDEE Initial Problem Area or Theme (given) Research > Background / Project Research Assignment (with help from Librarian Michael Wilson) > ME470 Engineering Info Wiki > More options for Data Base Searches Voice of the Customer: FOCUS Frame the project Organize resources Collect Information Plan for Customer Interviews/Observations: 1. Who you will interview and observe for a 360 degree perspective 2. What specific ?s you will ask each group (the Interview Guide) 3. What you will look for in the observations (the Observation Guide) 4. Who will do the interviews and observations 5. When do you plan to complete the first round 6. How will you review / compile / evaluate the data to inform your decisions.	Note: Define your audience and purpose, and outline your argument before starting to write * TIDEE Course Materials for Written Reports 1.Title page* and Introduction (context, problem, purpose, scope) (* Note: A Table of Contents and Abstract should be added after the rest of the report is complete) and 2. Customer Needs Assessment and Revised Need Statement	*Goals of Capstone Experience (pdf) * Design Notebook > Example of recording project activities Team Formation Survey a) Meyers Briggs Type b) Natural Team Role More Tools to Know Yourself – and understand others better > Learning Styles > Career Beam Profile Team Diversity and Product Development example: > IDEO Website > IDEO Video Evaluation ME Advisory Board - Panel discussion, responding to student questions about "How-2-Be" an engineer > Responses from David Althausen > Responses from Greg Goetz Team Effectiveness > Presentations by board Chairman Terry Russell on Basic info on effective teams > includes operating procedures and meeting roles Effective Meetings – Procedures and Tools > Agendas and Action Item Registers and Process Checks > Action Item Register Template (Excel) > More info on Teams, tasks & cooperation > More on Team issues and Conflict – the good, the bad, and resolution
Phase 1 Tollgate: Review of Problem Definition and the “Voice of the Customer” Duration: ~ 1 month; Review Materials: Problem Definition and Customer Needs Report [Sections 1 and 2 of design report]

Phase 2 - Specifications > Background / Project Research Assignment (with help from Librarian Michael Wilson) * ADA and other laws and regulations * Potentially applicable standards * Benchmarking info on solutions that have addressed similar needs (when identified) ASTM Presentations on Standards > Standards and You > Global Development of Standards > Summary Info on Standards > Value to Society (3/2003 ASME article on standards) * quote about Standards > ADA Standards > Standards Organizations (CPSC,ANSI, NSSN (Global), NIST, etc.) Info on Patents > DIY Patents (5/2008 ASME article) > Ordinary Innovation not patentable (9/2007 ASME article) > Case study – does 4 include 3? (1/2006 ASME article) > Intellectual Property Rights (AMSE Article) Quick image showing the path from customer to specifications (QFD) Quality Functional Deployment (QFD) - from the voice of the customer to design specifications Intro to Target Specifications > Example of different types of requirements > Example standards and specifications for a forklift (See previous SrD reports for more examples)	3. Benchmarking, Standards and Target Specifications [Includes Design Criteria and QFD or a similar method for converting customer requirements to meaningful design specifications] Presentation Preparation: > Crafting a Good Argument > Presentation Template (ppt recommended format) > Presentation Guidelines – key points (ppt file) > TIDEE Course Materials for Oral Presentations	Ethical issues in engineering > Notes_on_Engineering_Ethics [Dr. Halliday] > NSPE Code of Ethics > Engineering Ethics Project (2010) Project Planning (Overview presentation) Project Management Tools - Presentations by ME Board Chairman Terry Russell > Scorecards > Project Plan > Risk Management Project Management [from MIT OCW Project] > Factors for project success > Project Manager human aspects and communication > The Spiral Project Development Process > The Rework Cycle > Tollgate-based project management > More on Critical Chain (critical path) > Quality - Time - Cost Tradeoff > Organization tips [Kathy Peel]: 1. Try a "not-to-do" list to free up time for essential tasks. 2. “Do it now,” especially for unpleasant tasks. > Time Management [OSU Extension]: [http://extensionhr.osu.edu/TimeMangWebsite/ Advice for making decisions, dealing with interruptions, setting priorities, etc. [accessed 12/2007]
Phase 2 Tollgate: Review of the Specifications, Criteria and Standards that Define the Project Duration: ~ 2 weeks (can be concurrent with end of Phase 1 and start of Phase 3); Review Materials: Project Proposal Report (sections 1-3 of design report), and a Project Proposal Presentation (Sell the idea for the project, including information on the customer, the refined need statement, the customer requirements, and your team’s readiness ) [Note: May be an informal presentation]

Phase 3 – Conceptual Design Conceptual Design Intro and mind mapping > Free Online Tool for mind mapping your brainstorming session > 6-hats and other creativity-enhancing methods > Use mock-ups and physical models during this stage > Think like a beginner > Fail often to succeed sooner > Brainstorming (IDEO methods) and concept development using a Pugh Matrix Advanced creativity technique (useful to review for changing your perspective) > Creativity and TRIZ * TRIZ – 40 inventive principles Patent Searches sometimes yield useful concept ideas > Patent Searches (Elizabeth Pozydaev)	4. Concept Generation Note: Final grading of the team's concepts (based on the info in the design report) will include points for documenting failed attempts (fail often to succeed sooner) and will attempt to reward authentic creativity and risk-taking ideas that push the envelope.	Decision Making: Framework and Methods presented by ME Board Member Tom Wakeman > Framing the Decision and making the tools work for you > Decision Register Template > Decision Matrix Template > Theoretical Foundations for Decision Making in Engineering Design [Online Textbook from the National Academy of Engineering] Decision Making Methods: Who Decides? Leadership and Influence: Summary for SrD Teams
FOCUS: Select Analytical Models for Design. Concept Evaluation and Selection	5. Concept Selection (Detailed Feasibility and Effectiveness analysis, and concept development / scoring / selection) 6. Final Design Concept	Quote: Perfection
Phase 3 Tollgate: Review of Multiple Feasible Concepts and the Synthesized Concept Selected for Design Development Duration: ~ 1 month (can be concurrent with end of Phase 2); Phase 3 should be complete before start of Winter Quarter Review Materials: Conceptual Design Report, and a formal Project Review Presentation – Conceptual Design

Phase 4 – Prototype Design and Construction Design Methods Overview and design embodiment checklist (pdf) > Pareto Analysis (pdf) Failure Modes and Effects Analysis - Overview (pdf) > FMEA Worksheet (doc) Design For Safety * Overview * Example Presentation * Hazards Checklist * Textbook info * Domestic Product Failure Case Studies Mock-Ups & Prototypes [ME488] Design Analysis & Vendor Supplied Item Selection (pdf) > Finite Element Analysis - Overview (pdf) [ME 451] > FEA Checklist (pdf) [ME 451]	7. Prototype Design, Development and Testing (FMEA, Analysis, Mock up construction and Testing, Prototype construction and testing, Operating experience, …)	Performance Reviews and Professional Skills
Phase 4 Tollgate: Review of Design and Construction of Prototype (Alpha Design) Duration: ~ 3 months; Review Materials: Design Validation Report, and Project Review Presentations Preliminary Design Presentation – Jan. 20 – Feb 3rd. “How it Works,” including all operating modes, setup, accessories, etc. Failure modes, risk analysis, actions to reduce likelihood of failure, and key technical challenges (FMEA) Prototype Design Validation – Feb 24 - March 10. Details of the prototype design, and your validation (via tests, analysis, etc.) that demonstrates that it is safe and will meet specs and work well. End of Winter Quarter – Deadline for prototype and User’s Manual to be delivered to customer

Phase 5 – Final Design and Production Plan Design Methods Overview & Value Engineering Design for Manufacturability and Assembly > DFMA overview presentation with examples and manufacturing focus > DFMA Presentation from textbook (from MIT) with assembly focus > DFMA Lecture Notes from Dr. Halliday > Textbook info related to DFMA > Machining details > Assembly and fastening methods > Tolerancing Stackup Example > Fixtures and Jigs info Mfg and Assembly Drawings > Example parts lists > Example of a good Drawing Package (7MB pdf file) Cost Estimation > Rules of thumb for product costs > Cost Estimation Method Recommended for Sr Design > Note on cost issues related to suppliers and inventory and bending vs. cut and weld – (ME board member Suzanne Tkach)

8. Design Refinement for Production Final Design refinements based on prototype evaluation and application of design methods Final design validation 9. Final Design for Production Design Description and Operation (reference a User Manual included in the Appendix) How it is manufactured/assembled, Design Drawings, parts list, and bill of materials Production cost

Phase 5 Tollgate: Review of Final Design and Production Plan Duration: ~ 2 months (can be concurrent with end of Phase 4); Review Materials: Complete Manufacturing and Assembly Plan and Drawing Package, Final Design Report, and a Design Review Presentation

Phase 6 – Project Evaluation	10. Conclusions Did your project meet the objectives? Is it patentable (in full or part) Is it transferable – should more be built to help others? Recommendations for future work References: Citation format : Chicago Style
Phase 6 Tollgate: Project Evaluation Duration: ~ 1 week (can be concurrent with end of Phase 5); Review Materials: Project Evaluation / Continuation Memo [individual], and a Project Evaluation Presentation

Note: The Transferable Integrated Design Engineering Education (TIDEE) project focuses on developing and assessing students' capabilities in engineering design. TIDEE materials are based upon work supported by the National Science Foundation under Grants 9973034 and 0003291.