A
Aeronautical engineers, 100, 132, 135
Agency-loyalty, 255
Airline industry, 134
Airplane, 134
design, 5
prototypes of, 134
visible differences, 5
Air-quality issues, 216
Almost-but-not-quite-finished version, 27
Alternative designs, 31, 86, 95, 107, 111, 203
extension ladders, 18
American Beverage Company (ABC), 35, 56, 57
American National Standards Institute (ANSI), 123, 125, 164
wood safety requirements, 194
American Society of Civil Engineers (ASCE), 215, 252
codes of ethics of, 253, 255, 262
American Society of Mechanical Engineers Code of Ethics, 215, 281, 288, 295, 296
Anisotropic material, 266
Application-specific integrated circuit, 136
Arm support, for CP-afflicted student, designing, 44–46
Arrow Impossibility Theorem, 55
ASME Pressure Vessel and Piping Code, 22
Assembly drawings, 123, 124, 198, 209
B
Back-of-the-envelope, 59
model, 59
Balance laws, 171
Bardeen, John, 133
Battery-powered payload cart, modeling, 177
selection of characteristics
battery and battery operating, 181–183
motor and motor operating, 184–186
Beam, 168, 169, 188, 189, 190, 192
cross-sectional area, 168, 188
equations, 18
model, 191
Bell, Alexander Graham, 133
Best-of-class chart, 110
Beta testing, 27
chemically inert, 108
establishing metrics for, 61
Beverage-filled Mylar container, 133
B. F. Goodrich Company, 256
Big box retailer, 191
Bill of materials (BOM), 198, 199, 209
Block lettering, 120
Block tolerances, 285
Boston's code, 259
Bounded design space, 100
Brattain, Walter Houser, 133
Brick wall, 12
Building objectives trees, 49, 50
logistics of, 50
top-level goal, 50
Building techniques, 267
C
Capital-intensive, 254
Cap screws, 277
Carbon-fiber-reinforced polymer (CFRP), 195, 196, 306
Carpenter's glue, 270
design of stabilizer for microlaryngeal surgery, 27–34
Cerebral palsy (CP), 35, 44, 45, 46
Challenger's O-rings, 251
Children's beverage, 35
design of a container, 40
Chinese proverb, 129
Cigarette lighter designing, 261
basic functions, 73
secondary functions
required, 73
unwanted, 73
secondary functions, 73
Claremont Colleges, 40
Claremont (California) Unified School District, 44
five-stage, 224
three-stage, 20
Client, 255
clearer understanding of, 41
design problem, 41
desires, 25
goals, 76
intentions, 17
interpretations of, 5
marketing plan, 62
objectives, 21, 25, 29, 47, 49
identifying, 53
rank ordering, 54
representing, 29
obligations with, 150, 255–256
original problem statement, 29
Codes of ethics, 252
Commercial ladders, 13, 18, 194
Communication and design, 10–12
for manufacturing, 12
Competitive products, 26
Computational-fluid-dynamics (CFD) model, 136
Computer-aided-design-and-drafting (CADD), 117, 135, 139, 283
models, 139
packages, 283
Computer-based analysis, 27, 135
Computer-based model, 27
Computer-based packages, 148
Computer spreadsheets, 167
Concept screening, 69
Conceptual design, 5, 20–22, 28, 32, 93, 106, 128, 129, 190, 207
Concurrent engineering, 205
Conflicts, 228
basic strategies for resolving, 228
Confusing objectives, 60
Conservation law, 171
Conservation principles, 171
Constructive conflict, 227–229
idea-based conflict, 227
Contiguous solutions, 97
Controlled tests, 133
Coordinate measurement machine (CMM), 298, 299
indirect costs, 198
labor costs, 198
Cost estimation, 197–201, 204, 207
CP-afflicted student, 44
arm support for, 44
Cross-talk, 97
Crosswire support, 32
discussions, 98
method, 98
Cumulative distribution function, 210
Customers' requirements, 41, 86
Cyanoacrylates, 274
Cylindrically symmetric profiles, 267
D
Danbury arm support, 62, 69, 88–91, 101, 111, 126, 139, 155–158
constraints for, 69
final outcome, 158
final report elements for, 155–158
functions for, 88
managing, 157
metrics for, 64
project teams, 138
TSO for, 157
Danbury School, 44, 45, 70, 155
Dartmouth Avenue, 40
Data-driven metric, 62
last note on, 294
primary datum, 292
secondary datum, 292
tertiary datum, 293
Decision-support techniques, 107
Decomposing complex design spaces, 100
Design activities, open-ended nature, 15
Design alternatives, 18, 103, 216
generation of, 103
long-term consequences of, 216
selection of, 105
short-consequences of, 216
Design-and-construction company, 3
sources of information, 23
Design drawings, 122
pictorial representation, use of, 129
tolerances, 124
Designed artifacts, concepts for, 132
Designer-client-user triangle, 4, 6, 209
Designer-fabricators, 19
Designer's responsibilities, 214
Design for affordability, 206
Design for assembly (DFA), 207, 208, 218
Design for deflection, 194
Design for manufacturing (DFM), 12, 206, 209
Design for production, 206–209
Design for reliability, 210
Design for sustainability, 215–218
Design information, 54, 118, 119, 126
advantage of, 54
acquiring, 25
processing, 25
closing remarks on, 35
constraints, 180
criteria, 190
iterative elements of, 23
kinds of drawings, 122
morphological charts, 25
performance specification method, 25
quality function deployment (QFD), 86
requirements matrices, 32
systems-oriented definition of, 24
mathematical habits of thought for, 162
mathematical tools for, 186
Design problem, 12, 19, 25, 26, 76
framing, 28
ill structured, 12
open-ended, 12
solution-independent statement of, 54
Design process, 16, 19, 24–27, 223, 224, 226
communication, 19
descriptive models, 19
evaluation, 19
feedback, 27
formal methods for, 24
generation, 19
means, 20
methods, 24
organizing, 224
prescriptive models, 20
social activity, 250
strategies, 24
Design project, 14
monitoring and controlling, 245–248
scheduling tools (see Team calendar)
tools for managing
project's spending (see Budget)
work breakdown structures, 237–241
Design requirements, 12, 14, 20, 41, 129
attaching numbers to, 81
functional requirements, 41
interface performance requirements, 86
nature of, 15
performance requirements, 129
prescriptive requirements, 129
procedural requirements, 129
formal, 27
presentations, 27
Design space, 25, 31, 92, 93, 99, 100
contracting, 101
generation, 99
Design specifications, 9, 26, 81, 247
interface performance specifications, 85–86
performance, 81
prescriptive, 81
procedural, 81
setting performance levels, 84–85
Design team, 5, 26–28, 35, 41, 223, 226
and design process activities, 226–227
stages of group formation, 224–226
Destructive conflict, 228
personality-based conflict, 228
Detailed design, 5, 22, 25, 95, 126, 193
remarks on, 193
basic dimensions, 284
location dimensions, 284
orientation of, 284
placement of, 284
reference dimensions, 284
size dimensions, 284
some best practices of, 284
spacing of, 284
stock dimension, 284
Discipline-dependent differences, 129
kinds of, 129
Double-checked Gerber files, 136
Drawings, philosophical notes, 129
Dress, and protective gear
safety requirements for, 265
Dupuit, Jules, 19th-century engineer, 204
E
Economic issue, 134
Edison, Thomas, 99
Editor's role, 153
accuracy, 154
consistency, 153
continuity, 153
single voice, 154
Effective designers, 24, 144, 216
Energy-starved world, 216
Engineering design, 3, 7, 8, 9, 10, 12, 14, 28, 46, 92, 122–129, 171, 210, 215, 218, 294
achieving excellence, 12
best practices, 9
assumptions, 8
evolution of, 158
managing, 14
mathematical models, 171
measuring success, 9
Engineering designers work, 4
engineering services firms, 4
government, 4
not-for-profit organizations, 4
small and large companies, 4
start-up ventures, 4
Engineering economics, 197, 204
Engineering functions, 8, 43, 72
transfer of energy, 72
transfer of information, 72
transfer of materials, 72
Engineering sketches, 117–119. See also Sketching technique
Engineering societies, ethics, 7
Environmental issues and design, 215
Environmental life-cycle assessment, 218
Environmentally conscious engineers, 216
Environmental Protection Agency (EPA), 256
Estimating costs, 198
ASCE code, 255
IEEE code, 254
problems, 6
understanding obligations, 250
Evolution of design, remarks, 158
Executive summary, 154
Expansion spaces, 266
External clients, 4
External constraints, 101
F
Fabrication specification, 10, 11, 122, 127–128
assembly, 11
drawings, 11
instructions, 11
kinds of requirements, 128
ways of writing, 129
Fabricator's redesign, 11
Failure, 210
accident-causing, 210
building, 134
distributions, 211
incidental, 210
in-service, 210
strengths, materials properties, 192
Fantasy analogies, 117
double fixed fastener, 276, 297
fixed fasteners, 297
selecting, 269
Fastening wood, 270
Feature control frames, 287
First-angle projection, 281
Fitzgerald, Ernest, 251
industrial engineer, 251
Five-stage model, 224
Flood-control schemes, 215
Follett, Mary Parker, 227
Foothill Avenue, 40
Ford Motor Company, 256
Ford Pinto, 256
Formal design, review, 27
relationship of, 9
Four-objective ladder design, 54
Frank Lloyd Wright, 257
Full-size prototype, 134
tools for establishing functions, 73–81
black boxes, and glass boxes, 73–75
dissection/reverse engineering, 75–76
definition, 72
Functions-means tree, 31, 79, 80
for a lighter, 80
G
Gallery method, 98
Gantt chart, 243
Geometric dimensioning and tolerancing (GD&T) approach, 125, 268, 277, 285, 287
Geometric tolerances, 168, 268, 287, 288, 294, 298, 299
system, 287
George Washington Bridge, 78
German proverb, 129
Glass box method, 91
Global warming, 217
Goal-directed activity, 99
Goal-directed design generation, 248
Goal-oriented activity, 248
Green wood, 266
Group development, 224
adjourning phase, 226
forming stage of, 224
norming phase, 225
performing phase, 225
storming phase, 224
Group formation, stages of, 224
Gut-level feelings, 103
H
Hand-built prototypes, 267
Hand-held cigarette lighter, 261
Hard-to-measure objective, 60
Hartford Coliseum, roof bracing of, 128
Harvey Mudd College, 28, 35, 126, 283, 297
first-year design class, 35
first-year design course, 35
student-machined tools, 198
Hex-head cap screws, 277
High-speed production machines, 207
Hot-melt glue, 270
Hyatt Regency Hotel, 11
Hyatt Regency Hotel, walkway, 11
I
Identification-loyalty, 255
Ill structured process, 12
Implied solutions, 40
Inch dimensioning metric, 282
Industrial accidents, 265
fatigue, 265
intoxication, 265
Informal interviews, 26
Informing, design process
acquiring design knowledge to inform, 25–26
with formal design methods, 24–25
getting feedback to inform, 27
by thinking strategically, 24
Initial problem statement, clarifications, 40–41
Institute of Electronics and Electrical Engineers (IEEE), 252
code of ethics, 253
Interface performance requirements, developing, 86
Internal feedback loops, 23
Interval scales, 53
J
John Hancock Center, 257
K
Kahn's large X-frames, 257
Keynes, John Maynard, 36
case study, 36
L
Ladder design problem, 13
Ladder rung, 186, 188, 193–196
elementary beam, 188
preliminary design for, 193–196
Ladder's design, 18
build and analyze, 18
Law of diminishing returns, 98
common-sense dictum of, 115
Layout drawings, 122
Leading design teams, 229. See also Design team
leadership, and membership, 229–230
personal behavior, and roles, 230–231
Legal requirements, 17
LeMessurier, William J., 256–261
triangles, 257
Level of abstraction, 23
behavioral requirements, 23, 25
functional requirements, 23
Levels of abstraction, 23
Life-cycle assessment (LCA), 215, 218
impact analysis, 218
improvement analysis, 218
inventory analysis, 218
Light-emitting diode (LED) lenses, 136
Linear elastic spring, 163
Linear models, 170
Line types, 283
center lines, 284
dimension lines, 283
extension lines, 283
hidden lines, 283
leader lines, 283
Literature reviews, 25
Load-deflection behavior, 163
Low-cost ladder, 60
Low-rise industrial warehouse buildings, 100
Low-weight ladder, 58
Lumped element model, 163
M
Macro scales, 163
Maintainability, 214
controlling, 245
leading, 229
major functions, 20
controlling, 20
leading, 20
organizing, 20
planning, 20
organizing, 249
planning, 249
Managing design activities, 243
Managing engineering design projects, 14–15
3S model of management, 14
Manufacturing business, 12
Manufacturing-cost issues, 135
Marketing experts, 223
Market research, 26
Mars lander, gas-filled shock absorbers, 133
Material condition modifiers, 289
least material condition (LMC), 290
maximum material condition (MMC), 290
regardless of feature size (RFS), 290
Material selection, remarks, 213
Materials requirements planning (MRP), 209
Materials selection chart, 196
Mathematical approximations, 169
Mathematical modeling, 162, 164
abstraction, 162
basic principles of, 162
lumped elements, 163
scaling, 163
Mathematical tools, for design modeling, 163–164
conservation and balance laws, 171–172
mathematical approximations, 169–171
mechanical–electrical analogies, 176
physical dimensions in design, 164
physical idealizations, 169–171
series and parallel connections, 173–176
Mathematics, closing remarks, 196
Mechanical design drawings, principal kinds, 124
Member-by-member calculation, 259
Metal fasteners, 274
permanent, 274
temporary, 274
Metaphor, 95
6-3-5 Method, 95
Metric, 9, 26, 30, 58, 60–62, 64, 65, 82, 108–110, 210, 277
caution, 56
closing comments, 61
development of, 57
solution-independent, 61
Microlaryngeal instruments, 28
Microlaryngeal surgery, 27, 29
Microlaryngeal surgical stabilizer, design, 27
Micro scales, 163
Model-based prediction, 161
Model-building project, 141
margin for error, 141
Model process, 131–142, 161–165
atomic bonds, 163
building, 134
construction, 138
common materials for, 138
Monitoring and controlling, 245
tools for, 245
Morphological chart, 25, 31, 32, 79, 92, 93, 95, 100
Morphological chart, creating, 31
Mortise-and-tenon joint, 270
Morton-Thiokol company, 251, 256
Mylar containers, 133
N
Nails, 271
box nails, 271
finishing nails, 271
National Aeronautics and Space Administration (NASA), 133
National Beverage Company (NBC)
design teams, 56
National Beverage Company (NBC), 35
National Fire Protection Association, safety code, 125
Navigating design spaces, 99–100
complications, 100
morphological chart, suited to, 100
small/bounded space, 100
Newtonian mechanics, 172
Newton's equilibrium law, 181
Newton's law of motion, 164
New York City, 256
building code, 258
Building Commissioner, 261
Nicaraguan farmers, 8
Non-economic objectives, 68
Number of significant figures (NSF), 166
Numerical evaluation matrices, 107–109
O
Objectives, 43, 49, 53, 54, 57, 62, 111, 118
numerical evaluation matrices, 107–109
priority checkmark method, 109–110
reminders, for design evaluation, 111
caution, 111
measurement issues, 53
rank ordering, with pairwise comparison charts, 54–57
Old-fashioned butcher's scale, 175
Open-ended activity, 158
Opportunity costs, 201
presentations
Ordinal scales, 53
Orthographic views, 279
P
Pair-by-pair basis, 25
Pairwise comparison chart (PCC) process, 25, 30, 54–57
Pairwise comparison charts, 54–57
Parallel system, 212
Patents, 100
intellectual property, 76, 100
People-intensive, 254
Percent-complete matrix (PCM), 245, 249
Performance fabrication specification, 129
Performance specification method, 25
Personality-oriented criticism, 150
Physical box, 75
Physical dimensions in design (I), 164
dimensions, 164
units, 164
Physical dimensions in design (II), 166
significant figures, 166
Physical dimensions in design (III), 167
dimensional analysis, 167
Physical idealizations, 169, 170, 171
Physical quantities, 164
Physics, 196
closing remarks on, 196
Physiological surgical tremors, 28
Pilot-scale oil refinery, 136
Pliers, 269
Polymer fastening, 273
permanent, 273
temporary, 274
Post-consumer disposal, 217
Power drill, 73
top-level black box analysis, 74
Premature commitments, 24
Presentation, unique type, 149
Primary quantities, 164
Probability density function. (See Cumulative distribution function)
Problem definition, 26, 39, 40
clarifying client's objectives, 47–49
constraints identification, 67–70
Problem statements, revised, 43–44
Procedural fabrication, specification, 129
Product standards index, 125
Project end game, managing, 152
Project framing, 41
Project management process, 14, 15, 233, 243
definition, 241
framework, 241
road map of, 146
scheduling, 241
Project post-audits, 248
process of writing, 150
rough outlines of, 151–152, 155
topic sentence outline (TSO), 152, 153
Proof-of-concept test, 26, 132–134, 146, 241
building, 135
development, 26
Public, and the profession, 256–261
John Hancock Center, architectural design, 258
LeMessurier's Citicorp design, 256–257, 259
quartering wind, effects, 258–259
sketch, 260
Public hearings, 27
Public statements of design project, 43–44
Published performance requirements, 84
Pugh selection chart, 113
Q
Quality function deployment (QFD), 86
Quebec Bridge, 78
R
three inputs, 73
top-level function, 74, 75, 79
Radio frequencies (RF), 85
Rank-ordered objectives, 57
Rate equation, 172
Real-world environments, 133
Redundant system, 212
Regularly scheduled meetings, 27
Resisting forces, means, 95
Resisting shocks, means, 95
Resisting temperature, means, 95
Respect-based behavior, 226
Restricting functions, 103
Reverse engineering, 26, 73, 75, 76
Richardson's Manual, 200
Rivets, 275
blind rivets, 275
solid rivets, 275
Round-head machine screw, 268, 272
Row-by-row fashion, 25
R. S. Means Cost Guide, 200
Rung's midpoint deflection, 192, 193
S
Safety warnings, 264
Sample presentation, elements, 146
Seed-like detritus, 61
Series system design, 211
Setting performance levels, 84
Setting requirements, 67
Shockley, William Bradford, 133
Short-lived prototypes, 270
Simon, Herbert A., 10
Simon's definition, 10
Sketching technique, 98, 117–122, 119
Skilled practitioners, 14
Social security, 98
Soldering and brazing, 274
Solid-state electronic valve, concept, 133
Solution-independent metrics, 61
Solution-oriented technique, 80
Solvent-based adhesives, 266
Source of power, 73
diesel, 95
gasoline, 95
LNG, 95
steam, 95
Sources of information, 22
design codes, 22
handbooks, 22
Space of engineering designs, 92–99
C-sketch method, 98
defining, by generating morphological chart, 93–95
guiding thoughts, 99
thinking metaphorically, and strategically, 95–97
Spot welding, 274
Spring formula, 189
Spring-mass-damper sketch, analogy, 129
Stabilization system, 28
Stand-alone device, 76
St. Peter's Church, 257
Structured interview, 26
endpoint of, 127
Sullivan, Louis, 257
Supply-chain management, 209
Symbolic analogies, 98
System-level design, 5
T
Team-based projects, 227
Team charters, 234
Team writing, 154
Technical communication, guidelines, 143–145
responsibilities for, 134
Technical drawings, 125
Testing outcomes, 24
Testing prototypes and models, 133
building prototype, 134
principles and guidelines, 135–141
proof of concept testing, 133–134
Third-angle projection, 280, 281
Threads per inch (TPI), 277
Three-dimensional object, 118, 163
Three-stage model, 20
Thrower's nervous system, 14
Tight-tolerance items, 136
Time management tools, 150
Time to market, 206
design choices, 201
Tolerance zone shape, 289
virtual conditions, 299
Topic sentence outline (TSO), 151, 152, 153, 157
Top-level design goal, 25
Top-level objectives, 54, 56, 190
Top-level tasks, 239
Traditional specifications, 11
Transformation functions, 72
Tree-building issue, 50
Tree-like structures, 25
Tremor-inducing muscle tension, 31
Truss Opsit®, 270
self tapping left-handed thread screw, 270
Tube concept, 257
axonometric sketches, 119
oblique sketches, 119
perspective sketches, 119
U
Unanticipated side effects, 73
Unit-dependent versions, 165
Unweighted design objectives, 107
U.S. Department of Defense, 135
U.S. Department of Transportation regulations, 256
User needs, interpretations, 5
User questionnaires, 26
User surveys, 26
U.S. Patent Office (USPTO), 101
design patents, 101
utility patents, 101
Utility values, 83
V
Variate, 210
Velcro fastener, 96
Verbal communication, 97
Verb-noun combination, 73
Verein Deutscher Ingenieure (VDI), 254
Verne, Jules, 96
20,000 Leagues Under the Sea in, 96
tips and pointers, 147
Visual events, 147
Vocal cord surgery, surgeons, 28
W
Walkway connections, 128
Weakest-link phenomenon, 211, 212
Welding, 274
arc, 274
spot, 274
Welfare of the public, 261–263
Wellington, Arthur M., 204
location theory, 204
Whats vs. Hows section, 87
Wheelchair design, visible differences, 5
Who vs. Whats section, 87
Wooden extension ladders, 18
Wooden rail-road tie, 125, 217
Wood fasteners, temporary, 270
Wood joining, common adhesives, 270
flat-head, 273
oval-head, 272
round-head, 272
Work breakdown structure (WBS), 237, 240
Work-energy principle, 172
Working engineer, 3
World-class companies, 206
World's major bodies of water, 216
World Wide Web, 83
Wright's mentor, 257
Y
Young's modulus, 168