The 10 phase Design Process
PGR.BAT.DCCR.
1. Identify the Problem/product innovation
2. Define the working criteria/Goals
3. Research and gather data
4. Brainstorm/generate creative ideas
5. Analyze potential solutions
6. Develop and Test models
7. Make the Decision
8. Communicate and specify
9. Implement and Commercialize
10. Perform post-implementation Review and assessment
1. Identify the Problem/product innovation
What shall we do???
Initially:
problems are poorly defined
most decisive issues not yet apparent
Example Chemical ENGR problem:
Flow assurance engineer:
Petroleum Flow assurance issues:
Flow assurance solutions:
Hypothetical situation:
A chemical engineer working for an oil company was assigned to solve a problem involving an electric heater that was purchased & installed to heat a particular stream of liquid to a certain temperature. Upon investigation the engineer found:
The oil company had ordered the equipment from a reputable company who specialized in heat tracing.
The amount of power/length that the heater had to deliver had been specified by the oil company.
Once constructed, delivered, and installed the heater did not raise the temperature of the targeted liquid stream to anywhere near the desired value.
Everyone was debating as to the cause with elaborate theories supporting arguments of:
- Heater constructed improperly?
- Heater installed improperly?
What shall we do???
The Chem E decided to collect some data on the flow rates and temperatures of the stream going through the heater. Turns out:
- it was not an improper construction,
- it was not an improper installation...
For months the problem had been misconstrued - the problem was not a malfunction of the heater.
Example offshore rig:
Hibernia - World's largest oil platform
37,000 t (41,000 short tons) integrated topsides facility
mounted on a 600,000 t (660,000 short tons) gravity base structure. (GBS)
contains storage tanks for 1.2 million barrels (190,000 m3) of crude oil.
(right next to the ocean ranger - another platform that sank in a storm killing all 84 engineers on board)
2. Define the working criteria/Goals
Example working criteria:
How much will it cost?
Will it be difficult to produce?
What will be the size, weight, strength?
What will it look like?
Will it be easy to use?
Will it be safe?
Are there any legal concerns?
Will it be reliable and durable?
Can it be recycled?
Is this what the customer really wanted?
Will our customers really want to purchase it?
Will they purchase our version instead of a competitor's?
Goals = objectives
Example:
Produce an automobile that:
Example working criteria:
How much will it cost?
Will it be difficult to produce?
What will be the size, weight, strength?
What will it look like?
Will it be easy to use?
Will it be safe?
Are there any legal concerns?
Will it be reliable and durable?
Can it be recycled?
Is this what the customer really wanted?
Will our customers really want to purchase it?
Will they purchase our version instead of a competitor's?
Goals = objectives
Example:
Produce an automobile that:
- produces less emissions
- increases gas mileage
- avoids crashing
- drives itself
- augmented reality dash display
- doubled stopping power
- can fly
3. Research and gather data
Who has worked on it?
What did they come up with?
How much did it cost?
What information has been published about the problem?
What problems did everyone else run up against?
What are the advantages and disadvantages of the solutions out there?
Who has worked on it?
What did they come up with?
How much did it cost?
What information has been published about the problem?
What problems did everyone else run up against?
What are the advantages and disadvantages of the solutions out there?
4. Brainstorm/generate creative ideas
1. Postpone and withhold your judgements.
2. The wilder the ideas, the better
3. Quantity not quality
4. Build on the ideas of others. Group Think! Encourage embellishment!
5. Every person and every idea has equal worth.
Record all ideas on large board where everyone can see them.
Goals:
Take care of all problems
1. Postpone and withhold your judgements.
2. The wilder the ideas, the better
3. Quantity not quality
4. Build on the ideas of others. Group Think! Encourage embellishment!
5. Every person and every idea has equal worth.
Record all ideas on large board where everyone can see them.
Problems:
- Water conservation,
- even and complete coverage,
- weather issues (frozen pipes, rainy days),
- won’t interfere with lawn mowing,
- high visual appeal,
Goals:
Take care of all problems
Research:
Current models:
Brainstorm!
5. Analyze potential solutions
Write down the list
Eliminate duplicates
Ask clarifying questions about ideas
Evaluate pro's and cons.
Write down the list
Eliminate duplicates
Ask clarifying questions about ideas
Evaluate pro's and cons.
Create models with CAD, or create physical small scale models.
Test for:
- Durability
- Ease of assembly
- Reliability
- Strength
- Environmental issues
- Quality
- Safety
Engineers, craftsmen, computer designers, production personnel, etc. etc. Everyone has to be on the same page.
- written reports
- training materials
- operating manuals
- presentations
9. Implement and Commercialize
Final opportunity for revision or termination of project
Up to:
Final opportunity for revision or termination of project
Up to:
- Management
- Engineers
- Business - sales and marketing
- Legal
10. Perform post-implementation Review and assessment
- production efficiency
- quality control
- sales
- revenue
- costs
- expenditures
- profits
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