Class
Hours
Lecture:
MWF 12:00 - 12:50 PM
(Section 001), 1:00 - 1:50 PM (Section 002)
Design
Studio: TR 8:00-
9:50 AM, 10:00-11:50 AM, 12:00- 1:50 PM, 2:00-3:50 PM
Text
The
Mechanical Design Process, Third
Edition, David G. Ullman, McGraw Hill
Course Objective
The
objective of this course is to provide a team project-based, hands-on discovery
experience of developing prototype products through a well-organized
engineering design process including planning, problem definition, concept
design, product design/realization, and testing. Design processes and methods
are introduced through the Lectures; the processes and methods are applied in a
design project in the Design Studio. Achieving the course objective will be
measured through how well the students attain the following course learning
outcomes.
Course Learning Outcomes
By
the completion of this course, students must demonstrate the ability to:
1. Apply Gantt Chart techniques to identify project
deliverables and make a 10-week work plan for a small-scale engineering design
team project
2. State and illustrate the quality function
deployment (QFD) method by using QFD to define an open-ended engineering
design problem
3. Generate and evaluate conceptual design solutions
using functional analysis and prototype testing given a design problem
definition
4. Produce a product that meets functional requirements
5. Produce a product with originality, regulatory, and
aesthetic considerations
6. Perform as part of an engineering design team
Design Project – MARS ROCKS
This is the project developed
by American Society of Mechanical Engineers (ASME) for the 2009 ASME Student
Design Competition. A design problem description is available at the website:
http://www.asme.org/Events/Contests/DesignContest/Student_Design_Competition.cfm
An additional rule is being added to the contest for
this course. The maximum that can
be spent on off-the-shelf parts is $100/team. All prices are fair-market-value. New parts or components are considered at the price you paid
for them. If there is a widget in
your little brother’s toy box you want to use, then its value on E-bay or other
auction must be used.
Grading
Grading will be based on:
25%
- individual homework
20% -
individual design notebooks
20% - product development report (teamwork)
10% - design reviews (teamwork)
15% - field test results (teamwork)
10% - subjective evaluation (teamwork)
_____________________________________
Total 100%
Each of the graded items is described below.
I. Individual Homework (Document A1-A26, see VI for their descriptions)
Due
the Monday following the assignment at the beginning of class. The homework you turn in each week will
be a photocopy of the individual entries in the design notebook; it is your
responsibility to make sure that the photocopy is readable. The sequence of
doing homework and record keeping in design notebook is: you read the material
and do the assignment as part of your record keeping in your design notebook;
then photocopy the assignment parts as homework to turn in. Your name and group number
must be on each homework.
Note: You turn in the
homework on Monday and, during your lab on Thursday you discuss the topics and
reach team agreement on the results. Documentation of the team agreement
becomes part of the team's Product Development Report (see III for description).
II. Individual Design
Notebook
You
are required to keep a permanently bound 8.5” x 11” design notebook for use in
this course (this is a common practice for professional engineers in many
industrial companies). All work concerning the design project will be entered
into this notebook. The entries may include all individual homework, design
ideas and reflections, teamwork discussion/results, design studio exercises,
sketches, tables, and other contents that are closely related to the design
project. Your name and group number must appear on the cover of your design
notebook. Every page in the notebook must be numbered in ink at the beginning
of the term. No pages can be removed and each page must be dated and initialed
when used. In other words, everything you do on the project is included in the
notebook. It is suggested that you use a spiral bound quadrille notebook and
staple in pages as needed.
Each
notebook will be collected at the end of the term and graded on the number of
"quality entries" it contains. Typical examples of a quality
entry include: a significant sketch or drawing of some aspect of the design; a
listing of functions, ideas, or other features; a table such as morphology or
decision matrix; or a page of text. Entries that are unintelligible are not
"quality entries".
Note: do not
use your design notebook for recording lecture notes. The lecture notes will
not be counted as entries.
Notebook grading will be:
grade
of 100% for 60 or more quality entries
grade
of 95% for 55-59
grade
of 90% for 50-54
grade
of 85% for 45-49
grade
of 80% for 40-44
grade
of 75% for 35-39
grade
of 70% for 30-34
grade
of 65% for 25-29
grade
of 60% for 20-24
grade
of 55% for <20
Note that padding is obvious and not counted!
Your final
entry in the design notebook will be
at least one-page or more to reflect your design process, product performance,
teamwork, your contest experience, and what you have learned from it. This is required.
III. Product Development
Report (include Documents B1-B4, see VI for description)
This
is a self-contained, well-written report summarizing the design process and
team project. This file contains
the TEAM results of the design process and product. Document B1-B4 must be
included in this report. It is
highly recommended that each team keep a single file of the team results along
the product development process from earlier on during the term. At the end of the term the team will
refine this file into a Product Development Report. The complete report should contain at least the following:
-
Executive Summary
(a picture of your product is required)
-
Introduction
-
Team results for
the 32 items listed on the previous pages.
-
Discussion of
prototypes and final design including photographs
-
Evaluation of
field test
-
Conclusion
The
Product Development Report will be graded on its completeness of all the above
items, clarity of explanation/justification/discussion on your design decision
for each step, and writing quality.
Due time: 11am, December 8th, 2008, at ROG418. An example Design Report
Format can be found on the Blackboard.
You do not need to follow this, but it gives some good ideas.. The grading template for the product
development report is:
ME 382 Design Project: Product Development Report
Grading Sheet
Team Number
______________ Date _________________
Executive
Summary (max 2)____
Introduction
(max
1)____
Problem
Appraisal (max
4)____
Conceptual
Design (max
4)____
Product
Design (max
4)____
Drawings (max
4)____
Discussion
of Prototypes (max
3)____
Evaluation
of Field test (max
2)____
Conclusion (max
1)____
Team
Grade Total (max 25)
______________
IV. Subjective
Evaluation
The subjective evaluation will be performed by the
evaluation team from 12:00 - 5:00 PM on Thursday, December 4th, 2008.
All the teams must place their products in Rogers Hall 228 by 12:00 PM. The
grading template for subjective evaluation is:
ME 382 Design Project: Subjective Evaluation
Team Number
______________ Date _________________
Craftsmanship (3)
Compliance (2)
Originality (2)
Aesthetics (2)
Simplicity (1)
Team
Grade Total (max 10)
_____________
V. Field Test (announced broadly and open to general public)
The
field test (ME382 Design Contest) will be held at 6:00 PM Thursday, December 4th,
2008, at Milam Auditorium. The teams can pick up their products at Rogers Hall
228 at 5:00 PM and transport them to Milam. Grading will be based on how your team places with first
place receiving 100% and last place 60%. This event is open to the public.
VI.
Description of the Required Design Process Documents
A. Documents
that will be assigned as individual
homework and thus be part of the notebook. Specifics about the Assignment
are on Blackboard in the folder labels “Homework Assignments”. Many can be completed using
pre-formatted templates. These are
labeled with a * and are in the Templates Blackboard folder.
i.
Project Appraisal and Preparation Phase
Week
1: Planning the Project
A1. Task Titles, Objectives of each Task, Deliverable
and Metric for each Task, Personnel
Required for Each Task, Time Required for Each Task, all part of Project Plan
Template *
A2.
Schedule of Tasks
A3. Team Contract * and Personal Problem Solving
Dimension *
Week 2: Understanding
the Design Problem
A4.
Description of Customers
A5.
Customer's Requirements
A6.
Weighting of Customer's Requirements
A7.
Competition's Benchmarks Versus Customer's Requirements
A8.
Engineering Requirements
A9.
Competition's Benchmarks Versus Engineering Requirements
A10.
Engineering Targets
ii.
Conceptual Design Phase
Week
3: Concept Generation
A11.
Functional Decomposition
A12.
Function-Concept Mapping/Morphology *
A13.
Sketches of Overall Concepts
Week
4: Concept Evaluation
A14.
Technology Readiness Assessment
A15.
Go/no-go Screening
A16.
Decision Matrices to Determine Best Concepts
A17.
Analysis, Experiments and Prototypes Supporting Concept Evaluation
iii.
Product Design Phase
Week
5: Product Generation
A18
Analysis/Experiments and Prototypes – Test Report*
A19 Usable Off-the-Shelf Products (COTS)
A20. Shape Development Driven by Function (Individual
Layout Drawings)
A21.
BOM*
Week
6: Product Evaluation
A22.
Comparison to Engineering Requirements (cancelled)
A23.
Functional Changes Noted- Change Order *
A24
Analysis, Experiments and Prototypes Supporting Product Evaluation (cancelled)
A25. Design for Assembly Evaluation DFA*
A26. Cost Evaluation – Plastic Part Cost
Calculator*, Metal Part Cost Calculator*
Week 7: Product
Evaluation Continued
A27. Analysis of tolerances
A28. Analysis of failure potential
B. The following team documents are done by the team and are a part of the product development report. They are
not counted as part of the design notebooks.
Final
Product Documentation
B1.
Layout Drawings
B2.
Detail Drawings of Manufactured Parts
B3.
Parts List (Bill of Materials)
B4.
Assembly Sequence Instructions (optimized)
The drawings must be signed by the
instructor before building.
VII. Design Review During the 4th
and 7th week Design Studios you will have a Design Review. At these times you will present your
team’s effort to date to a panel that consists of Professors Ullman and Tumer,
and other professional engineers from the faculty and industry. A Team Health Inventory* will be
submitted independently by each team member at the beginning of the Review.
VIII. Teamwork Grade
Adjustment Based on Team Evaluation
To
make grading of team produced material fair, the team project grades will be
corrected for each student with a weighting factor. This factor will be developed through each team member's
confidential evaluation of all members in the team. Each member of the team will evaluate every member of the
team (including themselves) for the percent of his/her contribution to the team
project. The evaluations will be
averaged by the instructor to find each student's contribution and the
weighting factor made proportional to it.
Teamwork Contribution Evaluation Form
Team Number
Date
|
Name |
Concept (%) |
Analysis/ Testing (%) |
Building (%) |
Report (%) |
Total Contribution to Teamwork (%) |
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ME 382
Class Schedule