Chapter 1 Introduction Chapter 2 Development Processes and Organizations Chapter 3 Product Planning Chapter 4 Identifying Customer Needs Chapter 5 Product Specifications Appendix Concept -Scoring Matrix Example Chapter 6 Concept Generation Chapter 7 Concept Selection Appendix A Concept-Screening Matrix Example Appendix B Concept-Scoring Matrix Example Chapter 8 Concept Testing Appendix Estimating Market Sizes Chapter 9 Product Architecture Chapter 10 Industrial Design Chapter 11 Design for Manufacturing Appendix A Material Costs Appendix B Component Manufacturing Costs Appendix C Assembly Costs Appendix D Cost Structures Chapter 12 Prototyping Chapter 13 Robust Design Appendix Orthogonal Arrays Chapter 14 Patents and Intellectual Property Appendix A Trademarks Appendix B Advice to Individual Inventors Chapter 15 Product Development Economics Appendix A Time Value of Money and the Net Present Value Technique Appendix B Modeling Uncertain Cash Flow Using Net Present Value Analysis Chapter 16 Managing Projects Appendix Design Structure Matrix Example

Product Design and Development

The use of statistical techniques to build approximations of expensive computer analysis codes pervades much of today’s engineering design. These statistical approximations, or metamodels, are used to replace the actual expensive computer analyses, facilitating multidisciplinary, multiobjective optimization and concept exploration. In this paper, we review several of these techniques, including design of experiments, response surface methodology, Taguchi methods, neural networks, inductive learning and kriging. We survey their existing application in engineering design, and then address the dangers of applying traditional statistical techniques to approximate deterministic computer analysis codes. We conclude with recommendations for the appropriate use of statistical approximation techniques in given situations, and how common pitfalls can be avoided.

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Metamodels for Computer-Based Engineering Design: Survey and Recommendations

The purpose of this article is to provide a survey of the various stages in the development of response surface methodology RSM. The coverage of these stages is organized in three parts that describe the evolution of RSM since its introduction in the early 1950s. Part I covers the period, 1951-1975, during which the so-called classical RSM was developed. This includes a review of basic experimental designs for fitting linear response surface models, in addition to a description of methods for the determination of optimum operating conditions. Part II, which covers the period, 1976-1999, discusses more recent modeling techniques in RSM, in addition to a coverage of Taguchi's robust parameter design and its response surface alternative approach. Part III provides a coverage of further extensions and research directions in modern RSM. This includes discussions concerning response surface models with random effects, generalized linear models, and graphical techniques for comparing response surface designs. Copyright © 2010 John Wiley & Sons, Inc.

Response Surface Methodology.

This paper describes a new approach to testing that uses combinatorial designs to generate tests that cover the pairwise, triple, or n-way combinations of a system's test parameters. These are the parameters that determine the system's test scenarios. Examples are system configuration parameters, user inputs and other external events. We implemented this new method in the AETG system. The AETG system uses new combinatorial algorithms to generate test sets that cover all valid n-way parameter combinations. The size of an AETG test set grows logarithmically in the number of test parameters. This allows testers to define test models with dozens of parameters. The AETG system is used in a variety of applications for unit, system, and interoperability testing. It has generated both high-level test plans and detailed test cases. In several applications, it greatly reduced the cost of test plan development.

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The AETG system: an approach to testing based on combinatorial design

Probabilistic optimization design offers tools for making reliable decisions with the consideration of uncertainty associated with design variables/parameters and simulation models. In a probabilistic design, such as reliability-based design and robust design, the design feasibility is formulated probabilistically such that the probability of the constraint satisfaction (reliability) exceeds the desired limit. The reliability assessment for probabilistic constraints often involves an iterative procedure; therefore, two loops are involved in a probabilistic optimization. Due to the double-loop procedure, the computational demand is extremely high. To improve the efficiency of a probabilistic design, a novel method – sequential optimization and reliability assessment (SORA) is developed in this paper. The SORA method employs a single-loop strategy where a serial of cycles of optimization and reliability assessment is employed. In each cycle optimization and reliability assessment are decoupled from each other; no reliability assessment is required within optimization and the reliability assessment is only conducted after the optimization. The key concept of the proposed method is to shift the boundaries of violated deterministic constraints (with low reliability) to the feasible direction based on the reliability information obtained in the previous cycle. Hence the design is quickly improved from cycle to cycle and the computational efficiency is improved significantly. Two engineering applications, the reliability-based design for vehicle crashworthiness of side impact and the integrated reliability and robust design of a speed reducer, are presented to demonstrate the effectiveness of the SORA method.Copyright © 2002 by ASME

Sequential Optimization and Reliability Assessment Method for Efficient Probabilistic Design

From the Publisher:
Phadke was trained in robust design techniques by Genichi Taguchi, the mastermind behind Japanese quality manufacturing technologies and the father of Japanese quality control. Taguchi's approach is currently under consideration to be adopted as a student protocol with the US govrnment. The foreword is written by Taguchi. This book offers a complete blueprint for structuring projects to achieve rapid completion with high engineering productivity during the research and development phase to ensure that high quality products can be made quickly and at the lowest possible cost. Some topics covered are: orthogonol arrays, how to construct orthogonal arrays, computer-aided robutst design techniques, dynamic systems design methods, and more.

Madhan Shridhar Phadke

Papers

Quality Engineering Using Robust Design