Creative Design of Products and Systems

This exciting, new text for is intended use in undergraduate engineering design methodology courses. Niku presents a cross-disciplinary approach to engineering design with a strong emphasis on creative thinking and problem-solving. Included are a large amount of end of chapter problems and numerous in-chapter creative problem-solving exercises. The material presented is appropriate for courses from the sophomore to senior level. Topical coverage starts at the earliest step of ideation to the time the product will go to market. It introduces the designer to the practice of creative design by reviewing the mental barriers that prevent creative problem solving and design as well as ways to overcome these barriers. The text also covers design process, including Quality Function Deployment, Pugh matrix, and other related issues through mechanical, electrical, and architectural examples. By presenting a comprehensive, systematic approach to issues and factors that play a role in design, the text teaches the designer to understand the consequences of design decisions throughout the entire process, from when ideas are generated until the product or system goes to market. 

Table of Contents:
PREFACE vii CHAPTER1 CREATIVE PRODUCT AND SYSTEM DESIGN 1 1.1 Introduction 1 1.2 What is Design? 3 1.3 What is a Creative Design? 4 1.4 Innovation versus Invention 6 1.5 Globalization 6 1.6 Teamwork 7 1.7 That’s Not My Job 18 1.8 Project Scheduling and Management 18 References 24 Homework 24 PART 1 CREATIVITY AND DESIGN CHAPTER 2 CREATIVE MIND 29 2.1 Introduction 29 2.2 Whole-Brain Thinking 33 2.3 Creativity 35 2.4 What Makes an Individual Creative? 35 References 37 Additional Reading 37 CHAPTER 3 RECLAIMING YOUR CREATIVITY 38 3.1 Introduction 38 3.2 Mental Barriers 39 3.3 Types of Mental Barriers 40 3.4 False Assumptions and Nonexistent Limitations 42 3.5 Typical Solutions 45 3.6 Making Things More Difficult Than They are: Being Overwhelmed 51 3.7 Incomplete or Partial Information 54 3.8 Information and Sensory Saturation 56 3.9 Associative Thinking 59 3.10 Misunderstandings 60 3.11 Inability to Communicate Properly 61 3.12 Emotions-, Culture-, and Environment- Related Barriers 63 3.13 Fear of (You add the noun as you wish) 65 3.14 Orderly vs. Chaotic; Analysis vs. Synthesis 67 3.15 Falling in Love With an Idea 68 3.16 Improper Methods of Solution 69 3.17 Overabundance of Resources 71 3.18 Solutions and Related Mental Barriers for the Above-Mentioned Puzzles 73 References 81 Design Projects 81 Homework 84 CHAPTER 4 CREATIVE PROBLEM SOLVING TECHNIQUES 87 4.1 Introduction 87 4.2 Brainstorming 88 4.3 The 6-3-5 Method 92 4.4 Morphological Attribute Lists (Menu Matrix) 92 4.5 List of Alternative Actions 95 4.6 Analogy (Case-Based Reasoning) Method 98 4.7 Random Attributes 98 4.8 SCAMPER Method 99 4.9 Create Your Own Slogans 99 4.10 Asking Questions 100 4.11 Incubation 101 4.12 Synectics 102 4.13 TRIZ 106 References 109 Homework 110 CHAPTER 5 THE DESIGN PROCESS 111 5.1 Initial Benchmarking: A Design Project 111 5.2 The Iterative Design Process 111 Stage I. Initiation of the DesignProcess 115 5.3 Finding a Need or a Challenge 115 5.4 Accepting the Challenge 117 Stage II: Specification 119 5.5 Initial Study: Analysis of the Requirements of a Design 119 5.6 Quality Function Deployment (QFD), House of Quality 123 5.7 Specifications and Design Requirements: Development of a Problem Statement 133 Stage III: Ideation 136 5.8 Generation of Ideas 136 5.9 Analysis and Selection of Ideas 140 Stage IV: Implementation 157 5.10 Analysis, Detail Design, and Planning of the Converged Solution 157 5.11 Realization of the Idea 161 5.12 Assessment against Problem Statement and Verification 163 Stage V: Iteration 163 5.13 Iterations 163 References 168 Homework 169 CHAPTER 6 IMAGINATION, VISUALIZATION, GRAPHICAL REPRESENTATIONS AND COMMUNICATION 172 6.1 Introduction 172 6.2 Imagination 174 6.3 Drawing 183 6.4 Engineering Drawings 185 6.5 Realistic Drawings 191 6.6 Perspectives and Location of Objects 196 6.7 Determining Depth in Perspectives: Scale Factors 197 6.8 Drawing Perspectives 198 6.9 Sketching 201 6.10 Put-it-in-the-Box Technique 202 6.11 Sketching Human Figures 203 6.12 Answers 204 References 205 Homework 205 PART 2 THE DESIGN ENVIRONMENT CHAPTER 7 DESIGN CONSIDERATIONS, DECISIONS, AND CONSEQUENCES 211 7.1 Introduction 211 7.2 Cost 214 7.3 Size 215 7.4 Weight 217 7.5 Material Selection 218 7.6 Methods of Fabrication 219 7.7 Physical and Structural Standards 220 7.8 Functional Standards and Expectations 223 7.9 Performance 224 7.10 Efficiency 225 7.11 Reliability 227 7.12 Company Image and Mission 229 7.13 Quality 229 7.14 Serviceability 230 7.15 Styling, Shape, Aesthetics, and Packaging 232 7.16 Safety 232 7.17 Human Factors 233 7.18 Environmental Effects (On the Design and Caused by the Design) 233 7.19 Disposability 238 7.20 Sustainability 240 7.21 Assembly/Disassembly 242 7.22 Life Expectancy 243 7.23 Ethical Issues 246 7.24 Patents and Other Intellectual Property 250 7.25 Legal Matters 251 References 252 Homework 252 CHAPTER 8 HUMAN FACTORS IN DESIGN 254 8.1 Introduction 254 8.2 Human–Machine Interface 254 8.3 Anthropometric Data 255 8.4 The Civilian American and European Surface Anthropometry Resource (CAESAR) Project 263 8.5 Basic Applications of the Anthropometric Data 265 8.6 Software-Based Application of the Anthropometric Data 266 8.7 Inside-Out versus Outside-In Design 267 8.8 Deficiencies and Shortcomings of Anthropometric Data 268 8.9 What Can Be Done 273 8.10 Left-Handed versus Right-Handed Users 274 8.11 Sensory Information Exchange 275 8.12 Human–Machine Interface 276 8.13 Physical and Psychological Characteristics of Humans 280 8.14 Visual Characteristics of Humans 281 8.15 Auditory Characteristics of Humans 284 8.16 Temperature and Humidity 290 8.17 Acceleration Capabilities and Limitations 292 8.18 Psychological Factors 294 8.19 Human Factors and Safety 297 8.20 Occupational Injuries 299 8.21 Human Factors and Maintainability 301 References 302 Homework 303 CHAPTER9 AESTHETICS OF DESIGN 305 9.1 Introduction 305 9.2 Aesthetic Elements of Design 307 9.3 Form and Function Relationship 308 9.4 Lines 314 9.5 Color 315 9.6 Harmony, Unity 321 9.7 Variety 321 9.8 Balance 322 9.9 Proportion 323 9.10 Composition 324 9.11 Style 325 9.12 Art and Technology; A Reciprocal Relationship 327 References 328 Homework 328 CHAPTER10 MATERIAL PROPERTIES, SELECTION, AND PROCESSING 330 10.1 Introduction 330 10.2 Material Properties 330 10.3 Types of Materials 333 10.4 Metals, Alloys 333 10.5 Woods 335 10.6 Plastics, Polymers, and Synthetic Materials 338 10.7 Other Materials 343 10.8 Material Selection 348 10.9 Material Processing and Manufacturing 352 10.10 Design for Manufacturing (DFM) and Design for Assembly (DFA) 366 10.11 Design for Disassembly (DFD) 371 10.12 Computer Aided Manufacturing (CAM) and Computer Integrated Manufacturing (CIM) 376 10.13 Rapid Prototyping 379 10.14 Lean Production 380 References 381 Homework 381 CHAPTER11 ECONOMICS OF DESIGN 383 11.1 Introduction 383 11.2 Value of a Product or System 383 11.3 Global Economics Models 384 11.4 Costs, Revenues, and Profits 386 11.5 Cost Breakdown of Products and Systems 390 11.6 Product Life Span 397 11.7 Engineering Economy 399 References 411 Homework 411 CHAPTER12 QUALITY IN DESIGN 413 12.1 Introduction 413 12.2 Definition of Quality 414 12.3 Historical Background 415 12.4 Statistical Quality Control 415 12.5 Tolerances 416 12.6 What is Quality? 418 12.7 The Concept of Zero Defects 419 12.8 Deming’s Principles 420 12.9 Taguchi Methods 421 12.10 Design of Experiments 432 12.11 Six-Sigma 442 12.12 Lean Production 443 References 450 Homework 451 CHAPTER13 DESIGN AND PRODUCT LIABILITY 453 13.1 Introduction 453 13.2 Product Liability: History and Background 454 13.3 The Legal System of the United States 455 13.4 Major Administrative Laws Related to Product Liability 456 13.5 Some Basic Definitions of Terms 457 13.6 Basic Theories of Product Liability Law 458 13.7 Who May Be Held Liable 461 13.8 Origins of Product Defects and Liability 462 13.9 The Unreasonably Dangerous Product 466 13.10 Reducing Product Liability Risk 468 13.11 Failure Mode and Effect Analysis (FMEA) 470 13.12 Code of Ethics for Engineers 477 13.13 Standards and Codes 477 13.14 What Protection Does the Designer Have? 480 References 480 Homework 481 CHAPTER14 INTELLECTUAL PROPERTY PROTECTION PATENTS, TRADEMARKS, COPYRIGHTS 482 14.1 Introduction 482 14.2 Patents 482 14.3 What is a Patent? 482 14.4 Utility Patents 483 14.5 Requirements for Utility Patents 483 14.6 To Patent or not to Patent: That is the Question 487 14.7 Process of Patenting 489 14.8 Claims 491 14.9 Application and Maintenance Fees 492 14.10 Interference and Diligence 493 14.11 Provisional Patent Application 493 14.12 Infringement of Patents 494 14.13 Patent Marking and Patent Pending 495 14.14 International Patents 495 14.15 Documentation and Record Keeping 497 14.16 Licenses and Assignments 497 14.17 Sample Patent 499 14.18 Confidential Disclosure Statement 499 14.19 Most Numerous Recent Patent Holders in the United States 503 14.20 Bayh-Dole Act 504 14.21 Design Patents 505 14.22 Copyrights 505 14.23 Trademarks 506 References 507 Homework 507 CHAPTER15 ENTREPRENEURSHIP AND INNOVATION 508 15.1 Introduction 508 15.2 Innovation in a Global Business World 509 15.3 Entrepreneurship and Entrepreneur 509 15.4 The Entrepreneurial Bridge 511 15.5 Risks and Rewards 512 15.6 Motivations and Objectives 513 15.7 Should You Start a Business? 514 15.8 Market Research 515 15.9 Business Plan 516 15.10 Development of a Business Plan 518 15.11 Presenting your Business Plan 519 15.12 Legal Structure of a Business 520 15.13 Financing your Entrepreneurship 522 15.14 Execution of a Business Plan 527 15.15 End Game Planning 528 References 529 PART 3 DESIGN ANALYSIS CHAPTER16 DESIGN ANALYSIS OF MACHINE COMPONENTS 533 16.1 Introduction 533 16.2 Loads: Forces, Moments 534 16.3 Free-Body Diagrams 535 16.4 Stresses, Strains, Material Strengths 536 16.5 Stress Analysis 539 16.6 Stress vs. Strength: Safety Factors 552 16.7 Design for Strength vs. Design for Strain 553 16.8 Stress Concentrations 553 16.9 Fatigue Analysis 555 16.10 Selection of Power Sources and Actuators 567 16.11 Selection of Actuators 574 16.12 Design Project 575 References 575 Homework 575 INDEX 578