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A ROADMAP for DECOMPOSITION: ACTIVITIES, THEORIES, and TOOLS for SYSTEM DESIGN by Derrick Tate

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A ROADMAP for DECOMPOSITION: ACTIVITIES, THEORIES, and TOOLS for SYSTEM DESIGN by Derrick Tate A ROADMAP FOR DECOMPOSITION: ACTIVITIES, THEORIES, AND TOOLS FOR SYSTEM DESIGN by Derrick Tate Submitted to the Department of Mechanical Engineering on December 28, 1998 in partial fulfillment of the requirements for the degree of Doctor of Philosophy Abstract Many design theories lack scalability to systems with many elements. They provide guidance to designers about specific facets of a design task but are too cumbersome to apply thoroughly from conceptual to detailed design. Thus the opportunity for rational design is missed. Axiomatic design (AD) seems ideal for directing the design of large systems because it proposes general principles and a recursive design process. AD provides a fundamental basis for understanding decision making during design. It contains representations for the design object (a hierarchy of functional requirements, design parameters, and design matrices) and the design process (decomposition and zigzagging) combined with rules for decision making (the independence and information axioms). Challenges remain, however, in implementing the theory to large system designs. The challenge addressed in this thesis is decomposition, the activity through which details of the design emerge. In decomposition, FRs satisfied by conceptual DPs are reduced into sets of sub-FRs. This activity is repeated until the design is completely embodied as a physical system of hardware and/or software. A question asked about decomposition concerns consistency: How can decisions about sub-FRs, and the rest of the decomposed design, be made so that they match the design decisions and representations of the design that were made at higher levels of the design hierarchy? To enable designers to do this, this thesis extends AD by providing a model of the decomposition process that identifies the activities performed and provides guidelines and tools to assist the designers. The designers’ goals and guidelines for achieving them have been generalized and evaluated for each of the decomposition activities: generating sub-FRs, identifying relevant customer needs, integrating sub-DPs, directing progress of the decomposition, dimensioning DPs, layout of DPs, carrying down and refining constraints, and ensuring consistency between levels. The theoretical concepts, the model, guidelines, and tools, have been validated through application to industrial cases including a new reticle management system accommodating customer variety, software algorithms for machine control, system analysis, reuse of design rationale, and software design. The cases examined cover a wide breadth, are from different fields, and have different numbers of designers. Thesis Supervisor: Nam P. Suh Title: Ralph E. and Eloise F. Cross Professor of Manufacturing Head of the Department of Mechanical Engineering 3 If he had said this to me two weeks ago I would have popped him in the mouth, six weeks ago I would have broken his arm, four months ago and I would be telling this story to my death-row prison mates. Today all I could do was laugh at him.—Eddy L. Harris, South of Haunted Dreams, p. 244 On occasions when [Robert E.] Lee and General Francis Smith, Superintendent of VMI, marched together in some joint exercise, Lee consistently marched out of step. A faculty member recalled, “He simply walked along in a natural manner, but although this manner appeared so natural, it seemed to me that he consciously avoided keeping step, so uniformly did he fail to plant his foot simultaneously with General Smith or at the beat of the drum.” —Emory M. Thomas, Robert E. Lee, p. 396 A Roadmap for Decomposition: Activities, Theories, and Tools for System Design Table of contents A ROADMAP FOR DECOMPOSITION: ACTIVITIES, THEORIES, AND TOOLS FOR SYSTEM DESIGN Abstract 3 Table of contents 5 Chapter 1: Introduction 9 1.1 Motivation 9 1.1.1 Needs of designers in industry 9 1.1.2 Impact of design theory in industry 9 1.2 Background and context 10 1.2.1 Paradigm for design theory 10 1.2.2 Aim and scope of design theory 11 1.2.3 Basis of axiomatic design 13 1.3 Area of research: current theory and needs 13 1.4 Research goal of the thesis 17 1.4.1 Research question 17 1.4.2 Needs 17 1.4.3 Scope and contributions of the thesis 18 1.4.4 Structure of thesis 18 Chapter 2 Theory Development 21 2.1 Introduction 21 2.2 Vision 21 2.2.1 Consistency: a measure of success in decomposition 21 2.2.2 Note on software implementation 23 2.3 Understanding the design process 23 2.3.1 Desired characteristics of the design process 24 2.3.2 Existing models of the design process 24 2.4 Rules 27 2.4.1 Discussion of the relationship between goals in decomposition and the overall design process 27 2.4.2 Approach 28 2.5 System design issues and tools 30 2.5.1 Definition of system design 31 2.5.2 Unique features of system design 31 2.5.3 Motivation for specific tools for system design 32 2.6 Summary 35 5 A Roadmap for Decomposition: Activities, Theories, and Tools for System Design Chapter 3: Activities and Guidelines for Decomposition 37 3.1 Introduction 37 3.1.1 Decisions that the designers make 37 3.1.2 Approach to this chapter 43 3.2 Activities in the design and decomposition process 46 3.2.1 Sequencing the decomposition 46 3.2.2 Generation of sub-FRs 46 3.2.3 Identification of relevant CNs 47 3.2.4 Carrying down and refining Cs 47 3.2.5 Dimensioning of sub-DPs 48 3.2.6 Layout of DPs 48 3.2.7 Physical integration of DPs 48 3.2.8 Ensuring consistency between levels: FRs, DPs, DMs, Cs 49 3.3 Goals 49 3.4 Guidelines for the design and decomposition process 51 3.4.1 Sequencing the decomposition 51 3.4.2 Generation of sub-FRs 56 3.4.3 Carrying down and refining Cs 61 3.4.4 Physical integration of DPs 66 3.4.5 Ensuring consistency between levels: FRs, DPs, DMs, Cs 68 3.5 Summary 70 Chapter 4: System Design Tools and Applications 75 4.1 Introduction 75 4.2 Concepts of modularity in AD 75 4.2.1 Resource modularity 76 4.2.2 Operational modularity 77 4.2.3 Interfacial modularity 82 4.2.4 Uses and discussion 84 4.3 Applications 84 4.3.1 Command and control algorithms (CCAs) 85 4.3.2 Physical integration 93 4.3.3 Additions to information content to account for flexibility 94 4.4 Summary 97 Chapter 5: Case Study Methods 99 5.1 Introduction 99 5.2 Axiomatic design as a “scientific” basis for this work 99 5.2.1 Can axiomatic design be considered a science of design? 99 5.2.2 Scientific basis for this work 100 5.2.3 Case studies and validation 101 5.3 Summary 102 6 A Roadmap for Decomposition: Activities, Theories, and Tools for System Design Chapter 6: Case Study Results and Discussion 103 6.1 Introduction 103 6.2 Discussion of theory evaluation 103 6.2.1 Design process: activities, connections, goals 104 6.2.2 Guidelines 105 6.2.3 Tools 105 6.3 Introductory descriptions of cases 106 6.3.1 Photolithography tool 106 6.3.2 Hardware-software interface: CMP 107 6.3.3 New sub-system: RMS 108 6.3.4 AD Software 109 6.3.5 Track machine 113 6.3.6 Target-oriented product data management (PDM) 114 6.3.7 Reuse of design rationale for manufacturing cell design 114 6.4 Discussion of theory application 115 6.4.1 Roadmap and guidelines 115 6.4.2 Tools 127 6.5 Summary and conclusions 129 6.5.1 Academic considerations 129 6.5.2 Industry considerations 130 6.5.3 Extension of work to software 130 Chapter 7: Conclusions 131 References 137 Appendix 1: Research Methods for Design Theory 145 A1.1 Introduction 145 A1.2 Design theory: the need for a unifying paradigm 146 A1.2.1 Discussions of research methods 146 A1.2.2 Design as pre-paradigm science 148 A1.3 Areas of fundamental knowledge for design theory 151 A1.4 A research process model and framework for design theory 152 A1.4.1 Research process model 152 A1.4.2 Framework for design theory 154 A1.4.3 Approaches to philosophy of science 156 A1.5 Research activities 157 A1.5.1 Data gathering 157 A1.5.2 Theory development 158 A1.5.3 Use of consequences derived from theory 160 A1.5.4 Theory validation 162 A1.5.5 Application to history of science 167 A1.5.6 Summary 167 A1.6 Discussion on axiomatic design 167 A1.6.1 Axiomatic design: a science of design? 167 A1.6.2 Axiomatic design as a progressive research program 169 A1.6.3 Summary 171 A1.7 Conclusions 171 7 A Roadmap for Decomposition: Activities, Theories, and Tools for System Design Appendix 2: Design Process Roadmap 173 A2.1 Introduction 173 A2.2 Model of the design process 174 A2.2.1 Properties of the design process model 174 A2.2.2 Descriptions of the generic activities and their problem situations 176 A2.2.3 Connecting the activities 179 A2.3 Summary 179 Appendix 3: Scope and Evolution of Design Research 181 A3.1 Introduction 181 A3.2 Scope and evolution of design research 181 A3.2.1 Evolution of research methods 181 A3.2.2 Scope and motivation 183 A3.2.3 Evolution 185 A3.2.4 Process for selection of design tools by industry 189 A3.3 Summary 189 Appendix 4: Fundamentals of Axiomatic Design 191 A4.1 Introduction 191 A4.2 Basic concepts of axiomatic design 191 A4.2.1 Domains and mapping 191 A4.2.2 Use of AD concepts 196 A4.3 Advanced topics in AD 196 A4.4 Relationship of this work to AD 196 A4.5 Summary 199 Appendix 5: Function Structures of Pahl and Beitz 201 A5.1 Introduction 201 A5.2 Compare and contrast Pahl and Beitz versus AD 202 A5.3 Comparison of specific guidelines 203 A5.4 Summary 205 Acknowledgments 207 Biographical information 8 A Roadmap for Decomposition: Activities, Theories, and Tools for System Design Chapter 1: Introduction 1 CHAPTER 1: INTRODUCTION 1.1 Motivation Why is design theory important? What issues does it cover? Is it useful for real-life applications? This introduction places the research presented in this thesis into the larger context of design theory in general by addressing these questions.
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