Western Michigan University ScholarWorks at WMU Master's Theses Graduate College 6-1994 Recent Advances in Engineering Design: Theory and Practice Andrew J. Moskalik Follow this and additional works at: https://scholarworks.wmich.edu/masters_theses Part of the Mechanical Engineering Commons Recommended Citation Moskalik, Andrew J., "Recent Advances in Engineering Design: Theory and Practice" (1994). Master's Theses. 805. https://scholarworks.wmich.edu/masters_theses/805 This Masters Thesis-Open Access is brought to you for free and open access by the Graduate College at ScholarWorks at WMU. It has been accepted for inclusion in Master's Theses by an authorized administrator of ScholarWorks at WMU. For more information, please contact [email protected]. RECENT ADVANCES IN ENGINEERING DESIGN: THEORY AND PRACTICE by Andrew J. Moskalik A Thesis Submitted to the Faculty of The Graduate College in partial fulfillment of the requirements for the Degree of Master of Science Department of Mechanical and Aeronautical Engineering Western Michigan University Kalamazoo, Michigan June 1994 Reproduced with permission of the copyright owner. Further reproduction prohibited without permission. RECENT ADVANCES IN ENGINEERING DESIGN: THEORY AND PRACTICE Andrew J. Moskalik, M.S. Western Michigan University, 1994 In the last few years, industry and academia have focused greater attention on the area of engineering design. Manufacturers have implemented new design methods such as concurrent engineering and design for manufacture, and academia has increased research in design-related issues. This paper will attempt to summarize the recent advances, both scholarly and industrial, relating to the field o f design. I will examine new methodologies and supporting tools for the design process, both in use and under research. This paper will cover concurrent engineering, design for manufacture, quality methods, design theory research, computer-aided design, expert systems, analysis programs, manufacturing, and other subjects related to design, including engineering education. I will look at the newest advances forming the current state of these areas, the relationships among the areas, and the utility of each area. I will also comment on the future trends in engineering design. Reproduced with permission of the copyright owner. Further reproduction prohibited without permission. ACKNOWLEDGMENTS I would like to begin by acknowledging the influence of two men I have never met: Dr. John Dixon of the University of Massachusetts and Dr. David Ullman of Oregon State University. Their enthusiasm for and support of academic work in design theory (and the quality of their own work) inspired me to pursue the subject, and ultimately led to the work contained in this thesis. Secondly, I would like to thank the people who took time to discuss with me their perceptions of the topics contained herein, specifically Dr. Jerry Hamelink, Ralph Damato, and James Moskalik. I also thank the members of my graduate committee, Dr. Jerry Hamelink, Dr. Dennis VandenBrink, and Dr. Judah Ari-Gur, for taking the time to review my work. I would particularly like to thank Dr. Ari-Gur for helping winnow the wheat from the chaff and bring some cohesiveness to the broad subject material I am presenting. His help in coalescing my ideas into something substantive has been invaluable. Lastly, I would like to thank my wife, Teresa, for having the patience to watch me sit in front of a CRT and tap keys night after night, with nothing but this stack of paper to show for it. Andrew J. Moskalik ii Reproduced with permission of the copyright owner. Further reproduction prohibited without permission. INFORMATION TO USERS This manuscript has been reproduced from the microfilm master. 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Further reproduction prohibited without permission. TABLE OF CONTENTS ACKNOWLEDGMENTS............................................................................................. ii CHAPTER I. INTRODUCTION.............................................................................................. 1 Background ................................................................................................... 1 Areas o f Advancement in Design .............................................................. 3 Relationships Among Design Subfields .................................................... 4 II. DESIGN THEORY AND METHODOLOGY.............................................. 7 Descriptive Models...................................................................................... 7 Protocol Analysis............................................................................... 8 Creativity in Design ........................................................................... 10 Prescriptive M odels..................................................................................... 11 Taxonomies................................................................................................... 13 Analysis Methodologies .............................................................................. 15 Conceptual D esign ............................................................................. 16 Optimization....................................................................................... 16 Design Representations .............................................................................. 17 Issues in Design Theory .............................................................................. 19 Design Science? ................................................................................. 19 Social Issues........................................................................................ 21 Response of Industry to Design Theory......................................... 22 Future of Design Research......................................................................... 24 III. LIFE-CYCLE DESIGN AND CONCURRENT ENGINEERING 27 Design for Manufacture and Assembly ..................................................... 27 iii Reproduced with permission of the copyright owner. Further reproduction prohibited without permission. Table of Contents—Continued CHAPTER Life-Cycle Design ......................................................................................... 28 Concurrent Engineering .............................................................................. 29 Teams................................................................................................... 30 Cautions................................................................................................ 31 Problems With Life-Cycle Design and Concurrent Engineering 32 Future of Concurrent Engineering and Life-Cycle Design .................... 33 IV. QUALITY METHODS...................................................................................... 36 Methodologies ............................................................................................. 36 Quality Function Deployment........................................................... 36 Failure Modes and Effects Analysis................................................ 37 Taguchi Methods............................................................................... 38 Methodological Comments ............................................................... 39 ISO 9000...................................................................................................... 39 V. DESIGN PROCESS MODIFIERS................................................................... 42 Complex Vs. Simple Products..................................................................