2B rescheduled - WPI Workshop on Axiomatic Design 2010

7:00-8:15 breakfast
7:30 registration and coffee - location of sessons TBA
8:15 welcome - Brown
8:30 parallel sessions I
    I.1 Intro to Axiomatic Design - Richard 
    I.2 Axiomatic Design of Safe Interfaces for People and Machines – Brown
    I.3 TBA
10:00 morning break, coffee, pastries
10:30 parallel sessions II
    II.1 Decomposition Rules - Towner
    II.2 Axiomatic Design of Surface Metrology Systems – Brown
    II.3 Case Study - Design of Sustainable Systems to Become Lean - Cochran
12:00 lunch
1:30 parallel sessions III
    III.1  Understanding the Customer Domain - Richard
    III.2  Reducing Software Development Lead Times by 50% with Functional Requirements Analysis -Pallaver
    III.3  Using Acclaro - Carignan
3:00 afternoon break
3:30 parallel sessions IV
    IV.1 Case Studies in Consumer Product Development - Howell
    IV.2 Axiomatic Design of Transactional Processes - Dickinson
    IV.3 Axiomatic Design of Thin Film Manufacturing Processes  - Bathurst
5:00 reception and  group design exercise on health care cost control - Towner  & Bergstrom
6:00 dinner - short plates & high tables - promotes networking and working on the group exercise
8:00 evening program - concluding design review - Towner
9:00 end


7:00-8:30 breakfast
8:00-8:30 registration and coffee - WPI Campus Center - location of sessons TBA
8:30 parallel sessions V
    V.1 Basic Elements of Axiomatic Design - Bergstrom and Brown
    V.2 Case Studies in Consumer Product Development - Howell   
    V.3 Axiomatic Design of Thin Film Manufacturing Processes  - Bathurst
10:00 morning break, coffee, pastries
10:30 parallel sessions VI
    VI.1 Applications of AD to Innovation in Product Design and Feedback Control System Design - Deo  
    VI.2 Axiomatic Design of Safe Interfaces for People and Machines – Brown
    VI.3  Sustainable Enterprise System Design part 1 - Cochran
12:00 lunch
1:30 parallel sessions VII
    VII.1 Mechanical Design Case Studies - Bergstrom and Dickinson
    VII.2 Conducting a Design Review - Towner and Brown
    VII.3 Sustainable Enterprise System Design part 2 - Cochran
3:00 afternoon break
3:30 parallel sessions VIII
    VIII.1 Solutions to AD Process Problems - Brown
    VIII.2 Understanding the Customer Domain - Richard
    VIII.3 TBA
5:00 concluding remarks - Brown



Session Descriptions

Axiomatic Design of Thin Film Manufacturing Processes  - Bathurst

Case Study: Thermal Ink Jet Printing of PZT
Many groups have worked to incorporate thin film lead zirconate titanate (PZT) into a wide range of devices including: actuators, energy harvesters, resonators, pressure sensors, pumps, nano-positioning stages, and MEMS switches. However, the use of PZT has been limited in many MEMS designs due to the coupled nature of the standard spin coating process. Not only is spin coating inherently wasteful of the expensive PZT solution, but it prevents the deposition of PZT films on non-planar substrates and requires difficult, low yield, patterning. Direct printing of PZT thin films eliminates the need for photolithographic patterning and etching, allows for controlled deposition over non-planar topographies, and enables the fabrication of devices with varying thickness. This case study focuses on the Axiomatic Design based coupling analysis that lead to the selection of a dot on demand deposition process as the best manufacturing solution for small volume MEMS products. Furthermore, it highlights the various ways in which Axiomatic Design principles guided the development of this new deposition process, ultimately resulting in a new PZT deposition process.

Introduction to Axiomatic Design - Richard

A primer for those new to the AD methodology.  Covers the key elements including the Axioms, the design matrix, evaluation of existing designs and design optimization processes.  Practical examples and exercises to fully absorb basic concepts.  back to top of schedule

Applications of AD to Innovation in Product Design and Feedback Control System Design - Deo

This session will begin with a case study of Axiomatic Design of customizable automotive suspension systems. The coupling in existing suspension systems that is manifested by the conflicting requirements of comfort and handling will be highlighted and several approaches to eliminate this coupling will be discussed. The case study will highlight application of Axiomatic Design in innovation, product design and design of feedback control systems.  This will be followed by an instructor-led exercise in product design. The specific problem will be selected based on interest of the participants.  back to top of schedule

Reducing Software Development Lead Times by 50% with Functional Requirements Analysis - Pallaver

Axiomatic design techniques create a framework for analyzing and optimizing software system requirements.  The presentation will review the process and tasks used to define the requirements architecture and risk mitigate a problem tracking IT system resulting in development effort reductions of more than 40%.  back to top of schedule

Case Study - Design of Sustainable Systems to Become Lean - Cochran

Collective System Design (CSD) uses Axiomatic Design to express the logical design of a system.  This case study shows how the Unit Cost Equation creates unnecessary bias in the development of manufacturing systems.  In fact, the design parameters that result from the use of the Unit Cost Equation leads companies to develop:  DP1: high speed, DP2: automated systems in DP3: low-wage countries.  This false thinking is leading to the demise of the U.S. Industrial base.  Axiomatic Design provides an unbiased method for creating the logic that is necessary to implement sustainable systems.  Collective System Design provides a methodology to enact change and provides the managerial accounting foundation to make appropriate decisions.  Dr. Cochran’s Shingo-prize winning research will be used to illustrate this narrative of how to design sustainable systems - that are lean.

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Sustainable Enterprise System Design Workshop parts 1 and 2 - Cochran

The INCOSE definition of Systems Engineering, “is an interdisciplinary approach and means to enable the realization of successful systems. It focuses on defining customer needs and required functionality early in the development cycle, documenting requirements, and then proceeding with design synthesis and system validation while considering the complete problem:  operations, performance, test, manufacturing, cost and schedule, training and support, and disposal.  Systems Engineering integrates all (of) the disciplines and specialty groups into a team effort forming a structured development process that proceeds from concept to production to operation. Systems Engineering considers both the business and the technical needs of all customers with the goal of providing a quality product that meets the user needs http://www.incose.org/practice/whatissystemseng.aspx”

Collective System Design (CSD) enhances Systems Engineering.  The intended purpose of CSD is to design effective, sustainable systems that are lean.  Sustainable systems are more than just green (Werbach, 2009, p.12).  This mini-workshop challenges the participants to really start with understanding customer needs and the boundary of a system prior to defining objectives and/or measures.  Dr. Cochran will define system-design principles for sustainability.  These principles will be used during the workshop to develop a sustainable manufacturing system.  Axiomatic design will be used to cascade customer needs to system Functional Requirements (FRs).  A physical simulation will be used to work-out the details of the Physical Solutions (a.k.a., Design Parameters – Suh, 2001) that are required to achieve the FRs in an uncoupled way.

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 Using Acclaro - Carignan

Understanding the Customer Domain - Processing Voice of Customer to Strategic Advantage  - Richard

Developing a product from concept to commercialization continues to be a challenge for many organizations under pressure from financial and competitive forces.  Executing on the wrong project due to an in adequate understanding of customers and be devastating.  Developing a comprehensive, prioritized interpretation of customers needs focuses the design process on functional requirements of significant value.  A description of the key steps and tools involved in developing the customer domain as well as common problems and examples for discussion will be covered. back to top of schedule

Case Studies in Consumer Product Development - Howell   

Rick Howell’s approach to consumer-product development will be outlined utilizing real case study material from snowshoeing and clipless bicycle pedaling.  Discussion will include (1) axiomatic-derived identification of consumer-needs pertaining to functional requirements; (2) deriving an axiomatically-generated “re-positioning” consumer advertising platform, before  (3) developing the design parameters of the product.  This sequence, uniquely developing the advertising platform prior-to developing the product, insures product definition matches customer-needs as well as maximizing manufacturing process requirements, including cost, lead-time and product-durability—in a way that causes explosive and sustained revenue while significantly expanding the entire category within which the target-customer operates.  Howell will decompose top-line consumer needs, marketing strategy, product-definition and manufacturing-planning—utilizing the fundamental principles of axiomatic design.  back to top of schedule

 

Basic Elements of Axiomatic Design – Bergstrom and Brown

This is intended for two groups: one, for beginners as an introduction to axiomatic design, and two for those who would like to teach axiomatic design as an instructional method.  Axiomatic Design is decomposed into three elements: axioms, structure, and process.  These are further decomposed into two components: independence and information, domains and hierarchy, decomposition and integration.  The basics of the use of these components are covered and the relations between these elements are developed.  Beginners will learn the basics of applying axiomatic design by doing decompositions, using design matrices, and calculating information content. back to top of schedule

Conducting a Design Review – Towner and Brown

This is intended for designers and managers to improve the value adding process during design reviews.  Design reviews can be costly in terms of time.  There should be a return as value added to the design and to the knowledge base.  Value in the design process and in the knowledge base will be defined in terms of Axiomatic Design.  Progress monitoring during the design review will be explained.  Techniques for managing design reviews will be discussed.  back to top of schedule

Axiomatic Design of Safe Interfaces for People and Machines – Brown

Case studies in the design of ski and snowboard bindings will be developed to show how to decouple control loads from potentially injurious loads to people and damaging loads to machines.  These case studies will include user exercises and discussions to explain how the lessons can be applied to other systems.  Existing systems will be critiqued.  The exercises will include applications of axiom one and two. back to top of schedule

 

Axiomatic Design of Surface Metrology Systems – Brown

Solutions to design problems in surface metrology will be developed as exercises and discussed. Although they will cover applications to measurement and characterization, they can easily be generalized to apply to other systems. Axiom one will be applied quantitatively to the controls for a scanning laser profiler will be reviewed to show how to avoid imaginary complexity in existing designs.  Axiom two will be applied to the selection of instruments and characterization parameters. back to top of schedule

 

Decomposition Rules – Towner and Brown

This is intended for beginners and for anyone who has had difficulties with decomposing a design.  An essential element to developing a good design is a good decomposition.  The basic rules for a good decomposition will be discussed.  Typical problems and solutions will be presented.  Participants will get experience attempting and critiquing decompositions.  back to top of schedule

Mechanical Design Case Studies – Bergstrom and Dickinson

This is intended provide examples in axiomatic design for those who have some basic knowledge in axiomatic design or who have at least attended and introductory lecture. A simple adjustment and locking mechanism for an automotive steering column is examined and students will be challenged to build a top-level design matrix and identify if coupling exists.Common elements in mechanical designs will be presented and illustrated with several case studies.  Translating the mechanical elements into other applications will be discussed. back to top of schedule

Axiomatic Design of Transactional Processes  - Dickinson

Transactional (or administrative) processes can suffer similar problems as hardware and manufacturing processes when designed as coupled systems.  This presentation examines two examples of application of Axiomatic Design to transactional processes.  The first describes the design of a technical education program for a global company with widely distributed and time-constrained resources.  The second examines a typical product design process (PDP) in an engineering department.  In both cases, students will learn through active participation in the FR-DP decomposition, based on their own experiences. back to top of schedule

 

Solutions to Common AD Process Problems – Brown

This is intended to help designers and managers recognize and address common problems that hamper the progress of the axiomatic design process.  After an energetic introduction to Axiomatic Design users run into problems that stops their progress and damps their enthusiasm, which often leads to abandoning AD.  The roots and symptoms of common problems are discussed.  Effective treatments are presented. back to top of schedule