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Learning Objectives
At the end of this session, you will be
able to:
1. Describe at least three ways to test your
projects
2. Describe how prototypes can be used in
testing
3. Categorize potential failures for a design
Testing
How do we know our projects will work?
o When we deliver it?
o For the intended life?
• What is the expected life?
How do we know the project will
function like we want and for the users
intended?
How do we know we are meeting the
right needs?
Testing
Designers have to know that their
design will function
o Plan testing along the way
Tests look at
o Function – does it perform like we intended
• Under what conditions?
o User testing – does it meet needs
• Can people use it as intended
“Fail quickly and cheaply”
Prototyping….rough, quick, very
interative
o IDEO working with Gyrus ACMI to
design new apparatus for
operating on delicate nasal tissues
o Prototype:
http://cataligninnovation.blogspot.com/2008/11/prototyping-foundational-competency-of.html
Think, pair, share….
What questions and/or issues need to
be tested for your current project?
Find one or two others to share your
answers
o Introduce yourself
o Describe your project
o Answer the first question
More discussion
Individually
o What tests need to be done on the project?
Share what you answered for your
project with the same person or pair.
Test plans
Create a test plan for your design
o What tests need to be done?
o What will they measure?
o What are the criteria for success and failure?
Test Plans
What will be
tested
Who and/or
where will it
be done
What will be
measured?
Success or
failure
Test #1
Test #2
Test #3
Test #4
Clearly define what will
be done and by whom
Sample Test Plan Template Sharepoint > Teams > Shared Documents > Templates_Tools > Test Plan Template.docx
1 Description of Product
1.1 Components of interest
1.1.1 Dimensions
1.1.2 Photographs
1.2 Specific, important characteristics
1.2.1 Materials, tolerances, limitations
1.2.2 How close is this test vehicle to the expected final product
2 Objectives of Test
2.1 Overall goal (characterization, optimization, test to failure, e.g.)
2.2 Specific parameters to be measured
2.3 Target values of outputs
2.4 Test Success Criteria Definition
2.4.1 What new knowledge will you have gained
2.4.2 How will you use the new knowledge
2.4.3 Is the comfort/safety of humans interacting with the product compromised
2.5 Is a redesign required
More Template
3 Equipment List, Test Location
3.1 For every output parameter, there should be a way to measure it
3.1.1 Camera should generally be included to photograph/video the set up, test point execution
3.2 Description of test location
4 Test Procedure
4.1 Define conditions
4.1.1 Normal conditions
4.1.1.1 Static or steady cases
4.1.1.2 Dynamic cases
4.1.2 Failure or emergency conditions
More Template 4.2 Define inputs
4.2.1 Controllable inputs, ranges for each
4.2.2 Uncontrollable inputs
4.2.3 Sorted by least risk points being executed first
4.3 Define outputs
4.3.1 Pretest predictions
4.3.1.1 Analytical equations
4.3.1.2 Noted assumptions, unknowns
4.3.2 How to measure the outputs in test
4.3.2.1 Notable stopping points
4.3.2.1.1 increasing risk of damage to test vehicle or persons interacting with test vehicle
4.3.2.1.2 limits of measuring equipment
4.4 Step-by-step procedure for each test point
4.4.1 Equipment set up and calibration
4.4.2 Test vehicle preparation
4.4.3 Initial condition definition, set, measured
4.4.4 Test point execution
4.4.5 Outputs measured
4.4.6 Outputs recorded
4.4.7 Selection of next test point
4.4.7.1 Pass/fail criteria defined
5 Outbrief
5.1 Percentage completion of test points
5.1.1
5.2 New knowledge gained
5.3 Redesign required?
Discussion
In your pairs or groups, identify one test
that was proposed and develop the
who, what, where, why and the success
criteria
Test tips
User testing and prototypes
Component tests
o Small parts that are demonstrated can help
hold the team accountable
Fit and form tests
Simulate usage
o Walked on the Martian surface
Use Cases – software
o Build a case or example of how to use the
design and see if it works correctly
DFMEA Steps
1. Review the design
2. Brainstorm potential failure modes
3. List potential effects of failure
4. Rank failures a) Severity
b) Occurrence
c) Detection
d) RPN = Severity X Occurrence X Detection
5. Develop action plan
6. Implement fixes
7. Revisit potential failure risks
Rate failures
Rating
(1 to 10)
Severity How severe are the
consequences to
the failure
Occurrence
How often are the
failures likely to
occur?
Detection How easily are the
failures detected?
DFMEA Calculations
Scores for Severity, Occurrence and
Detection
o 1 to 10
o 1 = Low
o 10 = High
Risk Priority Number (RPN)
o RPN =Severity X Occurrence X Detection
Continue the process
Implement the plan to eliminate the
failure scenario
Revisit other potential failure risks
o Prioritize
o Eliminate failure scenarios
Continue until risks are below
determined thresholds
o Show to the design reviews for
confirmation
Can we get rid of all failures?
All cars have brakes that will eventually
fail
o Potentially catastrophic
o Early warning squealers to notify
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