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ME250: Project

ME 250: Design & Manufacturing I

School of Mechanical Engineering

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The Design Process

What is design?

Make something new How do the engineers design?

Start from need

Find the solutions

Estimate which solution is the best

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The Design Process

Technical skills Other human activities

Cognition Creativity Personal discipline Interpersonal relations

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The Design Process

Design requires the synthesis of:

TECHNICAL HUMAN ECONOMIC ENVIRONMENTAL

advanced safety cost material

technology use price machine

convenience recycle

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The Design Process

NEED PHYSICAL REALIZABILITY COMMUNICATION ECONOMIC WORTHWHILENESS FINANCIAL FEASIBILITY

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The Design Process

The design of the Boeing 777 What is a design-build team? What are the critical issues that the design-

build teams had to take into consideration during the project?

What do you learn from the Boeing 777 development project?

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Project

What is your project?

???

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Project

The project is a team effort. Each team will produce and turn in a working prototype of their design, a final written report and give a short oral presentation on the design and manufacturing processes used to create their prototype.

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Final Report Outline1         TABLE OF CONTENTS

1.1      Top Level Section Headings

1.2      List of Figures

1.3      List of Tables

1.4 List of Appendices

2         FOREWORD

3 SUMMARY

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Final Report Outline

4         PRODUCT DESIGN4.1      Concept Design/Generation and

Selection4.1.1      Results of market survey4.1.2      Product specs 4.1.3      Desired design characteristics

emphasized 4.1.4      QFD diagram and results 4.1.5 Sketches of preliminary design

considered

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Final Report Outline

4.2        Detailed Design

4.2.1      Why the final design concept was selected

4.2.2      Final Design Concept Sketch

4.2.3      CAD Drawings

4.2.4      GANTT Chart

4.2.5      Changes described, if any

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Final Report Outline

5          PRODUCT MANUFACTURING5.1      Manufacturing Process Plans-Prototype and

Production5.1.1      Manufacturing Resource Description5.1.2      Process Plans including process

parameters5.1.3      Assembly requirements (if needed)5.2      Prototype Manufacturing Details5.2.1      Cutter path generation5.2.2      Prototype fabrication methods5.2.3      Special requirements

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Final Report Outline

6         COST AND OTHER ISSUES

6.1      Prototype cost estimate

6.1.1      Cost estimates based on supplied data

6.2      Production cost estimate

6.2.1      Cost estimates based on supplied cost data on materials, tooling and mass production methods

7 DISCUSSION AND RECOMMENDATIONS

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Final Report Outline8         REFERENCES8.1      All coursepack pages, handbooks,

data, internet sources used for information

9         ACKNOWLEDGEMENTS9.1      Sources of information/help not

covered in 8.110         APPENDIX10.1      Sketches of all concepts, toolpaths,

other supplementary items you have referred to in the main body of the report.

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Teams

What is a team?“A team is a small number of people with

complementary skills who are committed to

a common purpose, performance goals, and

approach for which they hold themselves

mutually accountable.”

(Katzenbach and Smith, 1993)

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Teams

What are the habits of effective teams? Positive Interdependence

Mutual goals and rewards. Defined and assigned roles

Individual Accountability Measure the quality and quantity of member contributions

Face-to-Face “Mutual Promotion” Interaction Helping, sharing, and encouraging efforts to produce. “There is enough pie for everyone” – Crazy Pete

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Teams

Interpersonal and Small Group Skills Exercise social skills: activity, constructive

decision making, trust building, open communication, conflict management

Group Processing Groups should take specific time to discuss how

well they are achieving their goals and maintaining their relationships

(Johnson and Johnson, 1993)

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Team Development

5 Phases of Team Development Forming Storming Norming Performing (Success Phase) Adjourning

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Forming

When the team first comes together. The team can form if the team members

Exchange contact information State their individual interest level in the

course Share their personal goals for the team

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Storming

The least comfortable part of team development : Power struggle Picking well-understood team member

roles is one way to get pass the storming stage because team roles align individual goals with team goals.

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Norming

The group gets together and decides how it will function, establishing norms how good a job it really wants to do and what to do about people who do not perform.

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Performing

Everyone is working together toward a common goal.

Trust and respect between individuals has been established.

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Adjourning

When the team has completed its task. If all the stages of team development

have gone well, the team members will want to thank each other for the experience of working together.

The quicker you get to the norming phase, the more quickly you will become an effective team!

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Effective Team Meeting Introduction Promptness Review Agenda Communication Only accept jobs you can complete Complete all jobs you accept Seek an even partition of work on the team Be on time to team meetings Stay focused at team meetings Do not compete with your team member Do not ignore conflict Direct criticism at ideas, objects, or actions, not at an individuals

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Team Member Roles

In an effective team, work is organized to support the team’s function and everyone contributes equally without much overlapping effort.

Team member roles should be selected at the first team meeting. Leader Recorder CAD coordinator Manufacturing coordinator

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Teamwork Grading

In general, every student in a given team who signs and dates the final report will get the same grade. However, in exceptional cases the grade of an individual may be different, if there are clear evidence that he or she has not contributed.

You will do a member evaluation to evaluate the contribution of other members.

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From the Tao Teh Ching to the Leader

太上，不知有之；其次，亲而誉之；其次，畏之；其次，侮之。信不足焉，有不信焉。悠兮，其贵言。 功成事遂，百姓皆谓“我自然” 。

（道德经，第十七章） (Lao Tzu, ~350-250 B.C.)

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From the Tao Teh Ching to the Leader

To lead people, walk behind them.As for the best leaders, the people

do not notice their existence. The next best, the people honor and praise. The next, the people fear, and the next the people hate.

When the best leader’s work is done, the people say “we did it ourselves!”

(Lao Tzu, ~350-250 B.C.)