Design Support Using Distributed Web-Based AI Tools

Currently, designers are faced with searching through a ‘sea’ of on-line knowledge to support their decision making activities. This paper describes WebCADET, which is a reimplementation of the stand-alone CADET – a Knowledge-Based System (KBS) for product design evaluation. WebCADET aims to provide effective and efficient support for designers during their searches for design knowledge. WebCADET uses the ‘AI as text’ approach, where KBSs can be seen as a medium to facilitate the communication of design knowledge between designers. The development of WebCADET to include practical support via World Wide Web-based functionality, which illustrates the potential of the ‘AI as text’ approach, is described in the paper.     

A Subjective Design Framework for Conceptual Design of Polymeric Processes with Multiple Parameters

Polymer processes are in general difficult to model, especially because of coupling between process conditions, polymeric behaviors and geometries. Arising from high thermal gradients, non-Newtonian viscous behaviors and non-linear pressure effects, polymer processing is not well described mathematically. A conceptual design methodology is proposed formally as a useful tool for treating polymeric processes with multiple performance parameters on a structured design platform. Without resorting to engineering models, this approach deals with the initial selection of process conditions within a three-stage framework: (1) qualitative design; (2) process modeling; and (3) quantitative design. Based on subjective reasoning, this procedure makes it possible to account for one’s prior experience, and incorporate it into the process development. The notion of conceptual robutstness is introduced to ensure deesign quality in the early-stage process development. A case study of compression molding is illustrated in a step-by-step manner.     

Arrow's Theorem and Engineering Design Decision Making

This article establishes that Arrow”s General Possibility Theorem has only indirect application to engineering design. Arrow”s Theorem states that there can be no consistent, equitable method for social choice. Many engineering design decisions are based on the aggregation of preferences. The foundation of many engineering decision methods is the explicit comparison of degrees of preference, a comparison that is not available in the social choice problem. This explicit comparison of preference levels is coupled with the choice of an aggregation method, and some forms of aggregation may be inadequate or inappropriate in engineering design.     

A Study on Engineering History Base

During engineering processes, many kinds and amounts of information are used and produced. Such information is useful in successive cases, and thus its reuse is desired. In this paper, information on attributes of the products is referred to as ‘product information’, and information on the reasons for and/or history of a designer’s thought process is referred to as ‘process information’. According to this classification, process information can be used for obtaining an explanation of product information. The purpose of this work is to build a database, called an ‘engineering history base’, from which engineers can retrieve explanations to enable the reuse of product information. In this paper, explanation from the ‘process’ viewpoint is thought to be important in promoting the reuse of product information. There are two types of explanation for the process: teleological and causal. However, until now, little attention has been paid to the causal explanation for the process. Thus, in this paper, an information model which focuses on both types of explanation is proposed. The model is adopted for the engineering history base and a prototype system is developed. The appropriateness of this model is discussed by analyzing the actual data in the development of a color video printer.     

Structure and Matrix Models for Tolerance Analysis from Configuration to Detail Design

A substantial amount of all quality problems that arise during assembly can be referred back to the geometrical design, and especially the geometrical concept of the product, i.e. the way in which parts are designed and located with each other. Special emphasis should thus be put on geometry design, especially during the early design phases, to try to find robust concepts and avoid solutions that may cause down-stream production problems.  This paper presents a generic set of evaluation tools for robust geometry design encountering (i) potential tolerance chain detection in configuration design, (ii) assembly robustness evaluation in concept design, and (iii) tolerance sensitivity analysis in detail design. Special attention is given to the development of a new matrix-based evaluation tool for the configuration design part. The tool presented is based on a new way of representing geometry variation constraints in an enhanced function-means tree structure model. Different parts of the function-means tree that are of interest for analysis purposes are then extracted and converted to matrix representation. The reason for doing this is that the structure model is most suitable for modeling, but becomes unsuitable for analysis as the model complexity increases. For this latter purpose, the matrix representation is far better. The use of the different tools is demonstrated in the design of a new vehicle front system for which the geometry a priori is unknown.     

Tuning Parameter Tolerance Design: Foundations, Methods, and Measures

In this paper, a novel technique is presented to solve tolerance design problems. To achieve the desired performance tolerance, the technique uses a subtle, but significant, change in the design: the addition of a tuning parameter in place of an increase in component precision. Statistical models are used to develop a framework for the tuning parameter design method. Also developed is a new, dimensionless design metric which ranks candidate tuning parameters. A step-by-step method is developed for the application of tuning parameters using this metric. The step-by-step tuning parameter design method is applied to a heavy-duty manual stapler as a clarifying example.     

Observations on Some German Contributions to Engineering Design In Memory of Professor Wolfgang Beitz

This paper, written in memory of Professor Wolfgang Beitz, discusses some of the influences of the work undertaken in Germany on systematic engineering design. It highlights differences between the language regions, and gives examples of design research and design education linked to Konstruktionslehre– the standard text on systematic engineering design for which Professor Beitz was most widely recognised outside Germany. The paper finishes with a plea for a greater exchange of ideas.     

Framework for Modeling Dependencies in Collaborative Engineering Processes

This article describes an engineering process representation and modeling tool. The approach is especially suitable for describing large-scale, mature design processes involving numerous tasks, some of which may be performed by automated computer agents. The underlying representation is a graph of information-processing units with explicitly defined input and output feature elements. We show that this representation is more complete than those used in previous process modeling approaches and overcomes some of their limitations when dealing with design processes involving dependencies at multiple levels of detail. The representation is combined with rules for automatically operating upon the graph to preserve consistency when traversing to higher or lower levels of detail.     

Computing the Information Content of Decoupled Designs

The information content of uncoupled designs can be computed by summing the information content associated with each functional requirement. This paper proves that information cannot be summed for decoupled designs. To overcome this problem, this paper presents two algorithms for computing information content of decoupled designs. One algorithm is applicable to any joint probability density function for the design parameters; the second algorithm applies only to uniformly distributed design parameters. The algorithm for uniform distributions is based on a recursive procedure for computing the volume of a convex polytope in n -dimensional real space, where n is the number of design parameters. An engineering application of the algorithms is presented. The example demonstrates that summing information content can significantly over-estimate total information when compared to an algorithm that accounts for correlation. The example also demonstrates that decoupled designs can have lower information content than uncoupled systems with the same functional requirements and similar components.     

On the Influence of Functional Materials on Engineering Design

To obtain a better understanding of how to make use of functional materials in engineering design, the design-related behaviors of some of these materials have been analyzed and discussed with reference to a general design procedure model and the design tools currently available. The functional materials subjected to this examination are shape memory alloys, piezoelectric materials and magnetostrictive materials. The discussion has been carried out with a major focus on how benefits might be gained by selecting the functional material and utilizing complementary design tools at an early stage of the design process.     

‘Signposting’, A Parameter-driven Task-based Model of the Design Process

This paper addresses the need for computer support in aerospace design. A review of current design methodologies and computer support tools is presented, and the need for further support is discussed, with particular reference to the early formative stages of the design process. A parameter-based model of design is proposed, founded on the assumption that a design process can be constructed from a predefined set of tasks. This is supported by knowledge of possible tasks in which the confidence in key design parameters is used as a basis for identifying, or signposting, the next task. A prototype implementation of the signposting model, for use in the design of helicopter rotor blades, is described and results from trials of the tool are presented. Further areas of research are discussed.     

Developing Strategic Alliances: A Framework for Collaborative Negotiation in Design

This work applies a theory-based framework of collaborative negotiation to some of the disputes that regularly arise during group design. Although the framework was developed to provide general support for group work, this paper focuses on its use as a design tool. The framework, embodied in our system NegotiationLens, has four facets. It: 1. Provides a negotiation method intended to produce gain for all parties. 2. Provides an efficient process for conflict resolution. 3. Develops working alliances. 4. Lets parties decide quickly when they should go their separate ways. The framework produces the above results by: • Helping parties develop well-reasoned and clearly articulated points of view (Adelson and Jordan, 1991; Conklin and Yakemovic, 1991; Conklin and Begeman, 1988; MacLean et al ., 1991). • Creating a context of committment and respect. • Moving negotiating parties away from an adversarial stance and into a collaboration. • Allowing joint construction of solutions that are more beneficial than the unilateral solutions each party initially brought to the table. We present our framework for collaborative negotiation, describe NegotiationLens, and present two cases in which it was used. We present a third case, a large design project with recurrent design conflicts, and argue how NegotiationLens could have been of benefit there.     

A-Design: An Agent-Based Approach to Conceptual Design in a Dynamic Environment

This paper provides an introduction to a new design methodology known as A-Design, which combines aspects of multi-objective optimization, multi-agent systems, and automated design synthesis. The A-Design theory is founded on the notion that engineering design occurs in interaction with an ever-changing environment, and therefore computer tools developed to aid in the design process should be adaptive to these changes. In this paper, A-Design is introduced along with some simple test problems to demonstrate the capabilities of different aspects of the theory. The theory of A-Design is then shown as the basis for a design tool that adaptively creates electro-mechanical configuration designs for changing user preferences.     

Influences on Solution Search Processes in Design Organisations

A study was conducted of what influenced solution search activity in three design organisations. The influences were analysed in terms of how they affected search, whether their effect tended to be conservative or innovative, and the directness of the evidence they provided. Overall, the environment was found to provide more innovative influences than conservative ones. Innovative influences were mostly connected with the triggering of search activity, while conservative influences were mostly linked with restricting the search space of potential solutions. Also, search candidates were often evaluated in terms of their associations rather than their intrinsic merits, and ultimately this makes human judgment an essential component of search and evaluation activity. Finally, the environment provides many ‘seeds’ for effects like design fixation and functional fixedness but also provides strong incentives to positively avoid these effects.     

Evaluation of Product and Process Design Robustness

Critical design decisions are commonly made throughout the product development process assuming known material and process behavior. However, stochastic variation during manufacture can inadvertently result in inferior or unacceptable product performance and reduced production yields. Stochastic simulations have been developed to estimate the end-use performance distribution prior to the commitment of hard tooling. This article proposes a definition for integrated product and process robustness, and extends existing stochastic methods to model the important role of the manufacturing flexibility in elimination of defects and product optimization. The goal is to enable the designer to understand and account for not only the negative effects of manufacturing variation, but also the positive impact of manufacturing flexibility wherein instantaneous corrections in the manufacturing process can frequently improve the product quality and eliminate flaws in the product design. Then, a methodology is introduced and contrasted with conventional development methods in the evaluation of best practices for development of a molded plastic component.     

A Mathematical Framework for the Key Characteristic Process

To maximize product quality, a product design team selects concepts and dimensions to minimize a product’s sensitivity to variation. However, even for the most robust products, it is rarely possible to transition a product into production without encountering any variation-related problems. In a complex product, it is not economically or logistically feasible to control and/or monitor the thousands of tolerances specified in a product’s drawing set. To address this problem, many organizations are using Key Characteristic (KCs) methods to identify where excess variation will most significantly affect product quality, and what product features and tolerances require special attention from manufacturing. As simple as this principle seems, most companies struggle to effectively implement KC methods because no quantitative methods to prioritize KCs exist. This paper develops a mathematical definition of a KC based on a variation propagation model. In addition, it develops a quantitative effectiveness measure used to prioritize where verification, variation reduction, and on-going monitoring should be applied. The effectiveness measure incorporates the cost of control, the benefit of control, and the expected change in process capability. The methods are illustrated using an automotive door assembly.     

Coordination Approaches and Systems – Part II: An Operational Perspective

This is the second of two papers surveying research in coordination approaches and systems. This paper is concerned with operational coordination, which is aimed at coordinating activities such that the design process can be performed in a near optimal manner with respect to time, and the allocation and utilisation of resources. Aspects of coordination categorised as operational include resource management, scheduling and planning. The first of these two papers presents a review of coordination from a strategic perspective, which is concerned with the decision management aspects of coordination. Greater emphasis is now being placed on the significance of organising the design process as this affects time to market, product quality, cost, and consequently product success. The aim of this paper is to present a fundamental review of operational coordination approaches and systems. The 1990s has seen much progress being made towards a greater understanding and appreciation of coordination in various disciplines through the development of a wide range of approaches and systems. However, there remains a requirement to formally identify the key issues involved in coordination such that a widely accepted representation can be agreed upon. Consequently, research should continue to be supported in the exploration for a unified approach to coordination which will permit a broader and greater understanding of those aspects involved.     

A Theory of Complexity, Periodicity and the Design Axioms

One of the topics that has received the attention of mathematicians, scientists and engineers is the notion of complexity. The subject is still being debated, as it lacks a common definition of complexity, concrete theories that can predict complex phenomena, and the mathematical tools that can deal with problems involving complexity. In axiomatic design, complexity is defined only when specific functional requirements or the exact nature of the query are defined. Complexity is defined as a measure of uncertainty in achieving a set of specific functions or functional requirements. Complexity is related to information, which is defined in terms of the probability of success of achieving the Functional Requirements (FRs). There are two classes of complexity: time-dependent complexity and time-independent complexity. There are two orthogonal components of time-independent complexity, i.e., real complexity and imaginary complexity. The vector sum is called absolute complexity. Real complexity of coupled design is larger than that of uncoupled or decoupled designs. Imaginary complexity can be reduced when the design matrix is known. As an example of time-independent imaginary complexity, the design of a printing machine based on xerography is discussed. There are two kinds of time-dependent real complexity: time-dependent combinatorial complexity and time-dependent periodic complexity. Using a robot-scheduling problem as an example, it is shown that a coupled design with a combinatorial complexity can be reduced to a decoupled design with periodic complexity. The introduction of periodicity simplifies the design by making it deterministic, which requires much less information. Whenever a combinatorial complexity is converted to a periodic complexity, complexity and uncertainty is reduced and design simplified.     

Building Agility for Developing Agile Design Information Systems

Agile manufacturing relies heavily on the quality of information that organizations have and on their ability to organize and reuse it. Constant inflow of information and knowledge is the fuel of agile manufacturing. In the process of forming virtual enterprises, these new organizations have to be equipped with information systems that integrate their present legacy technology and improve upon it. To support the quick formation of virtual organizations, one must have the ability to develop such systems quickly. Over the past few years we have evolved, through collaborative projects with industry, an approach composed of methods and an information infrastructure called n-dim that improves the ability of becoming agile manufacturers of information systems, by responding quickly to information needs of new and evolving organizations. Following an analysis of the requirements of information systems for agile design, we discuss this approach; describe some of the infrastructure features; and present several examples of simple applications that illustrate them. We summarize by discussing the advantages and limitations of our approach.     

Improving Systems by Combining Axiomatic Design, Quality Control Tools and Designed Experiments

This paper presents an approach for solving design problems in existing designs. A design analysis with Axiomatic Design, called Design Object Analysis, describes a product or a system in terms of Customer Needs (CNs), Functional Requirements (FRs), Design Parameters (DPs) and Process Variables (PVs), as well as their associated Design Matrices (DMs). In this paper, the design analysis is combined with a thorough investigation of possible problems within the design, utilizing the seven quality tools, noise factor analysis, and designed experiments to form an approach for quality improvements and problem solving. The Design Object Analysis helps secure valid input-factors to the designed experiments, and the designed experiments correct or improve the assumptions made in the Design Object Analysis. Thus, a combination of product modeling by Axiomatic Design and designed experiments overcomes shortcomings of the two methods. The benefits of performing a Design Object Analysis, as compared to other methods, become clear when it comes to evaluating the results from the designed experiment, and preventing the problem. Once the critical parameters are confirmed, and the design matrices are updated, suggested design improvements can then be checked against the design matrices, and the system effect of a design-change-order can be estimated. The approach described in this paper was successfully applied and verified in a case study at a large automotive company.