ENGINEERING TEAM PROJECT (ETP)

Code : MCB3053
Facilitator:
Dr. Syed Ihtsham-ul-Haq Gilani
Mechanical Engineering Dept.

3rd. June, 2015

TOPICS

Introduction to engineering design

Engineering design process
Implementation of Engineering
Principles in ETP design.
Group management
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Project Management

Your expectations of UTP & ETP

Get good grades
Try new ideas
Getting your hands dirty

Experience working in a team

Have fun!!

Color your CV - medals /papers

LEARNING OUTCOMES of ETP

1.

Apply engineering knowledge and solve engineering

design problem.

2.

Work in a multi disciplinary team-based project work.

3.

Apply the principle of project management.

4.

Apply proper design process to produce creative and

innovative solution.

5.

Demonstrate effective communication, report writing,

presentation and entrepreneur skills.

Engineering is...
the profession in which a knowledge
of mathematics and natural sciences
gained by study, experience, and practice
is applied with judgment to develop
ways to utilize, economically, the
materials and forces of nature for the
benefit of mankind."
(ABET) Accrediting Board for Engineering and Technology
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STAGES OF MAIN ETP ACTIVITIES

Commencement of Project

Design

Fabrication

Presentations

Introduction
What is design ?
Websters dictionary says, to fashion after a plan
Another definition says, design is the essence of
engineering
Actual definition would be,
Design establishes and defines solutions to and
pertinent structures for problems not solved
before, or new solutions to problems which have
previously been solved in a different way
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DESIGNING YOUR PRODUCTS

Putting ideas on papers

Concept finalized. Whats next?

Design your product (then fabricate)
Make use of all the engineering & nonengineering knowledge.
Dont Just Do It

The Four Cs of Design

Creativity:
Requires creation of something that has not existed before
or has not existed in the designers mind before
Complexity:
Requires decisions on many variables and parameters
Choice:
Requires making choices between many possible solutions
at all levels, from basic concepts to the smallest detail of
shape
Compromise:
Requires balancing multiple and sometimes conflicting
requirements

Whats wrong with these?

Whats wrong with these?

Basic module in the design process

Example (Design of a Ball pen)

General
information

Specific
Information
size, ink type,
mechanism, etc.

Material, color,
weight, etc.

Design operation

Outcome

Ideas, software,
calculations, etc.

Yes

Evaluation

No

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Purpose and Nature

Science is the search for
knowledge and
understanding
Technology is the
application of knowledge
to satisfy human needs
They are both creative
problem solving
methods!

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Existing knowledge

State of the art

Scientific curiosity

Identification of need

Hypothesis

Logical analysis

Proof

Scientific method

Acceptance

Communication

Comparison between scientific method and

the design method

Conceptualization

Feasibility analysis

Production

Design Method

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The Engineering design process steps

The five steps used for solving engineering design
problems are:
1. Define the problem
2. Gather pertinent
information
3. Generate multiple
solutions
4. Analyze and select a
solution
5. Test and implement
the solution
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Engineering Design Process

Define
Problem
or Need

Does it

work?

Modify &
redesign

Select
& Test

What similar
things
exist?
Research
Investigate
Gather Info

Does
Proof
of

concept

solution

meet need?
Analyze
Evaluate
Solutions

Propose
Design
Solutions

The design process steps

Recognition of a need
Dissatisfaction with the existing system is called need and it is
generated by customer, marketing personnel or consultant etc.

Definition of a problem
A problem should express as specifically as possible what the
design is intended to accomplish. It should also suggest
clearly :
1.
Musts (set of requirements that must be met)
2.
Must nots. (a set of constraints)
3.
Wants (Requirements that are worth starting, but
are not hard and fast)
4.
Dont wants.
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Definition of a problem (Importance)

A user wants a new swing for the children to be placed on the tree

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Needs assessment

The aim is not to solve the problem but to

understand what the problem is

What does this client want?

What is the problem that the design is to solve?

The objectives (goals) and constraints of the

problem should be identified

Objectives: summary of the needs that the design is

to satisfy (helps us to choose among alternative
design configurations)
Constraints: the design must satisfy (takes logical
values 0 or 1, helps to decide acceptable or not)
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The design process steps

Gathering of information
Question the customer

To define the design problem

Where can I find it ? How can I get it ? How accurate
the information is ? Interpretation of the information ?
Any particular decision extracted from the information ?

To understand budget and schedule constraints

Reliability and maintenance constraints

Explore resources

Expertise (knowledge and experience)

Technical literature (books, journals,www)

Measurement and testing equipments (equipment suppliers)

Similar designs (competitors, patent search)

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Conceptualization

what s that

There are no hard and fast rules for a designer. Designs vary at
large, geometrically, functionality and aesthetically, depending
upon the visualization of the designer. Some guidelines for a
novice designer are:
1.

Dont follow traditional design procedures.

2.

Make a complicated design for a component instead making the

whole system a complication.

3.

Make allies of the materials from which you construct the design.

4.

Divide the complex designs into smaller and simple designs.

5.

Keep yourself abreast of developments in physical sciences.

6.

Avoid inventions which are not supported by science or analysis

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The design process steps

Cont,d..

Evaluation
Evaluation is used more in the sense of weighing and judging than
in the sense of grading. Generally evaluation means :

Verification of detailed calculations (manual or computer)

Performance of design by an analytical model.

Simulation of service testing of a model or prototype.

While evaluating a design, two types of checks should be made :

1. Mathematical checks
2. Engineering sense check.
Evaluation of the alternatives, involves :
Cost analysis, in terms of; Labor, Equipment and Payback
Implementation issues
Performance issues
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Morphological Chart and Concept Generation

Morphological Chart

A morphological chart is a
table based on the function
analysis.
On the left side of the chart
the functions are listed,
while on the right side,
different mechanisms which
can be used to perform the
functions listed are drawn.
It is a visual aid used to
come up with different
ideas.
The idea generation is
accomplished by creating
single systems from
different mechanisms
illustrated in the
morphological chart.
It is advised to generate
several feasible designs
using different mechanisms
for each function for each
concept.

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Concepts Generation

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Concept 1

For this concept, by looking at the

morphological chart, the following options
were chosen for the different functions which
govern the mechanism.

Vegetable Picking Device = NONE

Vegetable Placing Device = Option 1
Dirt Sifting Device = Option 3
Packaging Device = Option 1
Method of Transportation = Option 1
Power Source = Option 2

Method of operation: Pull from yokes in ydirection by horse. Front wheels turn belt
which in turns provides torque on blade
shaft. Blade and sifters sort debris from
vegetables. Vegetables are then slung into
carriage compartment where operator
packages product.
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Concept 2
For this concept, by looking at the
morphological chart, the following options
were chosen for the different functions
which govern the mechanism.

Vegetable Picking Device = Option 1

Vegetable Placing Device = Option 3
Dirt Sifting Device = Option 1
Packaging Device = Option 2
Method of Transportation = Option 1
Power Source = Option 2

The idea of this concept stems from modern

potato harvesting equipment. The principle
on which this mechanism operates with is
the fact that vegetables are very close to
the surface. By taking advantage of a plow
the vegetables will be ripped free from the
roots and travel up the plow to the conveyor
system.
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Concept 3
For this concept, by looking at the morphological
chart, the following options were chosen for the
different functions which govern the mechanism.

Vegetable Picking Device = Option 3

Vegetable Placing Device = Option 4
Dirt Sifting Device = Option 3
Packaging Device = Option 4
Method of Transportation = Option 1
Power Source = Option 2

Method of operation: Pulled by horse in the Y

direction. Front wheels turn making the
collecting wheel rotate. Tubes cut lettuce
dragging it against the cart. Once lettuce is
against cart it is guided inside the pipes until the
pipe reaches the upper position. There is a hole
at the bottom of each pipe where lettuce exits.
At this point there is a slide that carries the
lettuce to the back of the cart.
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Concept 4

For this concept, by looking at the morphological

chart, the following options were chosen for the
different functions which govern the mechanism.

Vegetable Picking Device = Option 2

Vegetable Placing Device = Option 4
Dirt Sifting Device = Option 3
Packaging Device = Option 1
Method of Transportation = Option 1
Power Source = Option 2

Method of operation: Pull from support brackets

in y-direction by horse. Plows pull vegetables
up and onto runners, where unwanted debris
falls through gap in middle. Sack is attached to
end of runners and entire unit is tilted back on
wheels to gather vegetables.

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Concept Screening
The concepts arrived upon using the morphological chart are then screened against each other
and against the customer needs. This is done as a preliminary decision matrix to see which
concepts are going to be further analyzed.

Concept Selection

Concept 1

Concept 2

Concept 3

Concept 4

10

10

10

10

Does not require manmade power source

Uses less than $100.00 worth of material other than wood

Can be operated by one person

10

10

10

10

Capable of harvesting several rows of vegetable

simultaneously

10

Does not damage crops

High Storage Capacity

Capable of sifting out excess dirt from vegetables

Simple shapes for ease of construction and replacing broken

parts

Few moving parts to increase lifespan and ease of

manufacturing

Resistant to environmental elements

10

Pre-cools vegetables for storage

Separate storage containers for different types of

vegetables

101

89

87

85

Capable of harvesting several types of vegetables

Useful for other aspects of farming as well as vegetable

collection

Total Points

As a result of detailed analysis, concept one was chosen to be the most compatible with the farmers
needs. Also, model 1 supplied sufficient methods of the wants form the specification table.

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Analysis and Selection

For each concept embodied by using the morph chart, an analysis must be performed in order to
choose one concept. This analysis can be done in a variety of manners. One such way is by using
a CAD tool, such as ProE in this case, to carefully analyze the concepts. From this analysis, the
results obtained will be used to choose the best concept.

Displacement and Stress analysis at point load on wheels of

100lbs/each. Data confirms stability of component.

Wheel displacement and stress

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Detailed Design
This includes the creation of a complete set of assembly and detailed
drawings. Each detailed drawing must specify all dimensions and material
specifications necessary to make the part. From these drawings a prototype
must be constructed for physical testing.

An engineering drawing
for each of the
components of the final
assembly is generally
needed for this phase.
However, for the
purpose of this web
page and space
limitations, a drawing
for the final assembly is
the only one shown.

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Prototyping and Testing

Construction of a physical model is necessary since a mathematical

model will never be as complete and accurate as the physical
representation. Prototypes are often very expensive but are the
cheapest way to build the design without building the entire device.

Usually, a working prototype is constructed to ensure the design

works. Adjustments may have to be made for unexpected last minute
problems that arise.
Testing of the model may range from simply actuating it to attaching
extensive instrumentation to accurately measure physical properties
and other parameters. Testing is needed for the optimization of the
final product.
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CHALLENGING YOUR DESIGN

Typical questions:
1. Is that the appropriate wheel?
2. How many bolt and nuts for this joint?
3. Can we use plastic for this structure?
4. Should I use 50 mm pipe or 100 mm one?
5. Is it fine to use rubber band to join those?
6. Dont we need to use bearings?
7. Can this float?
8. Which option is more economical?
9. How much heat can be removed by this?
10. Why use aluminum?
11. Will buckling happen?

Ask OUTSIDERS to challenge your design

Further considerations to detail design

Functional requirements

The essential requirement, of course would be that the design

must meet the required performance specifications. Besides, it
should present maintainability, availability & repairability.
Total life cycle
Material selection is a key element in total life cycle. The
properties of the selected material should be checked against
the service conditions. Environment protection is the latest
issue in the series, to be considered in material selection.
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Further considerations to detail design

Cont

Further major factors

1. Design as per Technical standards i.e. ASME, TEMA etc,

2. Design as per Health & Environment standards.

3. Aesthetics of the design
4. Cost

Design Strategies
1. One of-a-kind design
2. Design for mass production
3. Large expensive designs

4. Design to codes

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Design Group (Team)

Engineering design projects require

diverse skills
This creates a need for group (team)
work
Selection of team members is done by the ETP
Coordinators and it is based on following skills.
1.
Technical
2.
Problem-solving
3.
Interpersonal
35

Design Group (Team)

Develop decision making guidelines

1.
2.
3.

4.
5.

Decision by authority (leader)

Expert Member
Average member opinion
Majority
Consensus

36

Design Group (Team)

Teams that spend time together tend to

be successful teams

Respect each other

Listen actively
Consider your response to others
Constructively criticize ideas, not people
Respect those not present
Communicate your ideas effectively
Manage conflict constructively
37

Tips for Efficient Collaboration of Teams

Know the coworkers in person
Define and follow the rules

Communicate as much as you can

Share up-to-date information
Have regular meetings

Have an agenda
Show up prepared
Pay attention
Schedule time and place of next meeting
Summarize

Discuss the project more often

Assign tasks and responsibilities
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EFFECTIVE TASKS ASSIGNMENT

Step 1: Clarify what needs to be done and why it is important.
The background and context to a task will give it more meaning for people. Why is this job
important now? What is the rationale behind it? Are there particular stakeholders for whom this is
especially important?

Step 2: Make your expectations clear.

Spell out precisely what you expect and a date for its achievement. Express your confidence in the
persons ability to achieve the task

Step 3: Explain how results will be reviewed.

You will probably have a timetable in mind for a regular review of progress so that you can keep
abreast of progress without micro-managing. Who will be involved in that review, and what will
you expect to see on the review dates?

Step 4: Outline the resources and support available.

Finally, outline the resources that the team or individual will have access to, to help them do the
job. Let the person know who they can go to with questions or problems, and what level of support
they can expect.
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40

Project Management

Define for each activity

1.
2.
3.
4.
5.

6.

Work to be done
Timeframe
Resources needed
Responsible person(s)
Previous dependent activities
Checkpoints/deliverables for
monitoring progress
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Project Management

Guidelines
Project plan after design plan complete
Double time estimates and add 10%
Assign a lot of integration and test time
Remember lead times for parts ordering
Assign tasks based on skills and interests
Track progress versus plan
Plans change

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Project Time Management

A Gantt chart, commonly used in project management, is one of
the most popular and useful ways of showing activities (tasks or
events) displayed against time.

Series or Paralell
Gantt Chart.
Generally the Gantt Charts
are series and parallel.

Zoned Gantt. Chart.

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Project Time Management

On the left of the chart is a list of the activities and along the top is
a suitable time scale. Each activity is represented by a bar; the
position and length of the bar reflects the start date, duration and
end date of the activity. This allows you to see at a glance:

What the various activities are

When each activity begins and ends
How long each activity is scheduled to
last
Where activities overlap with other
activities, and by how much
The start and end date of the whole
project
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Thank you

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