Systematic Methods for Designing

Functional
Decomposition
and Synthesis

Logical approach for describing the transformation between the initial and
final states of a system or device.

Morphological
Analysis

Morphological chart approach to design generates alternatives from an

understanding of the structure of necessary component parts.

Theory of
Inventive
Problem
Solving

TRIZ (Teoriya Resheniya Izobretatelskikh Zadatch), the russian word, is to

systematically apply the strategies and tools to find superior solutions that
overcome the need for a compromise or trade-off between the two
elements.

Axiomatic
Design(given
without proof)

Design methodology using matrix methods to systematically analyze the

transformation of customer needs into functional requirements, design
parameters, and process variables.

Design
optimization

These algorithms predict design engineering performance once the design

specification have been set. Methods are deterministic/stochastic
/combination.

Decision based
design

Focus on problem solving in two ways; incorporation of customers

requirements as the driver of the process; second is the design outcomes
(eg. maximum profit, market share capture) as the ultimate assessment of
good design.

Functional Analysis Method

The starting point for this method is to concentrate on what has to be achieved by a new
design, and not how it is to be achieved.
The simplest and most basic way of expressing this is to represent the product or device to be
designed as simply a black box which coverts certain inputs into desired outputs. The
black box contains all the functions which are necessary for converting the inputs to the
outputs. It has to be broken down into sub-tasks or sub-functions.
In specifying sub-functions it is helpful to
ensure that they are all expressed in the
same way.
Each one should be a statement of a very
plus a noun: For example Amplify signal,
count items, separate waste, reduce
volume
It is useful to use different conventions; i.e.
different types of lines, to show the
different types of inputs and outputs, i.e.
flows of materials, energy ,signal

Functional Analysis
An organized method of presenting a
products operations is needed
Documentation
Personnel transitions
Future Modifications

Functional Analysis (or decomposition) is one

means of accomplishing these objectives

Functional Analysis
A function is
A physical behavior or action
Indicates
What the item must do
How the item must do it
Relate to other items/components/subsystems

Note: There are many documented methods of

doing functional analysis, but we will just do one,
simple approach.

Functional Analysis

Top-down approach:
1. Define generally how the product is operated
2. Refine the activities necessary to accomplish the
operations
1. Segregate operations into separate blocks, with simple titles
2. Arrows between blocks indicate flow of action, activity or
energy

3. Repeat refinement for each block

1. Document hierarchically at lower levels
2. Eventually, the subsystem/component functions are
identified in the these operations

4. Add the secondary operations as necessary and

repeat

Identify the overall function that needs to be accomplished using function basis terms.

Identify the energy, material and signal flows that will be input to the device and output
from the device once the transformations are complete.

Use the standard flow classes defined in Table. Common practice is to use different line
styles for arrows to represent each general flow types(i.e. energy, material and signal)

Label each arrow with the name of the specific flow

Using everyday language, write a description of the individual functions that are required to
accomplish the overall task described in the black box model

Having thought about the details of accomplishing the function described in the black box,
identify more precise functions(from table)

Having thought about the details of accomplishing the function described in the black box,
identify more precise functions(from table)

Arrange the function blocks in the order that they must take place for the desired functions

Add the energy, material and signal flows between the function blocks. Preserve the input
and output flows from the black box

Examine each block in the function structure to determine if additional energy, material or
signal flows are necessary to perform the function

Review each function block again to see if additional refinement is necessary

A functional tree for a car door

Physical Decomposition
1.

Decompose the product into subassemblies/components

2.

Understand the couplings

3.

Interactions or connections between subsystems/components

How couplings accomplish larger functions

Establish product architecture

4.

Note: Function understanding is valuable

Levels of assembly
Circuitry and software included

Refine until all subsystems or components are sufficiently

defined for functionality within product

Functional Analysis
and Physical Decomposition
The functional analysis allows for identifying
the operations, then subsystems and
functions, for a product/system design
concept
Physical Decomposition is a method by which
an existing product/system can be dissected to
establish subsystems and components

Functional Analysis
and Physical Decomposition
Together, these methods can be used to
check that all product operations are understood
check that all component/subsystem functions are
understood
better understand the hierarchy behind the
physical product/system architecture
Physical decomposition excellent means to understand
design for assembly (DFA) approaches as well

Functional Analysis
and Physical Decomposition
Cleaning up the work:
Establish common terms for subsystems/components
in each analysis
Which functions are associated with which physical
subsystems/components?

Important check:
Which subsystems/components in the PD are not
referenced in the FA?
Which functions and/or operations in the FA are not
traced to any items in the PD?
Which functions/operations and/or
subystems/components are not referenced at all?

Strengths and Weakness of Functional Synthesis

Creating function structures forces re- A function structure is not a complete

representation into a language that is conceptual design. Even after developing a

useful for the manipulation of mechanical function structure, you still need to select
design problems

devices, mechanism or structural forms to

fulfill the function

Method facilitates the examination of Function decomposition can lead to excess

options that most likely would not have parts and subsystem if the designer does
been considered if the designer moved not stop to integrate common function

quickly

to

selecting

specific

physical blocks and flows

principles or even work selecting specific

hardware

Transparent box for the corded power drill . In which cover of the black box is removed and
drilled down one level by reverse engineering in order to identify the major sub functions
performed by the major sub systems (and their sub-inputs and sub-outputs) needed to
realize the basic drill function
Exploded view of the major subsystems in
power drill. Switch(6); Universal motor
consisting of brushes(9,10), spur gear(12)
; spindle(11) and chuck(13)

Functional Analysis and Physical Decomposition

Standard Flow Classes and Member Flow

Types (adapted from Otto and Wood)
Flow Classes
Energy
Material
Signal
Human

Human

Status

Hydraulic

Solid

Acoustic

Pneumatic

Gas

Olfactory

Mechanical

Liquid

Tactile

translational

Taste

rotational

Visual

vibrational
Electrical
Acoustic
Thermal

Magnetic
Chemical

Procedure for Functional Analysis

Express the overall function for the

design in terms of the conversion
of inputs into outputs

Break down the overall function

into a set of essential sub
functions

Draw a block diagram showing the

interactions
between
sub
functions

Draw the system boundary

Search
for
appropriate
components for performing the
sub
functions
and
their
interactions

Functional Analysis of Washing Machine

Overall function of tensile testing machine

Sub function of tensile testing machine

Completed function structure for the overall function set out

Overall function of tensile testing machine

Sub function of tensile testing machine

Completed function structure for the overall function set out

Function analysis for the automatic tea

maker

Exercise

Analysis of paper
stapler function
structure

Analysis of a flow control valve with respect to its function structure

Example illustrates the
derivation
of
function
structures by the analysis of
existing systems.
This method is particularly
suitable for developments in
which at least one solution
with
the
appropriate
function structure is known,
and the main problem is the
discovery
of
better
solutions.

Figure shows the steps used in the analysis of a flow control valve (a typical onoff switch), showing the
individual tasks of the various elements and the subfunctions satisfied by the system.
The function structure can be derived from the subfunctions and then varied in order to improve the
product.

Function Structure black box for a pencil