A REVIEW ON EXPOSURE OF TRIZ IN MANUFACTURING APPLICATIONS
Rohan A. Shirwaiker
e-mail: ras1031@psu.edu
MS Student, Industrial and Manufacturing Engineering, The Pennsylvania State University
ABSTRACT
Since its introduction in 1946, Theory of Inventive
Problem Solving (TRIZ) has been widely applied as a
problem solving tool in the industry. Though it originated
in the engineering design domain, its applications today
extend to all its applicative fields including manufacturing,
service, aeronautics and architecture. This paper presents a
literature review of manufacturing related real life case-
studies implementing TRIZ methodology to develop
innovative solutions. The case-studies not only help in
understanding TRIZ and its importance in the industry but
also serve as guidelines to solve other problems. The
paper concludes with recommendations for future
research.
1. INTRODUCTION
Innovation plays an essential part in the growth and
progress of every industry. As global technology
competition becomes fiercer, an ability to solve
engineering problems expeditiously becomes critical for
the survival of individual businesses and entire industries
[1]. Numerous ideation techniques have found applications
in solving a variety of industrial problems. Especially,
TRIZ applications have been discussed in an array of
fields of literature including manufacturing, engineering
design and material sciences.
The advent of TRIZ in 1946 shook the contemporary
belief of innovation being an exclusive product of
spontaneity and intelligence. TRIZ made the innovation
process systematic and logical, extending its application to
a realm extending well beyond the scientist and research
community. TRIZ, invented by Generich Altshuller in
Russia, represents a fundamental shift in attitude towards
technical creativity. Its philosophy is based on some laws
that all systems follow [2]:
(1) Law of ideality – Systems evolve towards increasing
ideality, an ideal system being a one that does not
consume energy, does not cost anything and occupies no
space. It performs function without form.
(2) Law of transitioning to micro-level using energy
fields – Systems tend to shrink, replacing mechanical
systems by alternative energy fields while accomplishing
the required functionality.
(3) Law of dynamization – In the course of their
evolution, systems evolve from rigid structures into
flexible ones.
TRIZ is based on classifying any problem in terms of
technical or physical contradictions and using the
suggested inventive principles, separation principles or
substance field analysis to develop a solution. While using
the contradiction matrix, the problems are deciphered into
technical contradictions based on the 39 parameters. These
are then referred to the contradiction matrix to obtain
TRIZ design principles from amongst the 40 suggested
principles. The principles provide an explicit precise
direction and a line of thinking for the designers to follow
in order to generate more efficient and innovative
solutions. Alternatively, the problems can be classified as
physical contradictions and solved using substance-field
models and separation principles. Although these
separation principles and the inventive principles were
extracted from mechanical engineering solutions, both the
solution systems and the principles have much broader
significance [3]. Unlike many heuristic techniques, TRIZ
provides a definite direction to the thinking process.
Moreover, the concept of integrating other tools such as
brainstorming with TRIZ is not new and has been
effectively used in generating innovative solutions [4].
Section 2 consists of the literature review on
manufacturing related applications of TRIZ. The paper
concludes in section 3 with suggestions for a new
concurrent approach based on TRIZ and some other
problem solving tools.
2. LITERATURE REVIEW
This section consists of a review of TRIZ applications in
solving manufacturing related problems. Journal articles
and conference proceedings from publications such as
‘Journal of Intelligent Manufacturing’, ‘Computer
Integrated Manufacturing Systems Journal’, ‘Proceedings
of ASME Design Engineering Technical Conference’ and
various other on-line sources have been reviewed.
Compendex – the Engineering Database – was used to
access publications and conference articles. ‘TRIZ’, ‘TRIZ
applications in Manufacturing’, ‘Concurrent Engineering’
and ‘Innovation in manufacturing’ were the keywords used
for the literature search.
With the advent of concurrent engineering,
manufacturing has transformed into a cross-functional
activity associated with much more responsibilities than
just the final production of merchandise. Problems can
occur at different levels of the manufacturing phase.
Depending upon the nature of manufacturing related
problems, they can be categorized into three levels (as
shown in figure 1):
(1) Design for manufacturing
(2) Manufacturing processes
(3) Manufacturing systems
suggest the use of TRIZ to develop a solution for this
problem. The manufacturing design problem is codified in
terms of technical contradictions and principles suggested
by the contradiction matrix are used for resolving the
tradeoffs to develop a primary solution concept. The
suggested technical contradictions can be formulated into
a contradiction statement as follows: As the speed (9) of
take-off and landing increases (improving factor), the
adaptability (35) of the plane (using carrier for take off
and landing) decreases (worsening factor). The
contradiction matrix provides dynamism (15), preliminary
action (10) and copying (26) as recommended design
principles. Principle 15, dynamism, is used to develop the
concept of variable wing geometry as a possible solution.
Stratton and Mann [6] suggest the use of ‘separation in
time’ principle.

Manufacturing related problems

Design for Manufacturing Manufacturing

Manufacturing Process System

TRIZ (THEORY OF INVENTIVE PROBLEM SOLVING)

Concept Generation Process Improvement Systems Evolution

Figure 1. TRIZ applications at various levels of manufacturing related problems

2.1 TRIZ applications in Design for Manufacturing
TRIZ helps in concept generation for solving design
problems related to manufacturing. The final concept
selection can be done by concept selection methods
(CSM), virtual software tests or actual prototype testing.
More than 30 years ago, W. Skinner [5] used the concept
of mechanical design trade-offs to help acknowledge and
manage conflicting performance parameters associated
with manufacturing [6]. A problem of designing a 500
passenger plane that could land on a carrier and also break
the sound barrier was put forth. Stratton and Mann [6]
The wing spoilers can function differently at various
points of time. Their operations can be separated as a
function of time, i.e. they can perform the work of
boosters during take-off and function as maneuvers while
flying.
Tsai et al. [7] use TRIZ for concept generation while
redesigning a seated ball valve mechanism. The seat is a
part that is assembled in the valve body and may provide
part of the flow control orifice. The seat ring may have
special material properties and may provide the contact
surface for the closure member. The major function of a
seat is to make a seal surface with the closure member.
Soft materials such as plastics, Teflon, and Nylon are
usually used as the seat material because of their
flexibility. However, when these materials are under high
pressure, at a high temperature, or in a corrosive
environment, the seat may be distorted out of shape or
destroyed, and therefore will not form an effective seal [7].
Owing to this problem, it was decided to redesign the
valve seat using a metal instead of plastic. A ball valve is
shown in figure 2.
Figure 2. Ball Valve (adapted from Tsai et al., 2004)
The problem is defined in terms of technical
contradictions as well as a substance-field model in order
to generate potential solutions and the best solution is
determined using the QFD CSM. The contradiction
statement can be as follows: As the reliability (27) of the
valve seat functioning increases by replacing plastic with a
metal (improving factor), the manufacturability (32) of the
part decreases (worsening factor). The contradiction
matrix suggests all 40 recommended design principles.
Tsai et al. [7] use segmentation (1), asymmetry (4),
spheriodality (14) and porosity (31) to generate concepts
which are then modified and enhanced using substance-
field (Su-field) analysis. The Su-field model for the
problem is shown in Figure 3. Based on the analysis and
the 76 standard solutions of TRIZ, three class II and class
III solutions are selected for improving the effective
sealing of the seat – magnetic liquids, magnet and
electromagnet. The pool of generated concepts was finally
evaluated using QFD.
F1
S1 S2
Mechanical
BALL SEAT
Figure 3. Substance-Field Model
A TRIZ application in the automobile industry is
illustrated by Cascini and Rissone [8]. TRIZ is used for
redesigning aluminum wheel of a motorscooter using
plastic. Unlike the previous application where a CSM was
used for concept selection, the best concept in this case is
selected by prototype testing. Nowadays, polymers are
substituting metallic alloys in several mechanical
applications, even with structural functionalities, thanks to
their lower cost. However, several mechanical deficiencies
afflict polymeric materials. For example, compared with
metals, the most alarming for designers is the elasticity
modulus as in the best cases it is about one-fifth of that of
an aluminum alloy and one-fifteenth of a ferrous alloy [8].
Thus, even though polymers help to improve the
manufacturability in terms of manufacturing and material
costs, the part design needs thorough strengthening and
improvement in terms of stability. This particular problem
has been analyzed in terms of TRIZ inventive principles
and substance-field analysis. Figure 4 (a) shows the
current design and 4 (b) shows a modified concept which
was generated without using TRIZ.
(a) (b)
Figure 4. (a) Current Design using Aluminum
(b) Modified Design Concept (adapted from G.
Cascini and P. Rissone, 2004)
Even though the new conceptual design greatly
enhanced strength of the wheel to enable it to maintain its
shape, it posed manufacturing difficulties while injection
moulding. Thus, the contradiction statement for the
problem becomes: as the shape (12) of the wheel stabilizes
(improving factor), manufacturability (32) of the wheel
decreases (worsening factor). Contradiction matrix
recommends the following design principles: segmentation
(1), optical changes (32), dimensionality change (17) and
replace a mechanical system (28). Potential concepts were
generated using segmentation (1) and dimensionality
change (17). Based on segmentation, the rim could be split
into two separately molded pieces that could be assembled
later. Based on dimensionality change, the web could be
transformed from two dimensions to three dimensions
which would increase the radial as well as the lateral
rigidity of the rim and allow use of only a single mould.
These concepts are illustrated in figure 5 (a) and (b)
respectively.

(a) (b)
Figure 5. Concepts Generated using TRIZ principles
(a) Segmentation (b) Dimensionality change
(adapted from G. Cascini and P. Rissone, 2004)
Further, assuming that the wheel had to perform an
added safety function in the case of an accident by
dissipating as much energy as possible during the shock,
substance-field analysis was used to generate concepts.
Based on Condensed Standards I of TRIZ, a potential
concept would be to introduce a substance like foam or a
high viscosity matter into the hollow rim to raise its energy
dissipation rate. Another concept based on the same
principle would be winding a tape around the rim to
enhance its rigidity and rate of energy dissipation. The
final pool of generated concepts was evaluated using
prototype testing.
Bariani et al. [9] have used TRIZ (technical and
physical contradiction systems) in unison with design for
manufacture and assembly (DFMA) to redesign a satellite
antenna. The results have been stated as comparatively
lower manufacturing cost for the new design and a 43%
reduction in the assembly time.
The case-studies discussed above give a fair idea of
the role of TRIZ in enhancing manufacturability through
improvement in product designs. However, manufacturing
problems are not necessarily a result of faulty product
design. Sometimes, it is the processes which possess
inherent shortcomings and need modifications. TRIZ has
been successfully implemented for improvement of
manufacturing processes as well.
2.2 TRIZ applications in Manufacturing Processes
Monplaisir et al. [3] present a case-study based on the use
of TRIZ for improving the fluorination process of plastic
bottles. Fluorination process is a gas modified plastic
technology that reduces permeability and improves
chemical resistance through surface treatment of the
polymer. It enhances the usability of plastic container so
that it can carry different solvents to help maintain product
shelf life without solvent penetration [3]. The main aim of
this case-study was cost reduction in the fluorination
process. It was required to find such a resource that would
take the fluorine gas to each of the plastic bottle without
increasing the cost or system complexity. A physical
contradiction was found to exist. Increasing the amount of
fluorine gas enhanced the uniformity of fluorination in
plastic bottles, but it increased the process cost
substantially. On the other hand, reducing the amount of
fluorine gas brought about a substantial reduction in
manufacturing cost at the expense of non-uniformity of
fluorination among plastic bottles. Figure 6 represents the
Su-field diagram for the problem.
F1
S1 S2
FLUORINE BOTTLE
Figure 6. Su-Field Analysis for the Fluorination Process
F1 is the force of gas coming out of the nozzle.
Application of Class II standard solutions from the 76
standard TRIZ solutions suggests that the problem can be
solved by changing the field F1 acting on S2 or adding
another field F2 in addition to F1. Based on this concept, a
new fluorination system making use of gravity was
suggested. Gravity could take the fluorine gas up to each
plastic-bottle without complicating the system. Fluorine
gas being 1.5 times heavier than air would provide
additional help. The authors suggest placing showerhead
injection ports at the top of the process reactor to generate
better gas dynamics and hence uniform distribution as
opposed to the earlier design where the ports were at the
side of the gas chamber.
Yang and Zhang [10] demonstrate the potential of
TRIZ in process improvement by modifying an ampoule
sealing process. In the existing manufacturing process, a
burner is used to seal ampoules containing drugs.
However, there exists a possibility of the flame
overheating the drug inside the ampoule leading to its
degradation. This not only renders the product unsafe for
consumer use but is also against legal standards. In TRIZ
terms, the contradiction statement can be expressed as: As
manufacturability (32) of the sealing process increases
(improving factor), the stability (13) of the drug contained
inside the ampoule decreases (worsening factor). The
contradiction matrix recommends the following design
principles: beforehand cushioning (11), other way round
(13) and Segmentation (1). The problem can also be
expressed in terms of a physical contradiction as: greater
heat is required for better seal of the ampoule but at the
same time, no heat is desired for the stability of the drug.
A solution has been suggested for this problem by
combining the separation in space principle and
segmentation (1). The process setup is modified as shown
in Figure 7. The part of the ampoule containing the drug is
kept immersed in water while the burner seals its ends.
Figure 7. Modified Setup for Ampoule sealing
(adapted from Yang and Zhang, 2000)
Cavallucci et al. [11] applied TRIZ to improve a
bottle-filling process. The existing methodology of
inserting a nozzle-head into the bottle opening for water
filling and level gauging was fast but resulted into water
contamination. The sudden pressure also caused warping
of the bottle resulting into inconsistency in levels of water.
Following is a contradiction statement for the problem: As
the speed (9) of filling the bottle with water increases
(improving factor), harmful factors acting on the object
(30) (contamination of water and warping of the bottle)
increase (worsening factor). Contradiction matrix suggests
the following design principles: segmentation (1), replace
a mechanical system (28), physical or chemical properties
(35) and feedback (23). Based on segmentation, the
concept of splitting up the main tank into two parts was
suggested. This would allow for storage of same volume
of water but lesser pressure while filling. Based on the
principle of replacing a mechanical system, an acoustic
feedback system could be used which would detect the
water level based on the amplitude and frequency of water
drops. Alternatively, an optical detection system could be
used. Based upon the principle of physical or chemical
properties, the nozzle could be chemically sterilized so as
to avoid water contamination.
As seen in the above examples, TRIZ has been
successfully applied to enhance manufacturing processes.
A bigger challenge, however, lies in improving
manufacturing systems which involves more factors in
addition to product design and manufacturing processes.
Decisions about a system can change the position of the
entire enterprise. The following subsection establishes the
usefulness of TRIZ in solving problems at the systems
level also.
2.3 TRIZ applications in Manufacturing Systems
Supply chain management is a systems approach in
manufacturing. Stratton and Warburton [12] discuss a
case-study where TRIZ principles are used for
development of responsive and efficient supply chains.
Any manufacturing enterprise always encounters the
following physical contradiction: More goods should be
manufactured to prevent loss of sales; however, fewer
goods should be manufactured in order to prevent
obsolescence in case the product does not pick up in the
market. The authors use the separation principles to solve
this problem for an enterprise manufacturing fashion ski
wear - Sports Obermeyer. The primary problem faced by
the manufacturer was that they would commit to
production in October but receive their sales feedback in
February. Separation in time principle was applied to
change their supply chain focus from efficiency of
production to speed of response. They separated out early
and late production runs based on the predicted level of
uncertainty and were ready to respond with top-up orders
once demand levels could be established in February. In
this way, the balance between efficiency and
responsiveness was improved by separating out the supply
of product lines over time. Now, the early production runs
were efficiency focused and the later top-up orders were
delivery speed focused, in response to customer sales data
[12].
Skinner [5] and Hill [13] promoted separation of
different business requirements taking a note of the fact
that different products perform differently in the market
based of their functionality. They suggest that the concept
of group technology (GT) and flexible manufacturing
systems (FMS) evolved from the separation in space
principle. They put forth a case where the decision to
outsource fashion sportswear manufacture from the USA
to Honduras reduced the cost of manufacture, but had a
detrimental effect on critical market response. The conflict
was eventually resolved by separating out the requirements
in time and space. Honduras provided low cost early
supply, while the orders were completed once sales
demand at the start of the sales season had been
determined [6].
Table 1 summarizes all the applications of TRIZ
reviewed in Section 2.
3. CONCLUSION
A review of TRIZ applications shows that TRIZ has
tremendous potential for solving real industrial problems
in the manufacturing sector. However, it is seen that most
of the applications focus on improving product design or
manufacturing processes.
 Table 1. Summary of the review of manufacturing related applications of TRIZ
TRIZ System for TRIZ System for Suggested
Design Problem Potential Solutions
Problem Definition Problem Solution Parameters

(1) Technical (1) Contradiction • (15) Dynamism Variable Wing Geometry –

Design of a 500 passenger
Contradictions Matrix (10) Preliminary Action perform as boosters during
supersonic air plane
(2) Physical (2) Separation (26) Copying take-off and maneuvers
(Stratton and Mann, 2003)
Contradictions Principles • Separation in Time while flying.

• (1) Segmentation
Use of magnets, electro-
(1) Contradiction (4) Asymmetry
Design of a metal seated (1) Technical magnets or magnetic fluid
Matrix (14) Spheriodality
ball valve mechanism Contradictions for sealing for three
(2) 76 Standard (31) Porosity
(Tsai et al., 2004) (2) Su-Field Analysis designs illustrated in Tsai
Solutions • Class II and III
et al, 2004
Condensed Standards
• (1) Segmentation
Design for (1) Two-piece assembly
(32) Optical changes
Designing of (2) Three-dimensional web
Manufacturing (1) Contradiction (17) Dimensionality
motorscooter wheel using (1) Technical (3) Strengthening hollow
Matrix change
Plastics Contradictions rim with a high
(2) 76 Standard (28) Replacing a
(Cascini and Rissone, (2) Su- Field Analysis viscosity substance like
Solutions mechanical system
2004) foam for energy
• Class I Condensed
dissipation
Standards
(1) Making the antenna out
• (3) Local Quality of Plastic and coating the
(1) Technical (1) Contradiction (11) Previously placed reflector surface with a
Design of a Satellite
Contradictions Matrix pillow metal
Antenna
(2) Physical (2) Separation (10) Preliminary action (2) Properly designed
(Bariani et al., 2004)
Contradictions Principles (32) Optical changes rib/web to reduce the
• Separation in space material volume but
maintain stiffness.

Manufacturing Making use of gravity to

Improvement of (1) Physical
(1) 76 Standard • Class II Condensed induce uniformity into the
Fluorination Process Contradiction
Processes Solutions Standards fluorination process by
(Monplaisir et al, 1998) (2) Su-Field Analysis
placing gas port on the top.
 • (11) Previously placed Keeping the part of
(1) Technical (1) Contradiction
Improvement of the pillow ampoule containing drug,
Contradiction Matrix
Ampoule sealing Process (13) Other way round immersed in water while
(2) Physical (2) Separation
(Yang and Zhang, 2000) (1) Segmentation sealing its ends with a
Contradiction Principle
• Separation in Space burner.

(1) Splitting the main tank

• (1) Segmentation into two smaller tanks to
(28) Replace a reduce water pressure
Improvement in bottle-
(1) Technical (1) Contradiction mechanical system (2) Use acoustics or optical
filling Process
Contradiction Matrix (35) Physical or Chemical level gauging system
(Cavallucci et al, 2002)
Properties instead of physical contact.
(23) Feedback (3) Chemical sterilized
Nozzle

Supply chain focus shifted

Modifying Supply Chain
from efficiency of
Management for an
production to speed of
Fashion Apparel (1) Physical (1) Separation
(1) Separation in Time response. Early runs will
Manufacturer Contradiction Principle
be production focused and
(Stratton and Warburton,
Manufacturing later orders will be delivery
2002)
speed focused.
Systems The machine setups can be
designed according to the
part family designs.
(1) Physical (1) Separation (1) Separation in Space
Principle of FMS and GT Batches of different
Contradiction Principle (2) Separation in Time
families can be
manufactured in the same
cell.
Application of TRIZ for solving system related problems
has been very limited. This can be attributed to the fact
that system problems are much more complex in nature
than problems related to product design or manufacturing
processes. Systems problems in fact consist of more than
one inter-related problem.
In spite of its innovativeness TRIZ falls short in some
aspects. For example, TRIZ proposes defining any
problem in terms of a physical or technical contradiction,
which may not always be feasible in case of complex
multi-layered problems. Therefore, it might be a better
option to use it concurrently with some other problem
solving tool which mainly focuses on problem definition
and analysis. Such a concurrent approach might yield
better and efficient solutions for complex problems [14].
Axiomatic Design (AD) is a problem solving tool
which fits the bill. AD has the capability to systematically
define and breakdown the main problem and to analyze
effectiveness of the solution in terms of satisfying its two
axioms – independence and information axioms. AD
guidelines concentrate more on problem definition rather
than solution generation. Although creating and optimizing
solutions is a step in the AD methodology, it does not
propose any specific techniques for generating accurate
and efficient solutions. TRIZ can be used for this purpose.
Thus, the following concurrent approach is proposed
for solving complex problems. AD should be used to
define and analyze the problem. At every branch of the
hierarchy developed by AD, TRIZ should be applied to
define the specific problem in terms of its contradictions.
Based on principles suggested by TRIZ, brainstorming
technique should be used to generate potential innovative
concepts. Further, a suitable concept selection method
(CSM) from engineering design literature should be
applied to select the best concept. Engineering knowledge
can then be applied to convert the potential concept into
an actual solution.
4. REFERENCES
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