EG1000: Engineering 1

Unit 1 – Engineering Design

Process
Daniel Christie
College of Science and Engineering
James Cook University

jcu.edu.au
 What is Engineering Design?

• Define ‘design’ as you understand it.

en.wikipedia.org

http://www.davidbuckley.net en.wikipedia.org
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 What is Engineering Design?
• Design is ‘open ended’
Science Analysis Design
R Resistance 20 ꭥ ?ꭥ

P Power dissipated I Current 5 Amps

P = I2R
Power, resistance and
current are related by
the laws of physics.
P=? P = 500W
Determine a suitable
resistor and power supply to
P = I2R = 500 achieve a power dissipation
of 500W
Application of theory to Result relies on the
a set problem with one theory and application
correct solution but has many possible
solutions.

• Distinction between science, analysis and design

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 The 5 Step Design Process
Systematic problem solving process Verification &
Select the best Validation – have
Client Brief & Gather Generate Solution to the
Requirements Relevant Multiple meet the Requirements
Analysis Information Solutions Requirements been met?

Problem Options Analyse & Implement &

Definition Research Analysis Evaluate Test Solution

- Product Detailed Design

Specification Concept Design Feasibility
- Systems
Commissioning
Specification
- Basis of Creativity Review and Iteration Review and Iteration
Design
&
Innovation

Collaboration & Teamwork

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 Problem Definition Problem
Definition

• Define the problem/challenge. Research

• What actually has to be designed?

• Probably the most important step in the design process! Options
Analysis

• Should generally follow these stages: Analyse

&
Evaluate
• Stakeholder requirements (source presents the problem)
• Clarification of actual specifics and detail
• Produce a problem statement including a criteria for success Implement &
Test Solution

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 Problem Definition – Stakeholder Problem
Definition

Requirements
Research
• Identify the stakeholders. A (non-exhaustive) list of possible stakeholders
may include:
• Operators & users
Options
• Acquirers & customers Analysis
• Developers
• Suppliers
Analyse
• Regulators &
Evaluate

• We need these stakeholders to tell us about needs, requirements,

constraints and lifecycle concepts associated with the system we are Implement &
Test Solution
about to engineer.

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 Problem Definition – Stakeholder Problem
Definition

Requirements
Research
• We should be encourage them to think of this system as a
“black box” at this stage (rather than implementation details).
Options
Analysis

• In the first instance focus on:

• Functional requirements Analyse

• Performance requirements &

Evaluate

• Stakeholders may not always agree with one another and are not Implement &
Test Solution
always equal in terms of influence and interest.

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 Problem Definition – Clarification & Detail Problem
Definition

• Define Preliminary Lifecycle Concepts:

• Lifecycle concepts are driven by key stakeholders and need to be Research

identified and understood early in the engineering process.

• These concepts often highlight constraints or issues that will impact Options
Analysis
directly on the design program.
Analyse
• Concepts include: &
Evaluate
• Acquisition concept to be used including design, development and production
expectations
• Deployment and transition to use requirements Implement &
• Support concepts including training concepts Test Solution

• Retirement and disposal concepts

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 Problem Definition – Clarification & Detail Problem
Definition

• Identify Key Constraints:

Research
• We know who our stakeholders are and what they need from the system
• These needs help define the problem space
Options
• Constraints are also critical because they limit the solution space Analysis

• Enterprise constraints: generally dominated by cost and schedule

• External constraints Analyse
• Laws, regulations, standards, ethics &
Evaluate
• External systems and interfaces
• Solution-related constraints
• mandated technology Implement &
Test Solution
• physical constraints (eg. size and weight)
• User/Operator constraints such as capabilities and limitations

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 Problem Definition – Problem Statement Problem
Definition

• What are we trying to document? Research

• What the design needs to be able to do (function)

• How well the design needs to perform (performance) Options
Analysis
• What qualities must the design process (attributes)
• What other designs/systems involved in the operation (interfaces)
• Under what conditions must the design operate (environment) Analyse
&
• What are the constraints/considerations on the design (design, Evaluate

manufacturing, operational, support, disposal, etc.) (constraints)

• How the requirements will be confirmed or proven (verification) Implement &
Test Solution

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 Problem Definition – Problem Statement Problem
Definition

• What are we trying to document? (Another way to look at it) Research

• Performance & Functional Requirements – output, loading, design life,

etc. Options
• Operational Requirements – use, maintenance, cleaning, environment, Analysis

disposal, health, safety, etc,

• Manufacturing Requirements – installation considerations, packing, Analyse
transportation, quality, etc. &
Evaluate

• Constraints – legal, standards, dimensions, weight, interfaces, etc.

• Verification/Acceptance Requirements – inspection, testing,
Implement &
commissioning, etc. Test Solution

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 Problem Definition – Problem Statement Problem
Definition

• How should requirements be written? (Bahill, Bentz & Dean 1996; Lennard 2013) Research

• Focus – a requirement is expressed in terms of ‘what’ and ‘why’ or form, fit and function,
not in terms of how to develop.
Options
• Clarity – A requirement is readily understandable without analysis of the meaning of the Analysis
words or terms used.
• Measurability – A requirement is expressed so as to allow for only one interpretation of
meaning (ie. not words such as excessive, sufficient, resistant, etc.), that cannot be Analyse
measured. &
Evaluate
• Singularity – A requirement statement cannot be sensibly expressed as two or more
requirements having different agents, actions, objects or instruments.
• Testability – A requirement can be only demonstrated through a finite and objective Implement &
process. Test Solution

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 Problem Definition – Problem Statement Problem
Definition

• How should requirements be written? Research

• Other considerations:
• It should be written in business/customer/user language (not engineering Options
Analysis
“specification” language)
• A natural language style should be used
Analyse
• We want a wide range of people (not just engineers) to read and &
understand the document Evaluate

• To aid communication, we usually see a combination of:

• Statements Implement &
Test Solution
• Drawings (functional flows, interface, context, etc.)

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 Problem Definition – Problem Statement Problem
Definition

• The Problem Statement can take a number of forms: Research

• Production Design Specification (PDS)

• System Design Specification (SDS) Options
Analysis
• Systems Requirements Specification (SRS)
• Basis of Design (BoD)
Analyse
&
Evaluate

• Homework: Review Berth 8 Basis of Design Example

Implement &
Test Solution

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 Problem Definition – Why are Requirements Problem
Definition

Important?
• Design/System requirements analysis is a critical part of the Research

engineering design process and continues to influence the design

throughout its lifecycle.
Options
• Standish did some research on why development projects tend to fail. Analysis

• Incomplete requirements 13.1%

• Lack of user involvement 12.4%
Analyse
• Lack of resources 10.6% &
Evaluate
• Unrealistic expectations 9.9%
• Lack of executive support 9.3%
• Changing requirements 8.7% Implement &
• Lack of planning 8.1% Test Solution

• Didn’t need it any longer 7.5%

• Homework: Review Standish Paper
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 Research Problem
Definition

• Why do we need to conduct research (gather important Research

information)?
Options
Analysis

• Do not reinvent the wheel.

Analyse
&

• Leverage previous work and activity to

Evaluate

develop a better solution more

efficiently. (Leverage lessons learnt Implement &
Test Solution
both positive and negative)

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 Research Problem
Definition

• Where to start Engineers must be able Research

• Peers to efficiently locate
• Work Colleges
accurate, relevant and
• Professional networks
• Industry reliable information Options
Analysis

• Previous designs
• Internal & external (customer) Analyse
&
• Patents Evaluate

• Engineering information source documents

Implement &
Test Solution

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 Research – Engineering Information Source Problem
Definition

Documents1
Source Category Example Research

Codes of Practice National Construction Code (Building Code of

Australia) Options
Analysis
Design Guides and Templates Within your organisation (best or preferred
practice)
Equipment Brochures Warman SHW submersible slurry pump Analyse
&
Evaluate
Government Legislation Workplace Health and Safety Legislation

Handbooks ASM Handbook: Materials Selection and Design

Implement &
Test Solution
Local Government Policies State Environment Planning Policies

1. Dowling, D., Hadgraft, R., Carew, A., McCarthy, T., Hargreaves, D., Baillie, C. and Male, S. (2020). Engineering Your Future, An
jcu.edu.au Australasian Guide (4th ed.), John Wiley & Sons.
 Research – Engineering Information Source Problem
Definition

Documents
Source Category Example Research

Patents IP Australia
Options
Practice Notes Association of Consulting Engineers Australia Analysis

Professional Organisations Engineers Australia, IEEE, etc.

Analyse
&
Refereed Journals Engineers Australia Transactions Evaluate

Reports MKSEA GHD Engineering Report

Implement &
Test Solution
Standards AS/ISO/ASTM/MIL…….

1. Dowling, D., Hadgraft, R., Carew, A., McCarthy, T., Hargreaves, D., Baillie, C. and Male, S. (2020). Engineering Your Future, An
jcu.edu.au Australasian Guide (4th ed.), John Wiley & Sons.
 Research – Evaluating Information and Problem
Definition

Sources1
• Evaluating Information Sources: Research

• Credibility – Is the resource or site known for its credible information? Is

the author’s name and affiliation listed? Is the author respected in the Options
industry? Has the resource been peer reviewed? Analysis

• Accuracy – Can the information be verified by other sources? Are there

any obvious errors in the information? Has the work been cited by other Analyse
authors? Is there evidence of bias in the publication or source? Does the &
Evaluate
information fit with your understanding of the topic and your experience?
• Relevance – Who was the target audience for the information and did
the document achieve its purpose? Is the source relevant for your Implement &
Test Solution
project?

1. Dowling, D., Hadgraft, R., Carew, A., McCarthy, T., Hargreaves, D., Baillie, C. and Male, S. (2020). Engineering Your Future, An
jcu.edu.au Australasian Guide (4th ed.), John Wiley & Sons.
 Research – Evaluating Information and Problem
Definition

Sources1
• Evaluating Information Sources: Research

• Date – What is the publication date of the information or document? Is

the web-site up to date? Options
• Source – Was the website or publication published by a government or Analysis

professional organisation? Are the details of the website owner published

on the homepage? Analyse
&
Evaluate

Implement &
Test Solution

1. Dowling, D., Hadgraft, R., Carew, A., McCarthy, T., Hargreaves, D., Baillie, C. and Male, S. (2020). Engineering Your Future, An
jcu.edu.au Australasian Guide (4th ed.), John Wiley & Sons.
 Research – Evaluating Information Problem
Definition

• Evaluating Information: Research

• Scepticism – Are the results, conclusions or recommendations supported

by evidence? Have the author’s ideas or concepts been developed and Options
argued in a logical manner? Is the technical information correct? Analysis

• Objectivity – What questions have not been answered in the article? Is

the information appropriate for your purposes? Is it practical? Is the Analyse
information applicable for your projects contexts? (Contexts – technical, &
Evaluate
geographic, safety, legal, socio-cultural, environmental, etc.) What
limitations does the author place on using it?
Implement &
Test Solution

1. Dowling, D., Hadgraft, R., Carew, A., McCarthy, T., Hargreaves, D., Baillie, C. and Male, S. (2020). Engineering Your Future, An
jcu.edu.au Australasian Guide (4th ed.), John Wiley & Sons.
 Research – Evaluating Information Problem
Definition

• Evaluating Information: Research

• Open-mindedness – Does the information suggest an alternate approach

that should be considered for the project? Is the information compatible Options
with the other information gathered? Analysis

• Some other relevant questions:

• What issues need further exploration before the information can be Analyse
&
used? Evaluate

• Are there any other information sources in the document that should be
reviewed? Implement &
Engineers need to carefully analyse Test Solution

information before applying it

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 Research Problem
Definition

• Importance of research (it is not wasted time) Research

• Lesson’s learnt – what has and has not worked previously and under
what application and conditions/environment. Options
• Efficiency – accelerated development / advanced starting point. Analysis

• Benchmarks for data analysis, testing and comparison.

• Competitor activity. Analyse
&
• Identification of potential ‘legal’ issues and challenges. Evaluate

Implement &
Test Solution

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 Research – Bridge Project Problem
Definition

• For Project 1 – Civil Bridge Research

• What might you need to know?

• Where might you look for this? Options
Analysis

Analyse
&
Evaluate

Implement &
Test Solution

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 Options Analysis – Generate Multiple Problem
Definition

Solutions
• This is where Engineers earn their stripes! Research

• What are possible solutions to the problem presented within the

requirements and constraints! Options
Analysis
• Commonly referred to as Conceptual Design.

Analyse
&

Creativity, Innovation and Teamwork are the Evaluate

critical inputs to the development of great

designs and solutions. Implement &
Test Solution

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 Options Analysis – Generate Multiple Problem
Definition

Solutions
Research

Some features/tools for this part of the design process [Concept

Design/Options Analysis]
Options
Analysis
• Use of Creativity
• Harness Innovation [Leverages the research undertaken]
Analyse
• Brainstorming and group work &
Evaluate

• Ideation / sketching
• Rapid prototyping and test Implement &
Test Solution

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 Options Analysis – Generate Multiple Problem
Definition

Solutions
Creativity: Research
• “Creativity is playing with imagination and possibilities, leading to new and
meaningful connections and outcomes while interacting with ideas, people
and the environment.” E. And M. Ludsdaine, Creative Problem Solving, 2 ed.
nd
Options
Analysis
• Start with existing solutions [leverage the research undertaken]
Ø Find out what is wrong with them
Analyse
Ø Focus on improving weaknesses &
Evaluate
• There is no correlation between creativity and intelligence
Ø Creativity arises due to conscious effort
Implement &
Test Solution
Ø Everyone has a creative potential
Ø Many people don’t exercise it, so it doesn’t develop
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 Options Analysis – Generate Multiple Problem
Definition

Solutions
Brainstorming and Group Work - A good way to be creative! Research

• Generally an activity carried out by a group

• No judgement Options
Analysis
• Document everything (video / scribe)
• Plan stages for effective use of time Analyse
&
• Limit to 30 – 60 mins which might follow: Evaluate

• 5 mins to discuss the problem

• 20 mins of raw idea discussion → no criticism Implement &
Test Solution
• 25 mins of idea assessment (thinking hat exercise)
• 10 mins idea redevelopment following assessment
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 Options Analysis – Generate Multiple Problem
Definition

Solutions
Brainstorming and Research

Group Work
Options
Analysis

Analyse
&
Evaluate

Implement &
Test Solution

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 Options Analysis – Generate Multiple Problem
Definition

Solutions
Research
Ideation and Sketching

Options
Analysis

Analyse
&
Evaluate

Implement &
Test Solution

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 Options Analysis – Generate Multiple Problem
Definition

Solutions
Rapid Prototype and Test
Research
• Designing and building a ‘working model’
is the most effective way to communicate
the design and well as test against Options
requirements for the design. Analysis

• Physical Model/Prototype
• Digital Model/Prototype Analyse
&
• May be an option to build a couple of Evaluate

prototypes covering a number of the

possible options.
Implement &
• Cheap in comparison to getting Test Solution

the design wrong.

• Feeds into next phase – options analysis
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 Options Analysis – Generate Multiple Problem
Definition

Solutions
Research
• The options/solutions at the end of this part of the design process need to
be ‘technically feasible’ in that they are realistically able to meet the
specified requirements. (Although not fully verified or validated) Options
Analysis

• Enough work/effort is required to be completed to verify a level of technical

feasibility. Analyse
&
Evaluate

• Generally:
Implement &
• Should be able to meet technical requirements (including constraints) Test Solution

• Should be able to meet financial requirements

• Should be able to meet schedule requirements
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 Options Analysis – Generate Multiple Problem
Definition

Solutions
Options Analysis for Civil Bridge Project Research

• Based on understanding the requirements and research – develop a

number of potential designs that may be able to meet the requirements.
• Important not to focus on a single option – do not limit your thinking (this is Options
Analysis
where fully engaging your group is important).
• Options can be variations on a general design theme or number of themes. Analyse
&
• You will need to document the design options considered in your design Evaluate
report so ensure you capture and document.
Options and solutions generated at the end of this Implement &
Test Solution
part of the process should be ‘technically feasible’.
Enough work needs to be completed to confirm the
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technical feasibility.
 Analyse & Select Problem
Definition

• How do you select the best option from the options and designs Research

identified for this scenario/situation?

Options
Analysis

• Generally with use of a multi-criteria decision matrix:

• Technical performance / compliance Analyse
&
• Financial considerations – cost Evaluate

• Schedule considerations – time to implement

• Sustainability considerations Implement &

• Different ‘importance’ weightings can be applied to each Test Solution

criteria.
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 Analyse & Select Problem
Definition

Technical Performance / Compliance Research

• It is most likely not all options will meet the technical

requirements and constraints equally – performance, function,
safety, constraints, etc. Options
Analysis

• Need to undertake a more detailed level of engineering analysis

and rigor to evaluate each potential solution against the technical Analyse
&
requirements (feasibility level). Analysis may include: Evaluate

• Detailed engineering analysis

• Hand calculations, computer models, application of standards, etc. Implement &
Test Solution
• Experimentation
• On parts, pilot, benchmarks and/or the whole

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 Analyse & Select Problem
Definition

Technical Performance / Compliance Research

• For each option/design need to determine:

• Level of performance/compliance against each technical requirement
Options
• Any requirements not able to be met by the option/design Analysis

• Essential establish a graded rank (or degree of Analyse

&
performance/compliance) of the options/designs against the Evaluate

technical requirements.
Implement &
Test Solution

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 Analyse & Select Problem
Definition

Financial Considerations Research

• Each option/design will have different financial and cost

considerations and performance and these need to be Options
Analysis
established. (Engineers working with Accountants, Lawyers,
Business Analysts, etc.)
Analyse
&
Evaluate

• Need to consider the full life cycle costs of the

options/designs (ie. the complete life of the Implement &
Test Solution

system/design – not just design and build).

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 Analyse & Select Problem
Definition

Financial Considerations Research

• Life cycle costs to be considered:

• Capital costs – initial costs to design, build and implement (usually Options
Analysis
referred to as project costs)
• Revenue/Savings
Analyse
• Operational Costs &
Evaluate
• Disposal Costs

• Life cycle costs can differ greatly depending on the expected Implement &
Test Solution

life and it is obviously harder (less accurate) to

estimate/forecast future costs.
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 Analyse & Select Problem
Definition

Financial Considerations Research

• Capital costs include:

• All project management costs – project management, legal, finance, etc. Options
Analysis
• All design costs
• Equipment purchases
Analyse
• Fabrication costs &
Evaluate
• Logistic costs – moving parts/equipment to site
• Installation costs – labor + equipment (cranes, etc.)
• Initial spares Implement &
Test Solution

• Training
• Commissioning
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 Analyse & Select Problem
Definition

Financial Considerations Research

• Revenue/Savings include:
• Sales revenue – new products Options
Analysis
• Improved revenue – improved product, etc.
• Production efficiency – able to produce at a lower cost, etc.
Analyse
&
Evaluate

• Note: a project/design is usually to generate new or improved

revenue or realise efficiency and savings. This may not always Implement &
be the case and can be driven by regulatory, safety or Test Solution

environmental improvements or changes. Overall cost

remains a critical consideration.
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 Analyse & Select Problem
Definition

Financial Considerations Research

• Operating costs include:

• Input materials – feed, chemicals, etc. Options
Analysis
• Utilities – energy, water, air, etc.
• Operating – labor + consumables + licenses
Analyse
• Maintenance – labor + equipment/spares + consumables &
Evaluate
• Logistics / Transport
• Waste disposal and/or treatment
• Environmental – monitoring + testing + reporting Implement &
Test Solution

• Safety – labor + programs

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 Analyse & Select Problem
Definition

Financial Considerations Research

• Disposal costs include:

• Decommissioning – labor + equipment Options
Analysis
• Waste disposal and/or treatment
• Remediation – land, water, etc.
Analyse
&
Evaluate

Implement &
Test Solution

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 Analyse & Select Problem
Definition

Financial Considerations Research

• With all the different costs over different times how do you
effectively compare the financial performance of different Options
Analysis
options?
• Net Present Value (NPV) Analyse
• Used in investment planning to analyse the profitability of a projected &
Evaluate
investment/project.
• Value and timings of cash flows need to considered in making investment decisions.
• Tool to understand the total cost over the complete life cycle. Implement &
Test Solution
• If multiple options/designs the case with the lowest NPV is generally the best
performing from a financial consideration.

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 Analyse & Select Problem
Definition

Schedule Considerations Research

• Different options/designs will have different:

• Time to implement – time taken to get to production Options
Analysis
• Design life – how long will it operate / be relevant
Analyse
&
Evaluate

• Important to note - time is money and schedule directly

contributes to financial performance and overall risk. Implement &
Test Solution

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 Analyse & Select Problem
Definition

Sustainability Considerations Research

• Sustainability considerations may be included in the technical

performance and requirements. Options
Analysis

• Sustainability considerations include:

• Overall environmental impact – across the life cycle Analyse
&
• Reputation Evaluate

• Will be covered as a specific topic after the lecture recess. Implement &
Test Solution

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 Analyse & Select Problem
Definition

Weighted Decision Matrix Research

• Each option/design formally evaluated against the ‘pre-

determined’ weighted decision matrix. For example: Options
Analysis
• Technical performance/compliance (30%)
• Financial considerations (50%)
Analyse
• Schedule considerations (10%) &
Evaluate
• Sustainability considerations (10%)
• Weightings will vary for different scenarios and business Implement &
drivers and usually set by policy and/or executive Test Solution

management.
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 Analyse & Select Problem
Definition

Weighted Decision Matrix Research

• For each option/design there will be an assessed ‘level’ of

meeting each of the decision matrix criteria. Options
Analysis

• Example - Design 1
• Technical (80% assessed performance/compliance) x 30% Analyse
&
• Financial (second most cost effective (within xx% of cheapest) x 50% Evaluate

• Schedule (fastest to implement) x 10%

• Sustainability (third best sustainability performance) x 10% Implement &
Test Solution

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 Analyse & Select Problem
Definition

Weighted Decision Matrix Research

• The best overall scoring option/design generally progresses to

implement and test – detailed design, building/fabrication, testing Options
Analysis
and operational use.
Analyse
&
• Note: significant work can be required to develop enough Evaluate

information and knowledge to effectively apply the decision

matrix. Insufficient or inaccurate information can greatly affect Implement &

the outcomes and eventual decision – care needs to be Test Solution

taken.
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 Implement and Test Solution Problem
Definition

When the ‘preferred’ design option is identified this now needs to Research

be progressed through to implementation/realisation.

Involves: Options
Analysis
• Detailed design (this is what people generally associate with Engineers)
• Level of design and analysis to allow things to be ‘built or created’.
Analyse
• Detailed drawings, models, calculations, etc. &
• Creation of operational and maintenance instructions. Evaluate

• Can involve some iteration (but need to exercise caution)

• Manufacture, Fabricate, Build or Create Implement &
• Implementation of the design. Test Solution

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 Implement and Test Solution Problem
Definition

Involves cont.: Research

• Commission/Test
• Verification and validation that the requirements have been satisfied. Options
• Fundamental check step prior to use (safety) Analysis

• Use (monitoring of in-use performance)

• Modifications or upgrades (follows the same process) Analyse
&
Evaluate

Implement &
Test Solution

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