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Chapter 6: Establishing Product

Function and Concept Generation


BITS Pilani
Pilani | Dubai | Goa | Hyderabad
Dr. Nitin Kotkunde
Pr o d u c t D e v e l o p m e n t Pr o c e ss

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T h i n ki n g Pr o c e sse s th a t L e a d to C r e a ti ve
Ideas
• Aids to Creative Thinking: • Creative thinking process
– Develop a creative attitude

– Unlock your imagination


– Be persistent

– Develop an open mind


– Suspend your judgment
– Set problem boundaries

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Ba r r i e r s to C re a ti ve Th i n ki n g
Perceptual Emotional Blocks Cultural Blocks Intellectual Blocks Environmental
Blocks Blocks
Stereotyping Fear of risk taking Set of pattern Poor choice of Physical
problem-solving environment
language or problem
representation
Information Unease with chaos tradition bound Memory block Criticism
overload and are reluctant
to change
Limiting the Unable or unwilling Countries even Insufficient
problem to incubate new differ in their knowledge base
unnecessarily ideas attitudes toward
Fixation Motivation Incorrect information
Priming or
provision of cues

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C re a ti ve Th in ki n g M e th o d s

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I n t u i ti ve M e th o d s

• Brainstorming:

• Brainwriting:

• 6-3-5 Method:

• Collaborative Sketching (C-Sketch) method:

• Affinity diagram

• Concept maps:

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M e t h o d s to i m p r o vin g b r a i n sto r m i n g s e ss io n s

• Stick to the rules

• Pay attention to everyone’s ideas

• Include both individual and group approaches

• Take breaks

• Do not rush

• Stay persistent

• Facilitate the session

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C h a l l e n g e s to e ffe c ti ve g r o u p b r a i n sto r m i n g

• Blocking

• Collaborative fixation

• Evaluation apprehension

• Personality characteristics

• Social matching

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6 -3 - 5 Br a in wr i ti n g

• It is fundamental to assure that all participants share a deep


background knowledge on the topic of the brainwriting session.

• One of the main advantages of using 6-3-5 brainwriting is that it


is a very straightforward method and therefore is easy and quick
to learn.

• Issues in clarity of ideas.

• Stress due to time constraints might cause quality of ideas to


decrease.

• Risk of clash of similar ideas.

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Affi n ity d ia g r a m ( KJ M e th o d )

• The affinity diagram is a business tool used to organize ideas and data.

• The tool is commonly used within project management and allows large numbers of ideas
stemming from brainstorming to be sorted into groups, based on their natural relationships, for
review and analysis.

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Affi n ity d ia g r a m ( KJ M e th o d )

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D i re ct o r L o g i ca l M e th o d

• Functional decomposition:

• Morphological Method:

• Theory of Inventive Problem Solving (TRIZ / TIPS):

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F u n cti o n a l De co m p o si tio n a n d Sy n th e sis

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F u n cti o n a l De co m p o si tio n a n d Sy n th e sis

• “If one generate one idea it will probably be a poor idea; if one generates many ideas, one
good idea might exist for further development” (Ullman, 1992).
• The emphasis is on attaining a correct description of what the product is to do as a system
of functions.
• Functional modeling provides a basis for organizing the design team, tasks, and process.
• Derived or generated directly from the customer needs.
• The function defines clear boundaries to associate assemblies or subassemblies of the
final design solutions.

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F u n cti o n a l De co m p o si tio n a n d Sy n th e sis

• Primary functions, secondary functions and constrains.

• What is function?
• A function of a product is a statement of a clear, reproducible relationships between the
available input and the desired output of a product, independent on any particular form.
• It is simplest representation of the product.
• Usually just a “an active verb and Noun” Examples “ Chop beans”, “ Clip nails”

• The next step is to decompose the functions into various sub-functions


• The relation between the various sub-functions and functions are often governed by
constrains or input – output relations.

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F u n cti o n a l De co m p o si tio n a n d Sy n th e sis

• Abstraction:
• It is the process of ignoring what is particular or incidental and emphasizing what is
general and essential.

• Generic black box method:


• Constrain: It is set of clear criterion that must be satisfied by a product.

Input Product Function Output

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Si m p l e A p p r o a c h : Fu n ctio n Tr e e s

• FAST Method (Top-down approach)

• Subtract and operate Method (Bottom-up approach)

How Why

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Subtract and operate Method

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Black Box Method

Energy Energy

Material Product represented as a Material


Function Systems
Signal Signal

Finger force Sound KE in


hand motion nail
Finger nail, Remove excess length Cut nail, hand,
hand, debris debris
Long nail,
on finger nails
Good
hang nail, appearing
rough nail
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M o d e l l in g Pr o ce ss : s te p s

• Phase-I: Develop process descriptions as “Activity diagram”

• Phase-II: Formulate sub-functions through task listing

• Phase-III: Aggregate sub-functions into a refined function structure

• Phase-IV: Validate the functional decomposition

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Ph a se - I: A ctivi ty d ia g r a m

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Ph a se - II: Fo r m u l a te su b - fu n ctio n s th r o u g h ta sk l i st in g

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St e p s fo r Bl a c k Bo x M e th o d

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St e p s fo r Bl a c k Bo x M e th o d

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St e p s fo r Bl a c k Bo x M e th o d

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F u n cti o n Str u ctu r e : F i n g e r n a i l cl i p p e r

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Ex a m p l e s

Dish washer

Mechanical Pencil
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Ad va n ta g e s o f fu n cti o n d e c o m p o si ti o n

• It provide basis for organizing the design team, tasks and process.

• Functions or sub-functions may be directly derived from customer requirements.

• Creativity is enhanced by the ability to decompose the problems.

• It provides a natural forum to abstracting a design tasks.

• By mapping customer needs first to function and then to form, more solutions
may be systematically generated.
• It will facilitate the concurrent engineering process.

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M o r p h o l o g i ca l An a l ysi s

• The morphological method essentially is nothing more than an orderly way of looking at things.

• Morphological charts originate from the concept of the n-dimensional morphological box (Zwicky
box-1948).

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St e p s In vo lv e d i n M o r p h o lo g i ca l A n a l ys is

• In the first step of the integral design method, the individual designer makes a list of what he/she
considers to be the most important functions that need to be fulfilled based on the design brief.

• The morphological charts are formed as each designer translates the main goals of the design
task, derived from the program of demands, into functions and aspects. This is then inserted into
the first column of the morphological chart.

• In the second step of the process, the designer adds the possible part-solutions to the related
rows of the functions/aspects of the first column. Based on the given design task, each design
team member approaches the problem according to his/her active perception, memory,
knowledge, and needs.

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St e p s In vo lv e d i n M o r p h o lo g i ca l A n a l ys is

• These individual morphological charts can then be combined by the design team to form one
morphological overview.

• First, in step three, functions and aspects are discussed and then the team decides which
functions and aspects will be placed in the morphological overview.

• Then, in step 4, all participants of the design team can contribute their solutions for these
functions and aspects by filling in the rows within the morphological overview.

• Putting the morphological charts together enables individual perspectives from each discipline to
be put forward, which in turn highlights the implications of design choices for each discipline.

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M o r p h o l o g i ca l An a l ysi s

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M o r p h o l o g i ca l An a l ysi s

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M o r p h o l o g i ca l An a l ysi s

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M o r p h o l o g i ca l M e th o d : Exa m p l e

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M o r p h o l o g i ca l M e th o d : Exa m p l e

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T h e o r y o f In ve n tive Pr o b l e m So lvi n g ( TIPS
o r TR IZ )
• A Russian acronym: Theoria Resheneyva Isobretatelskehuh Zadach

• (Theory of Inventive Problem Solving)

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TRIZ

• These three categories are “ identifying conflicts and solving them with known
physical principles,” “ identifying new principles,” and identifying new product
functions and solving them with known or new principles.”
• Altshuller observed a number of trends in historical invention.

• Evaluation of engineering system is done by same pattern, independent of


engineering discipline.
• Conflicts (contradictions) are the key drivers for product invention.

• Compromises is unacceptable.

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TRIZ

• TIPS (TRIZ) is based on two basic principles


1. Somebody, sometime, somewhere has already solved your problem or one similar to it.
Creativity means finding that solution and adapting it to the current problem.
2. Don’t accept contradictions. Resolve them.

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En g i n e e r i n g P a r a m e te r s ( 3 9 )
1. Weight of moving object 18. Temperature 33. Complexity of device
2. Weight of nonmoving object 19. Brightness 34. Complexity of control
3. Length of moving object 20. Energy spent by moving object 35. Level of automation
4. Length of nonmoving object 18. Power 36. Productivity
5. Area of moving object 19. Waste of energy
6. Area of nonmoving object 20. Waste of substance
7. Volume of moving object 21. Loss of information
8. Volume of nonmoving object 22. Waste of time
9. Speed 23. Amount of substance
10.Force 24. Reliability
25. Accuracy of measurement
11. Tension, pressure
26. Accuracy of manufacturing
12.Shape
27. Harmful factors acting on object
13.Stability of object 28. Harmful side effects
14.Energy spent by nonmoving object 29. Manufacturability
15. Strength 30. Convenience of use
16. Durability of moving object 31. Repairability
17. Durability of nonmoving object 32. Adaptability

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I n v e n ti ve Pr in ci p l e s ( 4 0 )
21. Rushing through
1. Segmentation 22. Convert harm into benefit, "Blessing in disguise"
2. Extraction, Separation, Removal, Segregation 23. Feedback
3. Local Quality 24. Mediator, intermediary
4. Asymmetry 25. Self-service, self-organization
5. Combining, Integration, Merging 26. Copying
6. Universality, Multi-functionality 27. Cheap, disposable objects
7. Nesting 28. Replacement of a mechanical system with 'fields'
8. Counterweight, Levitation 29. Pneumatics or hydraulics:
9. Preliminary anti-action, Prior counteraction 30. Flexible membranes or thin film
10. Prior action 31. Use of porous materials
11. Cushion in advance, compensate before 32. Changing color or optical properties
12. Equipotentiality, remove stress 33. Homogeneity
13. Inversion, The other way around 34. Rejection and regeneration, Discarding and recovering
14. Spheroidality, Curvilinearity 35. Transformation of the physical and chemical states of an
15. Dynamicity, Optimization object, parameter change, changing properties
16. Partial or excessive action 36. Phase transformation
17. Moving to a new dimension 37. Thermal expansion
18. Mechanical vibration/oscillation 38. Use strong oxidizers, enriched atmospheres, accelerated
19. Periodic action oxidation
20. Continuity of a useful action 39. Inert environment or atmosphere
40. Composite materials
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T R I Z Ex a m p l e

• Statement: Bullet proof vests should be strong, but not


heavy.

• Step 1 – Identify the contradiction(s): Strength (improves)


versus Weight (worsens)

• Step 2 – Look at the list of features and identify those


important to your contradiction.

Strength – #14 Weight – #2

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T R I Z Ex a m p l e
1 Segmentation
Principle 27: Cheap short-living objects
26 Copying
• Replace an inexpensive object with a multiple
27 Cheap short living
of inexpensive objects, comprising certain
40 Composite materials qualities (such as service life, for instance).

Principle 1: Segmentation
Principle 40: Composite materials
• Divide an object into independent parts.
• For lighter-weight, stronger vests, the use of
• Make an object easy to disassemble.
composites is an active area of research.
Principle 26: Copying
• Polymers (Kevlar) reinforced with carbon
• Instead of an unavailable, expensive, fragile
nanofibers are currently being investigated as a
object, use simpler and inexpensive copies.
strong lightweight alternative to steel for structural
• Replace an object, or process with optical materials.
copies.
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T R I Z Ex a m p l e

• Iron product to remove the wrinkles:

Conflicts is we desired heavy iron to remove the wrinkles from the cloths but we do
not want a heavy iron due to the impact on ergonomics.
 8 – Principle of counterweight: Attach an object with lifting power or use the interactions
with the environment, e.g. aerodynamic lift.
 1 – Principle of segmentation: Divide the object into independent parts that are easy to
dissemble, increase the degree of segmentation as much as possible.
 37 – Application of thermal expansion: Use expansion or contraction of material by heat.
Use materials with different coefficient of thermal expansion.
 18 – Use of mechanical vibration: Make the object vibrate. Increase the frequency of
vibration.

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T R I Z Ex a m p l e

• Airbags need to inflate before contacting occupants to prevent forward motion.


We would like to inflate the air bags faster while decreasing the adverse effects.
– Principle 16: Partial or Excessive Action Use a lower powered air bag. By using less
power the acceleration of the bag is less, and injuries will be reduced. Use smaller air
bags with higher power. These bags will reach full inflation sooner.
– Principle 21: Rushing Through Inflate the air bag faster than current practice.

– Principle 40: Composite materials Airbag material that can’t grab skin as it is deployed

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Pr o d u c t D e v e l o p m e n t Pr o c e ss

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Pu g h C o n ce p t S e l e c ti o n
Choose the criteria for evaluation

Formulate the decision matrix

Clarify the design concepts

Choose the datum concept

Run the matrix

Evaluate the ratings

Establish a new datum and rerun the matrix

Examine the selected concepts for improvement opportunities

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Pu g h c o n c e p t se l e cti o n : Exa m p l e
• Improvement of on/off switch in a right-angle drill:

• Concept A is a modest change to the


existing switch, and will be the DATUM.
• Concept B adds three buttons for on/off/
and reverse.
• Concept C is a track and slider design.
• Concept D is an add-on accessory to make
it easier to operate the existing switch.

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Pu g h c o n c e p t se l e cti o n : Exa m p l e

• The highest-ranking design, an add-on


attachment that makes it easier to operate the
switch, has two negatives, poorer aesthetic
appeal and poor ergonomics (comfort to the
hand).
• Design D provides force amplification, but it is
not easy on the ligaments in the fingers.
• The next ranking design, the track and slider
design, has only a single minus for
“availability of materials.”

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Ex a m p l e : C o ffe e M i l l
• Evaluation of cleaning function of coffee mill:

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Ex a m p l e : C o ffe e M i l l

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Ex a m p l e : C o ffe e M i l l

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Ex a m p l e : Br e a d To a ste r

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Ex a m p l e : Br e a d To a ste r

Step 1: Identified set of criteria for evaluation

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Ex a m p l e : Br e a d To a ste r

Step 2: Select one concept as a datum

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Ex a m p l e : Br e a d To a ste r

Step 3: Compared all the concepts with respect


to datum concept.

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We ig h te d D e c is i o n M a tr i x
• The weighted decision matrix is a powerful quantitative technique. It evaluates a set of choices
(for example, ideas or projects) against a set of criteria you need to take into account. 

• It also is known as the "prioritization matrix" or "weighted scoring model". No need to get
confused.

• Procedure:
– List different choices

– Determine influencing criteria

– Rate your criteria


– Rate each choice for each criterion
– Calculate the weighted scores
– Calculate the total scores
– Make your decision
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We ig h te d D e c is i o n M a tr i x

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We ig h te d D e c is i o n M a tr i x

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We ig h te d D e c is i o n M a tr i x
• Four preliminary designs for sport-utility vehicles had the characteristics listed in
below Table. Appropriate weighing factor is selected based on objective tree. Using the
weighted decision matrix, which design looks to be the most promising?
Characteristics Parameter Design A Design B Design C Design D

Gas mileage Miles per gal 20 16 15 20

Range Miles 300 240 260 400

Ride comfort Rating Poor Very Good Good Fair

Ease to convert to 4- Rating Very Good Good Good Poor


wheel drive
Load Capacity Kg 1000 700 1000 600

Cost of repair Avg. of 5 parts $700 $625 $600 $500

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An a l yti c Hi e r a r ch y P r o c e ss ( AH P)

• The Analytic Hierarchy Process (AHP) is a problem-solving methodology for


making a choice from among a set of alternatives when the selection criteria
represent multiple objectives, have a natural hierarchical structure, or consist of
qualitative and quantitative measurements.
• AHP builds upon the mathematical properties of matrices for making consistent
pairwise comparisons.
• AHP is a decision analysis tool that is used throughout a number of fields in
which the selection criteria used for evaluating competing solutions that do not
have exact, calculable outcomes.

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An a l yti c Hi e r a r ch y P r o c e ss ( AH P)

• AHP is relevant for choice problems in the following categories:

• Comparing untested concepts


• Structuring a decision-making process for a new situation

• Evaluating non commensurate trade-offs

• Performing and tracking group decision making


• Integrating results from different sources (e.g., analytical calculations, HOQ
relative values, group consensus, and expert opinion);
• Performing strategic decision making.

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AH P Pr o c e ss

• AHP leads a design team through the calculation of weighting factors for decision criteria
for one level of the hierarchy at a time.

• AHP also defines a pairwise, comparison based method for determining relative ratings for
the degree to which each of a set of options fulfills each of the criteria.

• Let us take a crane hook example:


1. Material cost

2. Manufacturing cost
3. Reparability

4. Durability

5. Reliability

6. Time to produce.
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AH P Pr o c e ss

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AH P Pr o c e ss

• The rating of pair A to pair B is the reciprocal of the rating of pair B to A. That
means if it is determined that A is strongly more important than B, the rating of A
to B is set as 5. This makes the rating of B to A 1/5 or 0.20.
• AHP Process:

• Complete criteria comparison matrix [C] using 1–9 ratings described.

• Normalize the matrix [C] to give [NormC].


• Average row values. This is the weight vector {W}.

• Perform a consistency check on [C].

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AH P Pr o c e ss
• The matrix [C] is square with n rows
and columns, n being the number of
selection criteria.
• The matrix is constructed one
pairwise comparison at a time.
• The diagonal entries are all 1
because comparing (A) with (A)
means they are of equal importance.
• Once [C] is complete, the matrix
entries are normalized by dividing
each column cell by the column sum.
• Average each row to calculate a
candidate set of criteria weights
shown in vector {W}.

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AH P Pr o c e ss

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AH P Pr o c e ss
Consistency Check Process for AHP Comparison Matrix [C]:
– As the number of criteria increases, it is difficult to assure consistency. That is why the
AHP process includes a consistency check on [C]. The process is as follows:
1. Calculate weighted sum vector, {Ws} = [C] × {W}

2. Calcúlate consistency vector, {Cons} = {Ws}/{W}


3. Estimate λ as the average of values in {Cons}

4. Evaluate consistency index, CI = (λ – n) / (n - 1)


5. Calculate consistency ratio, CR = CI/RI.

6. If CR < 0.1 the {W} is considered to be valid; otherwise adjust [C] entries and repeat.

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AH P Pr o c e ss

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AH P Pr o c e ss fo r C r a n e h o o k

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AH P Pr o c e ss fo r C r a n e h o o k

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AH P Pr o c e ss fo r C r a n e h o o k

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AH P: E xa m p l e C a r Se le cti o n

• Objective
• Selecting a car
• Criteria
• Style, Reliability, Fuel-economy, Cost
• Alternatives
• Civic Coupe, Saturn Coupe, Ford Escort, Mazda Miata

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AH P: E xa m p l e C a r Se le cti o n

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AH P: E xa m p l e C a r Se le cti o n

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AH P: E xa m p l e C a r Se le cti o n

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AH P: E xa m p l e C a r Se le cti o n

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AH P: E xa m p l e C a r Se le cti o n

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AH P: E xa m p l e C a r Se le cti o n

DE G531 – P R O D U C T D E S I GN 79 BITS-Pilani, Hyderabad Campus


AH P: E xa m p l e C a r Se le cti o n

DE G531 – P R O D U C T D E S I GN 80 BITS-Pilani, Hyderabad Campus


AH P: E xa m p l e C a r Se le cti o n

DE G531 – P R O D U C T D E S I GN 81 BITS-Pilani, Hyderabad Campus


AH P: E xa m p l e C a r Se le cti o n

DE G531 – P R O D U C T D E S I GN 82 BITS-Pilani, Hyderabad Campus


AH P: E xa m p l e
• Peter is offered 4 jobs from Acme Manufacturing (A), Bankers Bank (B), Creative Consulting (C),
and Dynamic Decision Making (D).
• He bases his evaluation on the criteria such as location, salary, job content, and long-term
prospects.
• Step 1: Decide upon the relative importance of the selection criteria:

DE G531 – P R O D U C T D E S I GN 83 BITS-Pilani, Hyderabad Campus


AH P: E xa m p l e

1) Normalize the column entries by dividing each entry by the sum of the column.
2) Take the overall row averages

DE G531 – P R O D U C T D E S I GN 84 BITS-Pilani, Hyderabad Campus


AH P: E xa m p l e

Step 2: Evaluate alternatives w.r.t. each criteria

Location Scores Relative Location Scores


A B C D A B C D Avg.
A 1 1/2 1/3 5 A 0.161 0.137 0.171 0.174
B 2 1 1/2 7 B 0.227
C 3 2 1 9 C 0.322 0.275 0.257 0.293
D 1/5 1/7 1/9 1 D 0.312
0.484 0.549 0.514 0.489
0.409
0.032 0.040 0.057 0.044
0.045

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AH P: E xa m p l e

Relative
weights Relative scores
Relative Scores for Each Criteria for each for each
Location Salary Content Long-Term criteria alternative
A 0.174 0.050 0.210 0.086 0.164
B 0.510 x 0.496 = 0.256
C 0.293 0.444 0.038
D 0.012 0.289 0.335
0.489 0.312 0.354 0.130 0.238
0.290
0.044 0.194 0.398
0.188

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Pr o s a n d co n s o f AH P m e th o d

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Pr o fe ssi o n a l So ftw a r e

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THANK YOU!

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