INTRODUCTION TO ENGINEERING DESIGN AND PROBLEM SOLVING

Engineering design is the creative process of identifying needs and then devising a
solution to fill those needs. This solution may be a product, a technique, a structure, a project, a
method, or many other things depending on the problem. The general procedure for completing a
good engineering design can be called the Engineering Method of Creative Problem Solving.

Problem solving is the process of determining the best possible action to take in a given
situation. The nature of problems that engineers must solve varies between and among the
various branches of engineering. Because of the diversity of problems there is no universal list of
procedures that will fit every problem. Not every engineer uses the same steps in their design
process, but Wright (1) following list, which includes most of the steps of the design method that
engineers use.

1. Identifying the problem.

2. Gathering needed information.

3. Searching for creative solutions.

4. Overcoming obstacles to creative thinking.

5. Moving from ideas to preliminary designs (including modeling).

6. Evaluating and selecting a preferred solution.

7. Preparing reports, plans, and specifications. (Project Planning)

8. Implementing the design. (Project Implementation)

IDENTIFYING THE PROBLEM

Evaluating the needs or identifying the problem is a very important step in finding a solution. An
improper definition of the problem will cause the engineer to waste time or arrive at an incorrect
solution. It is important that the stated needs be real needs. A great design may be worthless if it
duplicates other known designs or doesn’t benefit many people.

Broadly define the needs and distinguish them from possible solutions. An example of not
distinguishing the needs from a possible solution is seen when looking at the problem of motor
vehicle fatalities. Traffic safety specialists defined the problem in terms of accident prevention
rather than loss reduction. By focusing on accident prevention, which is a possible solution to the
actual problem of loss reduction, they focused their solutions on driver behavior: driver
education, traffic enforcement, and “Drive Safely” campaigns.

GATHERING NEEDED INFORMATION

After defining the problem, an engineer begins to gather all the information and data necessary to
solve the problem. It could be physical measurements, maps, results of laboratory experiments,
patents, results of opinion surveys, or any number of other types of information.

Engineers should always try to build on what has already been done before. Information on
related problems that have been solved or unsolved may help engineers find the best solution.

SEARCHING FOR CREATIVE SOLUTIONS

There are several techniques to help a group or individual to produce original creative ideas. The
development of these new ideas may come from creativity, a subconscious effort, or innovation,
a conscious effort.

Some techniques suggests that may aid a group or individual in obtaining a creative solution are
brainstorming, checklists, attribute listing, the forced relationship technique, and adopting a
different point of view. Each of these will be discussed briefly. The purpose to most of these
methods, which can be almost like a game, is to break the set patterns of thought that every
individual develops.

Brainstorming

A popular technique for group problem solving is brainstorming. Typically, a brainstorming

Individuals can also use the same techniques to brainstorm without a group.

BRAINSTORMING RULES

1. All ideas are encouraged.

3. Combine and improve ideas.

4. Delay judgment and evaluation of ideas until end.

Checklists

One of the simplest methods for generating new ideas is to make a checklist. The checklist
encourages the user to examine various points, areas, and design possibilities.

For example to improve a device, you may want a checklist like this:

Ways the device could be put to other uses.

Ways the device could be modified.

Ways the device could be rearranged.

Ways the device could be magnified.

Ways the device could be reduced, etc.

Attribute Listing

With attribute listing, all the major characteristics or attributes of a product, object, or idea are
isolated and listed. Then, for each attribute, list ideas as to how each of the attributes could be
changed. Again, as in brainstorming, all ideas are listed no matter how impractical. After all the
ideas are listed, evaluate each idea bringing to light possible improvements that can be made to
the design of the product. For example, how can we improve a telephone design?

Attribute Ideas

1. Color Could be any color

Could be transparent

Could utilize designs such as plaid

Could have a personalized design

2. Material Could be metal

Could be glass
 Could be wood

Could be hard rubber

3. Dial Could be 10-push-button design

Could be lever system

Could use abacus-type system

Could be push buttons arranged in a line

4. Handset and base Make it square

Make it round

Make it oval

Use higher base

Use lower base

Eliminate handset by using microphone and

Forced Relationship Technique

The forced relationship technique takes a fixed element, such as the product or some idea related
to the product, and forces it to take on the attributes of another unrelated element. This forms the
basis of a free flowing list of associations from which hopefully new ideas will emerge. As
before, judge the value of the ideas after the process is complete.

For example, suppose we wish to design a weed-cutting device. This will be the forced object.
Suppose we randomly choose an automobile wheel as the other element. Some of the ideas that
may occur based upon the automobile wheel are:

A round weed cutter.

A rubber weed cutter.

A weed cutter that rolls.

A weed cutter that has spokes.

A weed cutter that has brakes.

A weed cutter that will not break

OVERCOMING OBSTACLES TO CREATIVE THINKING

Here are some specific actions and attitudes that can be employed to overcome obstacles to
creative thinking

1. Avoid placing unnecessary constraints on the problem being solved.

2. Search for different ways to view the problem, avoiding preconceived beliefs and stereo
typical thinking.

3. Recognize that there are non-engineering solutions to many problems. Consider approaches
that other disciplines might use.

4. Look for relationships that are remote and solutions that are unusual and nontraditional. Most
creative thought involves putting experiences and thoughts into new patterns and arrangements.

5. Divide complex problems into manageable parts and concentrate on solving one part at a time.

6. Allow time for incubation, after periods of intensive concentration.

7. Be open to a variety of problem-solving strategies.

MOVING FROM IDEAS TO PRELIMINARY DESIGNS

For engineers to move from ideas to a preliminary design, they must sort through the possible
solutions and determine which ones are unworkable and which might have promise. The
promising ideas are then molded and worked into plans. Preliminary designs evolve through
analysis and synthesis. Analysis is breaking apart the whole and studying its individual
components. Synthesis involves putting together many facts, laws, or principles into a whole idea
that will accomplish some result or solve a problem.

There are many techniques an engineer might use to determine if an idea has promise.
Preliminary sketching or analysis may show that the idea is a bad one. Laboratory tests may need
to be run on a component to see if it will work in a given situation. Perhaps a large research
project may need to be undertaken to examine the validity of a process, or its consequences if
used as a solution. The engineer must critically examine and study possible solutions, and
constantly eliminate poor or inappropriate solutions.

To facilitate the design process, engineers often rely on models. A model simplifies a system or
process so that it may be better studied, understood, and used in a design. There are three
common models used in engineering: mathematical, simulation, and physical.

Mathematical models usually consist of one or more equations that describe a physical system.
Many physical systems can be described by mathematical models. Such models can be based on
scientific theories or laws that have stood the test of time, or they may be based on empirical data
from experiments or observations. Mathematical models are usually employed for simple
systems. The difficulty in deriving the equations for complex systems outweighs their usefulness.

Computer simulation models allow engineers to examine complex systems. Such models may
incorporate many empirically based mathematical models as part of the total simulation model.
A computer program is developed to describe a system, and this model may then be subjected to
many different simulated operating conditions.

Physical models have long been used by engineers to understand complex systems. They
probably represent the oldest method of structural design. Physical models have the advantage in
that they allow an engineer to study a device, structure, or system with little or no prior
knowledge of its behavior or need to make simplifying assumptions. Full scale models are
sometimes built, but most often they have been scaled down anywhere from 1:4 to 1:48.

Examples of studies made with physical models include:

1. Dispersion of pollutants throughout a lake.

2. Behavior of waves within a harbor.

3. Underwater performance of submarines of different shapes.

4. Performance of aircraft by using wind tunnels to simulate various flight conditions.

EVALUATING AND SELECTING A PREFERRED SOLUTION

There are many criteria that engineers use to evaluate the value of a solution or design, which
may depend on the nature of the problem. If the solution involves a product, great importance
may be placed on safety, cost, reliability, and consumer acceptability.
Many designers use prototypes to test the operation of the design. The designer could then
identify any weak areas of the design and attempt to improve upon them. No idea should be
discarded solely on the basis of one prototype or one test. Many great designs have been
discarded prematurely and many working prototypes have failed to give acceptable products.

Indirect evaluation can be used as well, to evaluate a design. Scale models can be used to test
aircraft design at a fraction of the cost of building a prototype. Computer simulations and
mathematical models may not be accurate enough to allow understanding of all the complexities
of component interference or turbulence, but they still may be used to approximate the design of
the first scale model for wind tunnel testing.

PREPARING REPORTS, PLANS, AND SPECIFICATIONS

After selection of the preferred design, it must be communicated to those who must approve it,
support it, and translate it into reality. This communication may take the form of an engineering
report, or a set of plans and specifications. Plans and specifications are the engineer’s means of
describing to a manufacturing division or to a contractor sufficient detail about a design so that it
can be produced or constructed. Engineering drawings, written and oral communications, and
scheduling and planning a design project are very important in implementing a design smoothly
and efficiently.

Engineering Drawings

Engineers create detailed technical drawings that show what the design looks like, what parts are
necessary, how to assemble it, and how to operate it once constructed. These graphical
specifications are probably the most important type of documentation for engineering design
problems. They communicate visually to the technical team what verbal communications cannot
adequately convey. The drawings must be done clearly and according to standards and
conventions accepted by the team.

Written Communications

Memorandums, often called memos, are a brief and effective way to keep everyone involved
aware of the design’s progress. Memos can be distributed to one person or to a list of people
within the organization who have an interest in the subject.
A technical report is a much longer and complete record of the design process. It should include
everything that was done to solve the problem. As with any communication the technical writing
should be clear, direct, and readable by the intended audience. There are many types of reports
written by engineers, but in general they all include the following information: (4)

• Cover page, stating title of project, company name, author, and date

• Abstract, giving a short overview and summary of the work

• Table of Contents

• Body of the report, which elaborates on the problem solved, presents background material,
procedure used, results and significance of work.

• Conclusions and recommendations, which summarize the results and significance of work.

• Appendices, for the reader who wants to know everything about the work.

Oral Communication

At different stages during the design process an engineer may be called upon to give an oral
progress report to the design team, the supervisor, or management and marketing people.

The objectives of an oral presentation are the same for a written report: the engineer wants to
communicate information and convince the audience. The methods used however are very
different. The most important element in for a successful oral presentation is preparation.

Here are some pointers for a good oral presentation:

• Be very familiar with the subject of the presentation.

• Know how much time is allotted for the presentation.

• Practice the presentation to cover everything completely within the time limit.

• Know your audience. Match presentation level with audience’s understanding level.

• Speak clearly and eloquently.

• Have simple and uncluttered visual materials. Do not put too much information on one visual.

• Have a good summary and conclusion to highlight the important parts of the presentation.

• End the presentation, by asking the audience if they have any questions.
Scheduling and Planning a Design Project

Since a design project is usually much more complicated than finishing physics homework, a
complete solution will involve several steps or tasks. Some complex problems will require weeks
or months to complete. The design problem solution needs to include a schedule or a plan of
when to do the necessary tasks to complete the design. In a good schedule, each task should be
completed before its results are needed by another task. The schedule should also make use of all
the personnel all of the time. Also since designs frequently are changed and improved throughout
the entire process, it is a good idea to schedule design reviews at the end of each project phase.

IMPLEMENTING THE DESIGN

The final stage of the design process is implementation, the process of producing or constructing
a physical device, product, or system. Engineers must plan and oversee the production of the
devices or products and supervise the construction of the engineered projects. Different
engineers may, of course, be involved in this final phase. For the design engineer, implementing
the design is the most satisfying stage of all.