Teaching Engineering Design Skills: January 2011
Teaching Engineering Design Skills: January 2011
Teaching Engineering Design Skills: January 2011
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Nikos J Mourtos
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ABSTRACT
The Project-Based Learning approach is used to introduce design skills from the
freshman all the way to the junior and senior level in the BSAE Program at San
Jose State University. The culmination of this effort is a two-semester senior
capstone experience in aerospace vehicle design, in which students conceive,
design, and often build an air or a space vehicle. The paper discusses a systematic
approach for defining and teaching engineering design skills. Although the
examples presented in the paper are from the field of aerospace engineering, all
the principles apply to engineering design in general.
What makes the teaching of engineering design particularly challenging is that the
necessary skills and attributes are both technical and non-technical and come
from the cognitive as well as the affective domains. Each set of skills requires a
different approach to teach and assess. Implementing a variety of approaches for
a number of years at SJSU has shown that it is just as necessary to teach affective
skills as it is to teach cognitive skills. As one might expect, each set of skills
presents its own challenges.
INTRODUCTION
Design is the heart of engineering practice. In fact, many engineering experts
consider design as being synonymous with engineering. Yet engineering schools
have come under increasing criticism after World War II because they have
overemphasized analytical approaches and engineering science at the expense of
hands-on, design skills (Seely, 1999 and Petrosky, 2000). As the editor of
Machine Design put it, schools are being charged with not responding to industry
needs for hands-on design talent, but instead are grinding out legions of research
scientists…(Curry, 1991). Nicolai (1998) has expressed similar concerns.
Teaching Engineering Design Skills. Nikos J. MOURTOS
Proceedings, IETEC’11 Conference, Kuala Lumpur, Malaysia, Copyright © Nikos J. Mourtos, 2011
To define the skills necessary for design engineers we need to look at the
definition of engineering itself.
Teaching Engineering Design Skills. Nikos J. MOURTOS
Proceedings, IETEC’11 Conference, Kuala Lumpur, Malaysia, Copyright © Nikos J. Mourtos, 2011
It must also be beautiful, unique, and meaningful. This requirement adds a new
dimension to engineering design, a dimension that has much in common with the
creative arts.
The next step in our search for design skills is to look at the engineering design
process. Figure 1 is an attempt to illustrate this iterative process, as it takes place
in our brain (Nicolai, 1998).
Design begins with brainstorming of ideas. This takes place in the right (creative)
part of the brain. There are virtually no rules in generating these ideas. In fact, it is
desirable to come up with as many ideas as possible and allow for “wild” ideas as
well as conventional ones. While storming, the right brain tends to be holistic,
intuitive, and highly nonlinear (i.e. it jumps around). It sees things in their context
as well as metaphorically, recognizes patterns, focuses on relationships between
the various parts and cares about aesthetics.
Subsequently, each idea is evaluated in the left (analytical) part of the brain under
very rigid rules. The left brain acts as a filter on all the ideas generated, deciding
which ones are viable under the current rules and which ones are not. The left
brain tends to be logical, sequential, computer-like. It sees things literally and
focuses on categories.
Teaching Engineering Design Skills. Nikos J. MOURTOS
Proceedings, IETEC’11 Conference, Kuala Lumpur, Malaysia, Copyright © Nikos J. Mourtos, 2011
As Figure 1 illustrates, the design process involves an iterative cycling through a
sequence that involves creative, imaginative exploration, objective analytical
evaluation, and finally making a decision. It is this context, known also as
convergent – divergent thinking (Nicolai, 1998), in which one should look for the
skills and attributes necessary for a good design engineer.
Design also requires compromise because requirements often conflict with each
other. For example, to provide comfort for airplane passengers one needs a large
cross-sectional area. But a large cross-sectional area results in greater drag and
compromised fuel efficiency, especially at high speeds. A successful aircraft
designer must decide where to draw the line between these two conflicting
requirements.
Analytical Skills
The right-hand side of Figure 1 attests to the need for traditional engineering
analytical skills: solid fundamentals in mathematics, physical science (e.g.
physics, chemistry, etc.), and engineering science (e.g. fluid mechanics,
thermodynamics, dynamics, etc.). Outcome 3a of ABET EC 2000 (Engineering
Accreditation Commission) highlights this need.
Design skills build upon open-ended problem solving skills. Outcome 3e of ABET
EC 2000 highlights the need for such skills when it states that engineering
graduates must be able to identify and formulate engineering problems in addition
to being able to solve such problems.
Students who are open-ended problem solvers exhibit the following attributes
(Woods, 1997):
a. Are willing to spend time reading, gathering information and defining the
problem.
Teaching Engineering Design Skills. Nikos J. MOURTOS
Proceedings, IETEC’11 Conference, Kuala Lumpur, Malaysia, Copyright © Nikos J. Mourtos, 2011
b. Use a process, as well as a variety of tactics and heuristics to tackle problems.
c. Monitor their problem-solving process and reflect upon its effectiveness.
d. Emphasize accuracy rather than speed.
e. Write down ideas and create charts / figures, while solving a problem.
f. Are organized and systematic.
g. Are flexible (keep options open, can view a situation from different
perspectives / points of view).
h. Draw on the pertinent subject knowledge and objectively and critically assess
the quality, accuracy, and pertinence of that knowledge / data.
i. Are willing to risk and cope with ambiguity, welcoming change and
managing stress.
j. Use an overall approach that emphasizes fundamentals rather than trying to
combine various memorized sample solutions.
Teaching Engineering Design Skills. Nikos J. MOURTOS
Proceedings, IETEC’11 Conference, Kuala Lumpur, Malaysia, Copyright © Nikos J. Mourtos, 2011
The importance of taking into consideration non-technical constraints (e.g. social,
political, ethical, safety) is further reinforced in other ABET outcomes as well,
where engineering graduates are expected to have:
In summary, the design engineer must develop an aptitude for systems thinking
and maintain sight of the big picture, which is often influenced by technical as
well as non-technical factors. Clearly, it is very difficult to quantify a set of
specific skills to describe the ideal design engineer. Nevertheless, in an effort to
facilitate the teaching and assessment of these design skills, the BSAE Program at
SJSU adapted the following set performance criteria:
Teaching Engineering Design Skills. Nikos J. MOURTOS
Proceedings, IETEC’11 Conference, Kuala Lumpur, Malaysia, Copyright © Nikos J. Mourtos, 2011
Leonardo da Vinci (1452 – 1519) was one of the earliest engineers who
demonstrated mastery in freehand drawing, making it possible for us today to
visualize how his inventions worked and appreciate his genius (see for example
Figure 2). Freehand drawing is a right-brain activity because it is free of technical
symbols and it is closely associated with our ability to visualize things in three
dimensions, an indispensable design skill.
Unlike freehand drawing with its artistic flavor, engineering drawing is a precise
discipline based on the principles of orthographic projection. In contrast to
freehand drawing, engineering drawing emphasizes accuracy, something that has
been greatly enhanced by the use of modern computers and graphic capabilities.
Today a CAD is much more than a computer generated engineering drawing; it
involves an extensive database detailing the attributes of an object and allows it to
be rotated, sectioned, and viewed from any angle. This capability is indispensable
in the design of complex engineering equipment, such as an airplane, because
engineers can now superposition the various subsystems and immediately see
potential conflicts. CAD has led to Computer-Aided Manufacturing (CAM),
where the machines that manufacture the various components receive their
operating instructions directly from the database in the computer.
Kinematics
Teaching Engineering Design Skills. Nikos J. MOURTOS
Proceedings, IETEC’11 Conference, Kuala Lumpur, Malaysia, Copyright © Nikos J. Mourtos, 2011
understanding of kinematics (e.g. selecting the proper mechanism and visualizing
its operation) allows the design engineer to evaluate what will work and what will
not work. For example, in the design of an airplane landing gear, the designer
must be able to visualize how the gear will fold and retract in its proper space and
make sure that it will not conflict with other components in the process.
The skills described in this section fall under Outcome 3k of ABET EC 2000,
which states that engineering graduates must have an ability to use the techniques,
skills, and modern engineering tools necessary for engineering practice.
Archimedes designed his screw pump (Wikipedia, 2007) alone. This was not
uncommon in the ancient world. Similarly, Leonardo da Vinci designed his
engineering devices, such as the one shown in Figure 2, alone. Today, working
alone to design an engineering product is, for the most part, a thing of the past
unless, of course, the product is a very simple one. The complexity of modern
engineering products requires engineers to work in teams; in fact, sometimes
several teams must work together. For example, in the design of a new transport, it
is typical to have a team of engineers from each of the disciplines mentioned
above (aerodynamics, controls, manufacturing, etc.). These teams work closely
together to meet the same set of mission and airworthiness requirements, while at
the same time making sure there are no conflicts between the various airplane sub-
systems.
Hence, although in section 2.3.3 we expressed the need for design engineers to be
generalists to appreciate the multidisciplinary requirements that come into play in
the design of a new product, it is not possible for an individual to have enough
expertise in each and every one of the technical areas to adequately perform the
detail design of all the subsystems, not to mention the analysis of the impact of a
new product in a global, economic, environmental, and societal context.
Teaching Engineering Design Skills. Nikos J. MOURTOS
Proceedings, IETEC’11 Conference, Kuala Lumpur, Malaysia, Copyright © Nikos J. Mourtos, 2011
d. Demonstrate adequate understanding of other fields (ex. different branches of
engineering / physical sciences, economics, management, etc.) to participate
effectively on multidisciplinary projects.
e. Communicate ideas relating to aerospace engineering in terms that others
outside the discipline can understand.
Communication Skills
In addition to the skill described in (e) above, design requires clear and effective
communication between team members, as well as between the team and third
parties (management, customers, etc.). Communication usually takes two forms,
oral and written and can be informal, such as between team members or formal,
such as when the team presents information to third parties. All four types are
crucial for the success of a project. The need to communicate effectively is
outlined in Outcome 3g of ABET EC 2000. In the BSAE Program at SJSU the
following performance criteria were selected to express the skills embedded in this
outcome:
Ability to:
Like any set of skills, design skills must be introduced early, practiced often, and
culminate in a realistic design experience if students are to achieve the level of
mastery prescribed in ABET EC 2000 and expected in industry. The following
subsections describe how design is introduced at the freshman level, is dispersed
throughout the BSAE curriculum, and finally culminates in a senior design
capstone sequence. The Project-Based Learning (PBL) pedagogical model is used
in all courses where design is taught and students work in teams for all design
projects.
Teaching Engineering Design Skills. Nikos J. MOURTOS
Proceedings, IETEC’11 Conference, Kuala Lumpur, Malaysia, Copyright © Nikos J. Mourtos, 2011
each project, students work in teams to research, brainstorm, design, build, test,
and finally demonstrate a device in class (Mourtos & Furman, 2002). Typically,
students participate in two or three projects during the semester. This course
design followed well-established research, which shows that first-year design
courses help attract and retain engineering students (Ercolano, 1996).
E10 students report significant gains in their understanding of design and ethics,
design report writing and briefing skills (Mourtos & Furman, 2002). They report
slightly lower gains in open-ended problem solving skills, including estimation
and mathematical modeling. On the other hand, they report low gains in team
skills. This is probably due to the fact that team skills were not taught explicitly at
the time of the assessment. Despite a significant amount of time spent working in
teams, students needed more guidance and coaching on skills like conflict
resolution, task delegation, decision making, etc.). These skills are now taught
more explicitly.
Teaching Engineering Design Skills. Nikos J. MOURTOS
Proceedings, IETEC’11 Conference, Kuala Lumpur, Malaysia, Copyright © Nikos J. Mourtos, 2011
Senior Design Capstone Experience
In their senior year, aerospace engineering students have the option to take a
course sequence in aircraft design (AE171A&B) or in spacecraft design
(AE172A&B). Although only one of these course sequences is required, a few
students choose to take both in lieu of technical electives. Both courses involve the
conceptual and preliminary design of an aerospace vehicle. If the vehicle is small
(e.g. SAE 1 Aero-Design Competition or AIAA 2 Design/Build/Fly Competition),
students also carry out the detail design of the vehicle, build it, and test it. Often
engineering professionals from the aerospace industry mentor students in their
designs. In addition to participating in these competitions, students also submit
and present papers to student as well as professional conferences (e.g. Johnson et
al, 2009; Casas et al, 2008).
Safety, ethics, and liability issues are addressed in the course through aerospace
case studies involving accidents. Students research background information for
each case, make a class presentation, and argue about the various issues in class. A
written report is also required.
Teaching Engineering Design Skills. Nikos J. MOURTOS
Proceedings, IETEC’11 Conference, Kuala Lumpur, Malaysia, Copyright © Nikos J. Mourtos, 2011
school. After all, the venues available for publishing design work or seeking
funding to do such work are limited compared with traditional areas of
engineering research.
Hence, when a faculty member is asked to teach a design course, they often find
themselves unprepared. One way to address this deficiency is to require
engineering faculty to undergo some training in engineering design before
teaching a design course. There are many workshops on design for faculty
members as well as for engineers who work in industry, sponsored by professional
societies, universities, and engineering companies. Professional societies also
offer summer Fellowships for engineering faculty willing to spend a summer in
industry working alongside design engineers.
CONCLUSION
An attempt has been made to provide a comprehensive list of skills, technical and
non-technical, for design engineers. These skills include analytical, open-ended
problem solving, a view for total engineering, interpersonal and team skills,
communication skills, as well as fluency with modern tools and techniques used in
engineering design. In addition to these skills, design engineers must develop
certain attributes, such as curiosity to learn new things and explore new ideas,
self-confidence in making design decisions, taking risks by trying new concepts,
thinking out-of-the-box, and persistence to keep trying when things don’t work.
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Teaching Engineering Design Skills. Nikos J. MOURTOS
Proceedings, IETEC’11 Conference, Kuala Lumpur, Malaysia, Copyright © Nikos J. Mourtos, 2011
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Teaching Engineering Design Skills. Nikos J. MOURTOS
Proceedings, IETEC’11 Conference, Kuala Lumpur, Malaysia, Copyright © Nikos J. Mourtos, 2011
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Copyright © 2011 IETEC11, Author: Nikos J. Mourtos: The author assigns to IETEC11 a non-
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Teaching Engineering Design Skills. Nikos J. MOURTOS