College of Engineering

GE106:Introduction to Engineering Design

Problem Formulation
and
Case Studies
By

Matthew Amao
 Outline
• The Nature of Design
• Design Objectives
• Design Constraints
• Design Criteria
• Problem Definition
• Case Study 1: Washing Machine
• Case Study 2: Can Crushing Device
• Case Study 3: Car Coffee Cup Holder
• Lecture Summary

Monday, August 30, 2021 Introduction to Engineering Design GE-106 2

 The Nature of Design
Design problems have:

Objective(s) (or goal) to be achieved.

Some constraints within which the objective/goal must be

achieved.

Some criteria by which a good solution is recognized.

Constraints set specific (usually quantitative) targets or limits.

Criteria are more flexible and might be used for judging

between different design proposals, each of which meets the
specific constraint targets.
 Need Analysis
The purpose of Need Analysis is to make a case that will
help in identifying the problem statement and list of
specifications from which the design objectives,
constraints, and criteria can then be clearly defined.

• Quality needed • Maintainability

• Efficiency. • Flexibility
• Reliability • Durability
• Safety • Environmental impact
• Economic
• Social and ethical issues.
• Aesthetics
 Design Objectives
The complete statement of the
design objectives is an essential
part of the problem formulation.
Unless the designer is aware of
the totality of the problem he is
obviously not able to produce the
best solution. Primary Object (in Solar System): The Sun

It is convenient to consider two

components of the design
objectives:-
*Primary Objective(s) (MUST)
*Secondary Objective(s) (WANTS)

Secondary Objects (in Solar System): The Planets

 Design Objectives
The primary objective may be defined as
that aspect of the problem formulation
which is specified by the customer.

For example a customer presents a

problem to design a machine for
packaging a powdered foodstuff. This is
Main objective is customer defined
the primary objective of the design for:

If the machine fails to achieve these

requirements, it is a total failure.

Whenever questions of relative

importance are considered the primary
objective is obviously the most Helicopter crash due to engine failure
important.
 Design Objectives
The secondary (less important)
objective(s) may be described as those
which are not necessarily specified but
are nevertheless essential for the
satisfactory attainment of the primary
objective(s).
Primary Objective:
Design a machine for packaging a powdered
foodstuff

Examples of secondary objectives include:-

(a) Low initial and operating costs.
(b) Freedom from contamination (the presence of Secondary objective here is safety
a minor constituent in another chemical or mixture).
(c) Safety of operation.
(d) Ability to cope with variable foodstuff
properties.
(e) Ease of operation, maintenance and repair
(f) Ability to be installed in the factory.
 Design Constraints

Constraints are factors that

limit the engineer’s flexibility.
They form the design envelope
(the feasible design space).
 Constraints
• Constraints are boundaries that limit the
engineer’s flexibility; they form the design
envelope (feasible design space).
• They help to identify acceptable designs.
• Should be measurable.
• Should be answered with: True/False;
Yes/No
• Example: Cost <1000 SAR?
Weight <500 N?
Flexible system (yes/no)?

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 Sources of Design Constraints
• Cost: Cost to design, produce, maintain, support, guarantee, be
competitive
• Time: Complex project schedules, delivery dates, down-stream process, time
to market
• Knowledge
• Legal and ethical: Patents, intellectual property, product liability,
safety requirements.
• Physical: Size, weight, power, durability
• Natural factors: Topography, climate, resources
• Company practices: Common parts, manufacturing processes
• Human Factors/Ergonomics: Limitations based on human capabilities
and abilities
• Sustainability
• Environment: Bio-degradable materials, recycled materials, green energy
 Design Criteria
• Design criteria are requirements you specify that will
be used to make decisions about how to build and
evaluate the product.

• Criteria are derived from needs expressed by

customer.
• Criteria define the product physical and functional
characteristics.
 Design Criteria

• Criteria are indicators defining the success

of achieving the objectives.
• Criteria define the product physical and
functional characteristics.
• They represent descriptive adjectives that
can be qualified on a given scale:
examples: beautiful, low cost, low noise,
smart, low weight.
• Might be used for judging between
different designs.

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 Examples of General Evaluation Criteria
 Safety  Minimum Maintenance and
 Environmental Protection Ease of Maintenance
 Public Acceptance  Ease of Manufacturing
 Reliability  Aesthetic design (Appearance)
 Performance
 Geometry
 Ease of Operation (Usability)
 Physical Features
 Durability
 Inputs-Outputs
 Use of Standard parts

 Minimum Cost  Use Environment

These criteria (or whatever criteria you have) are to be qualified

(ranked) say on a scale 1 to 10, where 1 (worst) and 10 (best) *
 Remember!

Customer
Before solving a problem, answer: Statement
Why
(very few Need Analysis
know this) • Literature
• Interview/Survey
How • Market Studies
• Focus Groups
(some know
this) Interpret and
Summarize
What • Specifications
• Objectives
(everyone • Constraints
knows this) • Criteria

Problem
Formulation

Monday, August 30, 2021 Introduction to Engineering Design GE-106 14

Getting to Problem Definition

• Problem Statement
Need • Specifications
Analysis

• Objectives
• Constraints
Problem
Definition • Criteria

• A paragraph compiling
Problem the above points
Formulation

15
Summary
Problem Definition
• Turn the problem
statement into a
technical, quantified
problem definition
• Precise description of
the properties of the
object being designed
• Can be a long list

16
 Example 1

You were asked to design a simple machine for

washing clothes.

Tasks:
– Establish need.
– Define the problem.
– Specify the needed information to be gathered.
– Set up criteria for a successful design.
 What? • Dry clothes
Statement*: • Machine • Capacity up to 5 kg
• Can use voltage 110 V / 220 V
Why?
How? • Low power consumption/wattage less
• Wash
• Automatic
clothes
than 100 Watts
• Portable washing machine
Needs:
• Noise level must not exceed 65 dB
• Device to wash clothes
• Must be safe
• Can be easily operated
• Filter for the water
• Can be started by operating
• Water inlet and outlet
the timer manually
• Cost must not exceed 500 SR
• Variation of rotating speed for
• Weight must be less than 100 N
different types of clothes
Monday, August 30, 2021 Introduction to Engineering Design GE-106 18
Constraints
• Capacity: up to 5 kg
• Noise level less than 65 dB
• Size: 1 m x 0.9 m x 0.5 m
• Weight not more than 100 N (10 kg mass)
• Cost less than 500 SR
• After drying no water drop from the clothes
• 110 / 220 volts
• Portable
• Life more than 5 Years
• Electric consumption less than 100 W.h (Watt-hours)

Criteria
• High effectiveness of cleaning the clothes
• High durability
• Easy to use (simple)
• High number of cloth types
Monday, August 30, 2021 Introduction to Engineering Design GE-106 19
 Safety Specifications
• If overloaded, the machine shouldn’t start.
• Maximum water level to prevent water waste and dangerous
current short-cuts.
• Electrical grounding
• Stop spinner if the door is opened.
• Kids protection by motor isolation.

Monday, August 30, 2021 Introduction to Engineering Design GE-106 20

 Problem Formulation [paragraph(s)]
Design a simple washing machine that can wash different types of
clothes and dry them by various spinning speeds. The machine
should be 5 kg capacity and easily manipulated. Its size should be
limited to 1 m / 0.9 m / 0.5m and its weight is not to exceed 100 N.
The washing machine must be portable and able to function using
110 V or 220 V voltage. The machine consumption and cost should
be respectively limited to 100 watt-hours and to 500 SR. The
minimum life duration of the machine should be 5 years.

The machine should have a water level

to prevent water wastage and be
grounded to avoid electrical shortcuts.
Besides, it should not start If
overloaded and must stop spinning if
its door is open. A motor isolation for
kids protection is also a must.
Monday, August 30, 2021 Introduction to Engineering Design GE-106 21
 Examples of Needed Information to be Gathered
• Motor power to be used.
• Speed for various types of clothes.
• Timing needed to clean common types of clothes and
dry them.
• Common types of clothes to be washed.
• Characteristics of each type of clothes (spinning speed,
adequate washing temperature, etc.)

Monday, August 30, 2021 Introduction to Engineering Design GE-106 22

 Example 2

Problem Statement: It is required to design a simple

crushing device for cans.
Needs Analysis:
• Design a simple device to crash cans (soft drinks)
• The final product is recyclable (green design)
• Does not occupy large space
• High strength material
• It costs 80 – 100 SR
• High safety
• Design for kids
• Light weight (portable)
• Easy to use
• Easy to maintain
• Heavy and large base (does not tip over)
• Will be operated by human power* (foot, hands, or both)
• Using available materials/components
Monday, August 30, 2021 Introduction to Engineering Design GE-106 23
 Primary objective:
• To design a simple, easy to use device to crush cans.
Secondary objective:
• The device should be easy to construct, easy to maintain,
marketable and portable.

Constraints:
• The cost should not exceed 100 SR
• The weight should not exceed 5 kg
• Applied force should be less than 30 N*
• Does not tip over
• Safe
Monday, August 30, 2021 Introduction to Engineering Design GE-106 24
 Criteria*:
• Low cost
• Light weight
• Low force
• High safety
• Simple to manufacture
• Simple Design

Needed Information* *:
• Type of materials to be used
• Typical existing devices in the market
• Average force applied by kid's hand
• Different can sizes
• Mechanism for applying force
Monday, August 30, 2021 Introduction to Engineering Design GE-106 25
Design a device for securing a coffee cup near
the driver's seat of an automobile. The device
should prevent the cup from spilling and should
not interfere with the proper operation of the
car. It should be universally adaptable to a wide
variety of vehicles.
Tasks:
• Establish need.
• Define the problem.
• Specify the needed information to be gathered.
 Statement: Need a device for securing a coffee cup near the
driver's seat of an automobile
Needs Analysis:
 Coffee cup holder for car (near the driver seat)

 Locking system to prevent the cup from spilling

 It does not interfere with the proper operation of the car

 Adaptable to a wide variety of vehicles

 Detachable (designed to be unfastened or disconnected without

damage)
 Easy to use
 Durable material for various temperatures

 No need to modify car interior

 Cost not exceed 50 SR

 Flexibility of coffee cup size

Monday, August 30, 2021 Introduction to Engineering Design GE-106 27
 Primary Objectives:
 Design a device for securing a coffee cup
near the driver’s seat of an automobile
that preventing the cup from spilling,
not interfering with the proper
operation of the car and adaptable to a
wide variety of vehicle.

Secondary Objectives:
 The device should be detachable.
 No modification of car interior is needed.

Monday, August 30, 2021 Introduction to Engineering Design GE-106 28

 Constraints
 Spilling free
 Does not interfere with the driver
 Size max: 200 x 150 x 150 mm (H x W x L)
 Weight not to exceed 0.5 kg
 Cost less than SR 50
 2 years lifetime

Criteria
 Simple
 Easy to install and dispatch
 Durable
 Strong attachment to the car
 High adaptability to car types
 High adaptability to cup sizes
Monday, August 30, 2021 Introduction to Engineering Design GE-106 29
 Problem Formulation

Design a simple device for securing a coffee cup near

the driver’s seat of an automobile that prevents the cup
from spilling. The device should not interfere with the
proper operation of the driver and should be adaptable
to a wide variety of vehicles and coffee cup size. The
device should be easy to install and detach and no
interior modification of the car should be needed. The
maximum size and weight of the device are respectively
200 x 150 x 150 mm3 and 2 kg. It should also be durable,
offering a minimum of two years lifetime and a cost of
less than 50 SR.

Monday, August 30, 2021 Introduction to Engineering Design GE-106 30

 Needed Information*
 Average amount of coffee in cup
 Average coffee cup size and weight
 Coffee cup material
 General car interior layout/design
 Temperature inside the car (max/min)
 Available relevant holder designs in the market

Monday, August 30, 2021 Introduction to Engineering Design GE-106 31

 Lesson Summary
Design Objectives, Constraints and Design Evaluation
Criteria have been presented and reiterated.

Three case studies were presented on:

• How to conduct need analysis for a stated problem.
• Problem formulation from a customer need statement,
based on the objectives, constraints and criteria.
• How to come up with (determine) the needed
information for solving a design problem.
Monday, August 30, 2021 Introduction to Engineering Design GE-106 32
College of Engineering
GE106:Introduction to Engineering Design

Problem Formulation
and
Case Studies

By

Matthew Amao
Decisions and information flow during problem
formulation

Initial design
Formulating process problem statement
Literature, Surveys
Market Studies
Customer needs? Focus Groups
Seek info
Competition? Observation Studies
Benchmark Studies
Functional requirements?
Targets? Constraints? Interpret probe
Evaluation criteria? Summarize
revise
Gain
Preliminary problem formulation
consensus

Obtain instructor approval Review

continue

Engineering Design
Specification