Design 5 From your own experience, you probably know that design can consist of examining a design need and working on the problem by means of sketches, models, brainstorming, calculations as necessary, development of styling as appropriate, making sure the product fits together and can be manufactured, and calculation of the costs. The process of design can be represented schematically to levels of increasing formality and complexity. Figure 1.3 represents the traditional approach associated with lone inventors. This model comprises the generation of the “bright idea,” drawings and calculations giving form or shape to the idea, judgment of the design, and reevaluation if necessary, resulting in the generation of the end product. The process of evaluation and reworking an idea is common in design and is represented in the model by the iteration arrow taking the design activity back a step so that the design can be improved. Figure 1.4 illustrates the possible results from this process for a helmet providing peripheral and reverse vision. Figure 1.5 shows a more formal description of the design process that might be associated with engineers operating within a formal company management structure, The various terms used in Figure 1.5 are described in the following text. Recognition of Often design begins when an individual or company recognizes a need, or identifies a need potential market, for a product, device, or pracess. Alternatively “need” can be defined as the situation in which a company decides to reengineer one ofits existing products (for example, producing a new car model). The statement of need is sometimes referred to as the brief or the market brief. Definition of This involves all the specifications of the product or process to be designed. For example, problem this could include inputs and outputs, characteristics, dimensions, and limications on quantities. Synthesis This is the process of combining the ideas developed into a form or concept, which offers a potential solution to the design requirement. The term “synthesis” may be familiar from its use in chemistry, where it is used to describe the process of producing a compound by a series of reactions of other substances Analysis, This involves the application of engineering science, i.e. subjects explored extensively in traditional engineering courses such as statics and dynamics, mechanics of materials, fiuid flow, and heat eransfer, These engineering “tools” and techniques can be used t0 ‘examine the design to give quantitative information such as whether itis strong enough ‘or will operate at an acceptable temperature, Analysis and synthesis invariably go together. Synthesis means putting something together and analysis means resolving something into its constituent parts or taking it co pieces. Designers have to synthesize something before it can be analyzed. This is the famous chicken and the egg scenario! ‘When a product is analyzed, some kind of deficiency or inadequacy may be identified that requires che synthesis of a new solution prior ¢o reanalysis and repetition of the process until an adequate solution is obtained Optimization _This is the process of repetitively refining a set of often-conflicting criteria to achieve the best compromise Evaluation This is the process of identifying whether the design satisfies che original requirements. It may involve assessment of the analysis, prototype testing, and market research,