Preface v
Part 1 How Engineers Design 0
Introduction 1
Design Process Overview 5
Project Phases 10
Communicating throughout the Process 14
What Engineers Design 18
How Engineering Projects Are Initiated 22
Navigating the Engineering Design Process 27
Engineering School Projects 32
Part 2 Design Process 34
Requirements
Introduction to Requirements 35
Functions 43
Objectives 50
Constraints 56
Documenting the Context 61
Describing Stakeholders 69
Describing Users, Operators, and Clients 76
Characteristics of Good Requirements 83
Summary: Putting It All Together 92
Functional Basis 96
Multi-use Design Tools
Black Box Method 101
Decomposition 104
Information Gathering 108
Benchmarking 115
Pairwise Comparison 122
Idea Generation
Introduction to Idea Generation 125
Brainstorming 128
Creativity Methods 134
Morphological Charts, Analogy, and TRIZ 140
Decision-making
Design Evaluation and Selection 144
Selecting a Design Solutiona 150
Decision Methods for Teams 160
Iterating
Stages in Iteration: Generate, Select, Reflect 163
Suggested Iteration Process 167
Reflection Considerations for Iteration 173
Investigating Ideas
Using Metrics 177
Investigating Ideas through Models and Prototypes 180
Feasibility Checking 185
Routine Design 189
Post-Conceptual Design
Intermediate Design 194
Final Design 202
Post-Final Design Engineering 213
Part 3 Implementing a Project 218
Working in Teams
Introduction to Teamwork 219
Organizing 225
Tools for Organizing 230
Producing 237
Managing Teams 240
Management Strategies 247
Sample Team Documents 253
Project Management
Introduction to Project Management 261
Project Management Concepts 267
Creating a Project Plan 273
Estimating Cost and Time 279
Project Cycle (see www.wiley.com/college/mccahan)
Monitoring a Project (see www.wiley.com/college/mccahan)
Project Analysis (see www.wiley.com/college/mccahan)
Advanced Tools and Methods (see www.wiley.com/college/mccahan)
Personal Management (see www.wiley.com/college/mccahan)
MS Project Instructions 284
Client Interaction
Client Meetings (see www.wiley.com/college/mccahan)
Asking Questions and Listening (see www.wiley.com/college/mccahan)
Critical Thinking
Basic Concepts 293
Critical Thinking in Design Documents 300
Making and Supporting Statements Effectively 306
Skeptical Thinking 313
Communication
Engineering Communication 318
Organizing Communication 323
Putting Together an Engineering Report (see www.wiley.com/college/mccahan)
Diagrammatic Elements 330
Using Pictures and Photographs 339
Influencers of Communication 344
Organizing Presentations 349
Effective Slides 354
Part 4 Design for X 360
Durability
Design for Durability 361
The Environment
Design for the Environment: Introduction 365
Life Cycle Assessment (LCA) 369
LCA Goal Definition and Scoping 375
LCA Inventory Analysis 382
LCA Impact and Improvement 388
Sustainability 396
Flexibility
Design for Flexibility: Introduction 401
Managing Flexibility 408
Human Factors
Design for Human Factors: Introduction 413
Task Analysis 420
Use Case Method 426
Concept of Operations 433
Intellectual Property
Design for Intellectual Property: Introduction 438
Principles of Patentability 444
Intellectual Property in the Design Process 449
Frisbee Patents 454
Manufacture
Design for Manufacture: Introduction 460
Manufacturing Process Choices 468
Safety
Design for Safety: Introduction 475
Identifying Hazards 481
Safety in the Design Process 486
Workplace Safety 495
Testing & Maintenance
Design for Testing and Maintenance (see www.wiley.com/college/mccahan)
Part 5 Resources 498
Principles and Problem Solving
Problem Spectrum: Open, Constrained, and Closed (see www.wiley.com/college/mccahan)
Solving Closed Problems (see www.wiley.com/college/mccahan)
Writing up a Problem Solution (see www.wiley.com/college/mccahan)
Significant Figures (see www.wiley.com/college/mccahan)
Conservation of Mass and Energy (see www.wiley.com/college/mccahan)
Estimation
Introduction to Estimation 499
Estimation Techniques 504
Estimating Cost and Labor 515
Estimation Confidence 518
Probability & Statistics
Introduction to Probability and Statistics (see www.wiley.com/college/mccahan)
Discrete Distributions (see www.wiley.com/college/mccahan)
Continuous Distributions (see www.wiley.com/college/mccahan)
Fitting a Line (see www.wiley.com/college/mccahan)
Uses (see www.wiley.com/college/mccahan)
Economics
Introduction to Economics 523
Time and Money Calculations 528
Project Decisions 532
Types of Costs and Revenues 540
Payback 546
Failure & Risk
Introduction to Failure and Risk 550
Handling Risk 555
Why Things Fail 563
Part 6 Case Studies 570
Aerial Photography 571
The Razor Sole Skate (see www.wiley.com/college/mccahan)
A Video Titler for Sewer Inspection (see www.wiley.com/college/mccahan)
The Steam Whistle Brewery (see www.wiley.com/college/mccahan)
Selling Flowers (see www.wiley.com/college/mccahan)
Sample Design Briefs (see www.wiley.com/college/mccahan)
Historic Design Failures (see www.wiley.com/college/mccahan)
Glossary 577
Index 601
