Title: 1.1 Phase Clarify Problem: Specifications and Constraints Lesson
Course: ATEP - MMT: Module A: > Section: PHASE 1 CLARIFY THE PROBLEM: SPECIFICATIONS AND CONSTRAINTS

1.1.1 Stating and Defining the Problem

The initial task in the design process is to clearly state the problem in as many different ways as possible.  Review all possibilities and enter all of them into your engineering notebook for future reference.  Avoid getting caught up in your own initial ideas of what a solution should be and completely overlook the real cause.  State the problem in such a way that a solution is not implied.  Try to be objective and specific by separating the problem from its cause and symptoms. Be clear on what all possible causes of the problem might be or you cannot expect the solution to be effective. Create and review a problem statement. Is it correct? Does it need changing? Can it answer who, what, when, where and how?  Answering these questions will determine the specifications and constraints that will help to develop the product or service in later phases.
Creating a focus group, made up of possible end users or experts in the field, will help to clarify the problem.  Does the end user or customer say you have a problem ("Voice of the Customer")?

“We need to first define the problem. If I had an hour to save the world, I would spend 59 minutes defining the problem and 1 minute finding solutions.” “A man should look for what is, and not for what he thinks should be.”

— Albert Einstein

Knowledge note:  A problem statement and a needs statement are terms that are frequently used interchangeably.

1.1.1.1 Problem List Assignment

A good way to start is to write your problem by beginning with:

1. "Don't you hate it when........"  or
2. "Gee, I wish I had ................"

1.  Create a list of problems in your word processor (each team member; minimum of 10) that exist for you. Rank them in the order that is most important to you with #1 being the highest. Upload the list in the "Problem List Assignment" area after the lesson.

2.  Choose the most important problem and create a single presentation slide with an image and the problem statement.  Upload the slide in the "Problem list Assignment" area after the lesson.

1.1.2 Focus Groups

A focus group is a form of research in which a group of people are asked about their perceptions, opinions, beliefs, and attitudes towards a product, service, concept, advertisement, idea, or packaging. The questions are asked in an interactive setting where participants are free to talk with other group members. The group should be made up of end users and experts with knowledge pertinent to areas of product design, materials and production for the product.

The video "Inventing the Wheel" will give you a basic idea of what a focus group is and how you might  obtain pertinent information for your product or service. Describe the product and its use thoroughly to make sure the focus group fully understands the product and how it will be used. As you will see, you might also consider having more than one focus group to verify the information collected. Was this idea thoroughly described so that the audience fully understood the product?

Killing Good Ideas — Wheel

This second video, "Planning Ahead",  shows how the product or service might need added features or considerations. Team members and focus groups can add more extensive ideas to a project that a single individual may not see at first. It is always better to have too many ideas than not enough and then narrow them down to a final solution.

Tow truck tries to flip an eighteen wheeler but fails

1.1.2.1 Focus Group Assignment

Based on the product you are planning to design, list the types of people and their backgrounds that you should include in the focus group. Upload the list in the "Focus Group Assignment" area after the lesson.

1.1.3 Surveys

Surveys are one method of research. They are a means for obtaining pertinent information about a change in an existing design or a new design.

Survey research is usually based on a sample of a population of end users/customers. The success of the survey is dependent on how well the sample represents the target population of end users.

Survey methodology is a scientific field and a profession that  identifies principles about the sample design, data collection techniques, the statistics of data obtained, and analysis of the data. In order to achieve uniform results, the questions themselves must be thoroughly researched. Leading questions that infer specific answers must be avoided to obtain accurate data. Avoid open-ended questions. True/False and multiple choice questions are good for creating graphs and charts from the answers you obtain. Every respondent must read or hear the same questions. Even tonal inflections in the surveyors voice can point an answer in one direction or another.

The initial goal of creating and using a survey include making decisions on how to:

- Identify and select potential sample members.
- Contact sampled individuals and collect data from those who are hard to reach (or reluctant to respond).
- Evaluate and test the set of questions.
- Select the way of posing questions and collecting responses.
- Train and supervise interviewers (if they are involved).
- Check data files for accuracy and internal consistency.
- Adjust survey estimates to correct for identified errors.

Different methods of collecting information through surveys can change how respondents answer, and different methods have different advantages. The most common methods used for surveys are:

- Telephone
- Mail
- Online surveys
- Personal in-home surveys
- Personal mall or street intercept survey
- Combinations of the above

1.1.3.1 Survey Assignment 1

Who says that the problem selected is a problem?

Create a survey that will help confirm what you have stated is a problem to other people.

Ask questions that are directed to the purpose of the survey. By using true/false, yes/no or multiple choice questions, you will be able to construct a graph in the next assignment, that confirms your statement.  By placing the statistical information into a spreadsheet, you will easily be able to create several different types of graphs and charts which can be used later in a visual presentation.

Your survey must be taken by at least 10 different people that represent possible end users. The survey must contain at least 10 questions. Each question must have at least 3 possible alternative answers.  Type your survey questions in a multiple choice format in a word processor and upload them in the "Survey Graph Assignment" area after the lesson.  Click on "Return to ATEP."

1.1.3.2 Survey Assignment 2

Transfer the information from the survey to a spreadsheet program and create a graph indicating the results that you have obtained.  Upload the spreadsheet/graph to your instructor in the Survey Graph Assignment at the end of the lesson.  Click on "Return to ATEP."

1.1.4 Verify the Problem

Verify there is a problem or a need and not only a "want." Just because you might think there is a problem with a product, or that a product will be in high demand,  others might not.  You must be able to justify that there is a problem you intend to resolve.  Manufacturers need to know if there is a large enough group of people that will want to purchase the product.

- Do others agree with your logic?
- Who would benefit from solving the problem or need?
- Do they agree with you?

In the engineering notebook, explain the history of the problem and include detailed information.  Include references and resources that have brought you to the conclusion that the problem does exist.  Give justification to show the problem being addressed is valid and not easily resolved by existing solutions.  Verify that there has not been a solution to the problem in the past.

A team environment, a focus group and/or a survey will be able to expand on the thoughts of just one person and help to verify the need.  Take the time to ensure that you have truly defined the problem and not just problem solve a result of the problem or even the wrong problem. In other words, state the problem and then re-state the problem. By creating a simple flowchart, similar to the one shown here, you will be able to show a simplified version of the verification process.

1.1.4.1 Flowchart Assignment

Create a simple flow chart, similar to the one shown in the lesson, to show a simplified version of your verification process.  Remember a flow chart shows the logic of your thinking.  Scan it and upload it in the Flow Chart Assignment at the end of the lesson.  Click on "Return to ATEP."

1.1.5 List the Specifications and Constraints

Usually, a specification is a specific set of requirements to be satisfied by a material, product, or service. A constraint is used during the development more often because there isn't a set standard yet, but will still restrict, limit or confine within a prescribed bounds.

Preliminary brainstorming will help to generate alternative descriptions, specifications and constraints. Maximum creativity and imagination is critical. All ideas, regardless of how impossible they may seem, should be added to the engineering notebook for future reference. Again, add this information to the engineering notebook.

Defining a problem and its constraints is also best done in a team setting: “Here is what I think the problem might be. How do you see it? How can we tie these ideas together?”  View the Product Specifications below  the things that should be considered when creating product specifications and constraints.

Product Specification Outline
1.0  Scope:
This section outlines the key considerations as a product or service is being developed and during its entire life cycle. This is a controlled document and can only be altered under a formal Engineering Change Notice (ECN) or Engineering Change Order (ECO).
2.0   Document:
This section must include all documentation related to project design and development. This should include such items as material specifications. This section will include assembly as well as detailed drawings, illustrations, tooling drawings, sampling specifications.
3.0  Engineering:
This section should include all calculations, simulations, and testing related to the product. It will also include all performance specifications as required by marketing. These specifications may also be found in section 2.0.
4.0  Configuration:
This section is used for proper identification as it relates to other similar products. It should include part numbers, as well as envelope drawings.
5.0  Electrical Wiring:
This section should include any wiring diagrams which are used in the product and associated standards such as Underwriter Laboratory or International Standards.
6.0  Operation Characteristics:
This section should include all the performance characteristics which are dictated by marketing and engineering. This should include load bearing requirements, impact requirements, cycles to failure, weight, resistance to heat etc.
7.0  Styling:
This section should include all industrial designer considerations such as: conception drawings, illustrations, animations and color schemes.
 8.0  Packaging:
This should include the design and type of packaging. In addition, it should include any performance requirements.
 9.0  Special features:
This should include all special features required of the product different from previous versions as defined by marketing, sales and or engineering.
10.0  International Version:
This should include all specifications and documentation to allow products to be marketed globally. These may include registration to ISO 9001, quality control systems, ISO 14001, environmental management systems and compliance with Reduction of Hazardous Substances RoHS.
11.0  Service-Customers:
This should include all warranty terms for the product. Engineering should determine whether the product should be rebuilt or replaced. In addition, customer service contracts should be documented here.
12.0  Supplies:
This section should list all supplies which will be included for the use of the product, such as assembly tools, components, assembly instructions and recycling mailers.
13.0  Operating Information:
This section will include all customer software for the proper start-up, running and maintenance of the product.
14.0  Marketing Consideration:
This section will include all information related to market surveys. This section will include production requirements, manufacturing pricing, wholesale pricing, and suggested retail pricing.
15.0  Documentation Requirements:
This section will list all documents and their corresponding #.
16.0  Reliability Assurance:
This section will document all conditions for testing. This will include .performance testing of product, strength requirements, and visual inspection. This section will also include various materials testing such as relative viscosity, gel permeation chromatography, etc. Please see section 19.0 for more details.
17.0 Quality Assurance:
This section will include quality control technique to be employed, such as, statistical process control during the manufacturing of the product. This section will include the establishment of acceptable quality levels, disposition of defects, creating parts acceptance and rejection standards, and criterion for waivers.
18.0 Preparation for Delivery:
This section will include description for the requirements for the preparation of the product prior to shipment. This will include box specifications, labels, RFID tags, security labeling etc.
19.0 Safety Testing during Product the Pre-Market Phase:
This section will define and assess the safe characteristics needed to assure proper performance throughout its life cycle. This will include defining life cycle performance —  useful service life, number of cycles to failure environmental performance characteristics. This will include life cycle testing, alpha testing, beta testing as needed during the Pre-Market Phase to make sure defined safety characteristics are met.

In addition, this information will be transferred to the manufacturing in order to ensure that all critical parameters are under control that impacts the useful service life of a product. Topics will include legal aspects and implications of R&D and the incorporation of safety through all steps of the design and development process.

1.1.5.1 Product Specifications Assignment

Create a product specification sheet for your product using a word processor.  Use the sample outline shown in this section as a reference. Upload the document in the "Product Specifications Assignment" area after the lesson.  Click on "Return to ATEP."

1.1.6 The Design Brief

A design brief is a written document for a design pro ject focused on the desired outcome.   A example is shown to the right.

At this point, you should start a design brief by first clearly stating the problem in the narrative section.  Give the objectives and goals for the product or service.  Create a global statement that states what  your solution must do.  The target audience is important to help guide the project in the correct direction.

The  scope of the project defines how you will meet the objectives and goals.  The duties of the team members are also clearly stated and added to this section.

Then list the criteria and constraints. Criteria are things that the product must have while constraints are limits that can not be exceeded.  These are the specifics that narrow down your solution.  They are created during the initial idea review, but are also subject to changes during the different phases of the design process. Cost and time are two examples that may limit the design.

The procedures define the required outcomes of the project by how you plan to present it to an audience.  Different types of audiences will want different information and will therefore need a different approach of explanation.

The design brief must be easy to read and follow, clearly stating what the problem is, the limitations that must be adhered to, and how you intend to solve it.  Use the information that you place in the engineering notebook to assist in developing your "Design Brief."

1.1.6.1 Design Brief Assignment

Create a short one page design brief.  Use the outline shown in this section as a reference. Upload it in the "Design Brief" area under the lesson.  Click on "Return to ATEP."

1.1.7 Preliminary Sketches

A sketch is a quickly made freehand drawing that is not intended as a finished work.  Sketching is a quick way to record an idea for later use.

Sketches are a method of visual brainstorming, used to consider first thoughts in greater depth and then to refine initial ideas. They can also be used to communicate design ideas to other people. Words, on their own, are not always enough to describe an idea.  In reality, words can lead to confusion because what a description means in someone's mind might mean something quite different in someone else's.

Professional designers usually sketch dozens of ideas during the brainstorming phase, then they pick only a few to present to the client. The only way to separate the good from the bad is to have a lot of things to pick from. Don’t be fooled by thinking your first ideas are your best. Sketch, then sketch some more, so you can really separate the best from the rest.

Sketching is perhaps the oldest method of communication and it is the language used by designers.  As you can see on the right, even Leonardo DaVinci created sketches for his projects.  They are used to communicate when there are language barriers  or to get one person's ideas across to other people.   Freehand sketching is a quick and convenient way to get your ideas permanently preserved on paper for future reference before they are forgotten.   Sketches do not have to be perfect works of art as their primary function should be to inform and communicate design ideas.  Understanding and using the basic principles of sketching will help get your ideas across to others more quickly.  For example:

- Line types (Alphabet of Lines)
- Pictorial view drawings
- Multi-view drawings
- Dimensions
- Perspective

The ability to sketch will help you and your team to problem solve and design better products.  It helps to more clearly understand the product and pushes you to look at the details of the product.  Computer Aided Drawing (CAD) on the other hand, is not a substitute for sketching for the following reasons:

- CAD drawings require input of dimensions and more details than required at this stage.  With sketches, accuracy and details are not what is important.
- Sketching is a faster way to develop design ideas.
- CAD limits quick changes, especially when a variety of design ideas are being considered.
- Computers are not always available, but pen or pencil sketches can be produced on almost any surface.  Many great ideas were created and discussed on restaurant paper napkins during a meal.

By creating simple sketches with basic dimensions and annotations, you can help others "see" the problem and solution. Complete the "Sketching Assignment" next for your product and each of its parts.

1.1.7.1 Sketching Assignment

Create a set of sketches for your product.  Make sure you show dimensions, materials and any notes that will be needed to manufacture each part of the product.  Scan each sketch and upload to your instructor.  Make sure you have your name and date on each page. Keep the original in your engineering notebook.  Click on "Return to ATEP."