Axiomatic Design in Large Systems (eBook)

Professor Amro M. Farid received his Sc. B. in 2000 and his Sc. M. 2002 from the MIT Mechanical Engineering Department. He went on to complete his Ph.D. degree at the Institute for Manufacturing within the University of Cambridge (UK) Engineering Department in 2007. He has varied industrial experiences from the automotive, semiconductor, defense, chemical, and manufacturing sectors. He is currently an Associate Professor of Engineering at the Thayer school of Engineering at Dartmouth and leads the Laboratory for Intelligent Integrated Networks of Engineering Systems (LIINES). The laboratory maintains an active research program in Smart Power Grids, Energy-Water Nexus, Transportation-Electrification, and Industrial Energy management. He is also a Research Affiliate at the MIT Mechanical Engineering Department. He has made active contributions to the MIT-Masdar Institute Collaborative Initiative, the MIT Future of the Electricity Grid Study, and the IEEE Vision for Smart Grid Controls. He currently serves on the Executive Committee for the Council of Engineering Systems Universities (CESUN), the Executive Committee for Axiomatic Design, the IEEE Control Systems Society Technical Committee on Smart Grids, the IEEE Systems, Man & Cybernetics Technical Committee on Distributed Intelligent Systems, the IEEE Industrial Electronics Society Technical Committee on Industrial Agents, and the ASME Dynamics Systems & Control Division. Prof. Nam Suh was the 13th and 14th President of KAIST. During his tenure (2006-2013), the worldwide reputation of KAIST was significantly improved. In 2014, KAIST was the second highest ranked university in Asia. In engineering, its worldwide ranking is around 20. Doctor Suh has spent most of his professional career at MIT, where he is the Cross Professor Emeritus. He was the Director of the Park Center for Complex Systems, and the Head of the Department of Mechanical Engineering, MIT. In 1984-1988, Doctor Suh was a Presidential Appointee in charge of engineering at the U.S. National Science Foundation (NSF). He was appointed to this position by President Ronald Reagan and confirmed by the U.S. Senate. He received many awards, including the ASME Medal, the General Pierre Nicolau Award of CIRP, the Pony Chung Award, the Inchon Education Award, the Ho-Am Prize for Engineering, the Mensforth International Gold Medal of IEE (UK), the Hills Millennium Award from IED (UK), and the Distinguished Service Award of NSF. He received nine honorary degrees from universities in four continents. He serves on the boards of universities and industrial firms. He authored more than 300 papers and seven books (Axiomatic Design Theory, Principles of Design, Tribology, Complexity Theory, Mechanical Behavior of Materials, and Polymer Processing). He holds more than 100 US and ROK patents. His contributions include the delamination theory of wear, the solution wear theory, a theory on the genesis of friction, Axiomatic Design Theory, complexity theory, and microcellular plastics, and innovation theory. He invented the microcellular plastics (MuCell), the On-Line Electric Vehicle (OLEV), and the Mobile Harbor (MH), and many others. He was educated at MIT, CMU, and BB&N.

Preface 6
Contents 9
Contributors 16
Reviewers 18
Editorial Support 18
Introduction 19
1 An Engineering Systems Introduction to Axiomatic Design 20
Abstract 20
1.1 Introduction 21
1.1.1 The Evolution of Axiomatic Design 21
1.1.2 The Evolution of Model-Based Systems Engineering 21
1.1.3 The Emergence of Engineering Systems 22
1.1.4 Classification and Characterization of Engineering Systems 23
1.1.5 Methodological Challenges in Engineering Systems 24
1.1.6 Contribution 25
1.1.7 Chapter Outline 25
1.2 Four Domains in the Engineering Design of Systems 26
1.2.1 Stakeholder Requirements Domain 28
1.2.2 Functional Architecture Domain 31
1.2.3 Physical Architecture Domain 34
1.2.4 Process Architecture Domain 35
1.2.5 Multi-domain Mapping in the Engineering Design of System 36
1.3 The Allocated Architecture: Design Synthesis and Analysis 38
1.3.1 Design Synthesis 39
1.3.2 Design Analysis 41
1.4 The Independence and Information Axioms 43
1.4.1 The Independence Axiom 43
1.4.2 The Information Axiom 45
1.4.3 Axiomatic Design’s Theorems and Corollaries 46
1.5 Functional and Physical System Hierarchy in Large Systems 46
1.5.1 Large Fixed Engineering Systems 46
1.5.2 Large Flexible Engineering Systems 49
1.5.3 An Illustrative Example 52
1.6 Engineering Systems Applications of Axiomatic Design 54
1.6.1 Quantitative Understanding of Life Cycle Properties 54
1.6.2 Treatment of Cyber-Physical Systems 55
1.6.3 Treatment of Hetero-Functional Networks 58
1.7 Conclusion 59
References 59
2 Mathematical Exposition of the Design Axioms 65
Abstract 65
2.1 Introduction 65
2.2 Mathematical Exposition of Independence Axiom 66
2.2.1 AD Criterion for Functional Independence 66
2.2.1.1 Examples of Various Categories of Design 68
Water Faucet Illustrating Coupled and Uncoupled Design 68
Projector Illustrating Redundant Design 69
Disbursement Algorithm Illustrating a Redundant Design 71
Hubcap Illustrating Insufficient DPs 72
2.2.1.2 Car Door-to-Body Integration—Coupling in Large System 73
Capturing Functional Couplings with the Design Matrix 75
Reducing the Design Matrix to Uncover Functional Coupling 76
Implications from the Reduction of DM 78
2.2.2 |J| Criterion for Functional Independence 80
2.2.2.1 Derivation of |J| as a Criterion for Functional Dependence 80
2.2.2.2 Implications of |J| as a Criterion for Functional Independence 82
2.2.2.3 |J| for Various Categories of Design 84
Water Faucet 84
Projector Design 85
Disbursement Algorithm 86
Design with Insufficient DPs 86
2.3 Mathematical Exposition of Information Axiom 87
2.3.1 Recognition of Noise Variables 87
2.3.2 Countermeasures to Noise Variables 89
2.3.2.1 Compensation as a Countermeasure 89
2.3.2.2 Robust Design as a Countermeasure 90
2.3.3 Implementing Countermeasures to Minimize Information Content 90
Appendix A1: FR Decomposition of Door-to-Body System 92
Appendix A2: DP Decomposition of Door-to-Body System 93
References 94
Large Complex Products 95
3 New Developments to Guide Strategic Product Design and Systematic Innovation 96
Abstract 96
3.1 Introduction 97
3.2 The Linearity Theorem: Theoretical Framework 100
3.2.1 Problem Description 100
3.3 The Linearity Theorem: Practical Application 105
3.3.1 Basic Methodological Steps to Apply the Linearity Theorem 105
3.3.2 Case Study 1: Filtering System in Vacuum Cleaners 106
3.3.3 Case Study 2: Conceptual Design of a Fuel Supply System for Gasoline Engines 112
3.3.4 Compliance with the Information Axiom and Constraints 116
3.4 Conclusions: Applicability and Value to Industry 117
References 118
4 A Different Consideration on Information and Complexity in Axiomatic Design 120
Abstract 120
4.1 Introduction 121
4.2 Background 122
4.2.1 Background on Information in Axiomatic Design 122
4.2.2 Investigations for the Dependency of the Axioms 123
4.2.3 Background on Axiomatic Complexity 124
4.2.4 Breakdown of Complexity in the Context of AD 125
4.3 A Broader Application of Boltzmann’s Entropy in Useful Information 126
4.3.1 Elimination of Useful Information from a Design 126
4.3.2 Information Related to the Independence Axiom 127
4.3.3 Disruptive Character of the Independence Axiom 129
4.4 Total Decomposition of Information 129
4.4.1 Decomposition of Useful Information 129
4.4.2 Decomposition of Unorganized Information 131
4.4.3 Overview of Information in Design 131
4.5 Discussion on the Review of Information in Axiomatic Design 133
4.6 Monitoring Process Progression 135
4.6.1 The Axiomatic Maturity Diagram 135
4.6.2 Presumed and Legitimate Position in the Axiomatic Maturity Diagram 136
4.6.3 Determination of the Legitimate Position 137
4.6.4 Ideal Development Path in Product Design 137
4.6.5 Consequences of Typical Errors 139
4.7 Discussion on the Application of Information to Monitor Development Processes 141
4.8 General Conclusion 142
Acknowledgements 143
References 143
5 A Novel Approach for Axiomatic-Based Design for the Environment 145
Abstract 145
5.1 Introduction 146
5.2 The Smart Eco-design Platform 148
5.3 The Definition of FRs with a Different Time or Dimensional Scale 153
5.4 Functional System Approach 155
5.5 Merge of Smart Eco-design Platform and Functional System Approach 158
5.6 Conclusion 159
References 160
Buildings 163
6 Application of Axiomatic Design to the Design of the Built Environment: A Literature Review 164
Abstract 164
6.1 Introduction 165
6.2 Literature Review 167
6.2.1 Conceptual Design Phase 167
6.2.2 Models of the Design Process in Engineering and Architecture 168
6.2.3 Axiomatic Design Theory 169
6.2.4 Applications of Axiomatic Design to the Design of the Built Environment 171
6.2.4.1 Civil and Environmental Engineering 177
6.2.4.2 Mechanical Engineering 179
6.2.4.3 Urban Design 179
6.2.4.4 Building Design 180
6.2.4.5 Interior Product Design 182
6.3 Conclusions 183
References 185
7 Applying Axiomatic Design to Prefabricated Building Design in the Housing Industry: A Case Study Analysis 188
Abstract 188
7.1 Introduction 189
7.2 Literature Review 190
7.2.1 Conceptual Building Design 191
7.2.2 Building Prefabrication 192
7.3 Axiomatic Design Theory 193
7.4 Applying Axiomatic Design to Conceptual Building Design 195
7.5 Axiomatic Analysis of Prefabricated Houses 197
7.5.1 Case Study #1: Dwell Home 197
7.5.2 Case Study #2: Cellophane House 205
7.6 Conclusions 210
References 212
8 An Application of Quality Function Deployment and Axiomatic Design to the Conceptual Design of Temporary Housing 214
Abstract 214
8.1 Introduction 215
8.2 A QFD–AD 217
8.2.1 Quality Function Deployment (QFD) to Ensure Customer Needs Drive Design 217
8.2.2 Fundamental Concept of Axiomatic Design 219
8.3 Case Study: Design of a Refugee House 220
8.3.1 Case Study Brief 220
8.3.2 Assessing Customer Needs 222
8.3.3 Decomposition of a Refugee Shelter 227
8.3.4 Checking Appropriateness of the Solution 231
8.4 Conclusion and Future Work 232
Acknowledgements 233
References 233
Manufacturing Systems 236
9 Design and Implementation Approach for Distributed Manufacturing Networks Using Axiomatic Design 237
Abstract 237
9.1 Introduction 237
9.2 Literature Review 241
9.2.1 Changeable, Scalable, and Distributed Production in Franchise Models 241
9.2.2 Axiomatic Design Approach for the Design of Manufacturing Systems 242
9.2.3 Research Gap and Need for Action 243
9.3 Axiomatic Design-Based Derivation of Parameters for the Design of Distributed Franchise Manufacturing Systems 244
9.3.1 Customer Needs and Functional Requirements on the Highest Level 244
9.3.2 Mapping and Decomposition Process 245
9.3.3 FR-DP Tree and Design Parameters 248
9.4 Design Fields and Design Elements 249
9.5 Approach for Implementation—A Three-Level Model 251
9.5.1 Design Level (Normative Framework) 252
9.5.2 Planning Level (Strategic–Tactical Framework) 253
9.5.3 Operational Level (Operational Framework) 253
9.5.4 Feedback Loop (Redesign and Replanning) 253
9.6 Application in a Case Study 254
9.7 Conclusion 257
References 258
10 Axiomatic Design of Production Systems for Performance Improvement: A Project Identification and Prioritization Model 263
Abstract 263
10.1 Introduction 264
10.2 Production System Design: Theory 265
10.3 Production System Design and Axiomatic Design: Design to Target Improvement Efforts 267
10.4 Concluding Remarks 282
References 282
11 Challenges in Designing and Implementing Large Systems (Overcoming Cost Overruns and Missed Project Schedules) 285
Abstract 285
11.1 Introduction 286
11.2 Major Projects with Cost Overruns and Missed Schedules 287
11.2.1 Why Cost Overruns, Missed Schedules, and Poor Performance? 290
11.2.2 Lessons Learned: Development of Technological Systems 290
11.3 Industrial Journey and “Data” on the Design of Systems 291
11.3.1 Design of Products and the System for Mass Production of Foam/Straight Plastic Laminate Plates, Dishes, etc.—Journey in Guild Plastics, Inc. 291
11.3.2 High-Pressure USM Molding Process for Composite Shoe Soles 292
11.3.3 Coated Tungsten Carbide Tools (Surftech Corporation) 295
11.3.4 Unsuccessful Projects 296
11.3.5 Axiomatic Design and LMP at MIT 296
11.3.6 Lessons Learned from the Systems I Invented in Industry and MIT 298
11.4 Foundations of Axiomatic Design 298
11.4.1 Large Technology Systems Created Using the Design Axioms 299
11.4.1.1 Mixalloy 300
11.4.1.2 OLEV (On-Line Electric Vehicle) 303
11.4.1.3 MuCell 304
11.4.2 Likely Root Causes of Technical Systems Failures 305
11.4.3 Important Roles of System Architects 306
11.4.4 Observations on System Design 307
11.4.5 Design of Large Organizations 310
11.4.5.1 MIT Laboratory for Manufacturing and Productivity (LMP) 311
11.4.5.2 National Science Foundation (NSF) 312
11.4.5.3 MIT Mechanical Engineering Department 313
11.4.5.4 KAIST (Korea Advanced Institute of Science and Technology) 314
11.4.6 Theorem on Development of Large Systems 316
11.4.7 Why Is the Coupled Design so Attractive and Enticing to Some? 317
11.4.8 Dilemmas and Action Items 318
11.4.8.1 Dilemmas 318
11.4.8.2 Action Items 319
11.5 Conclusions 320
Acknowledgements 321
References 321
Appendix: Axioms, Corollaries and Theorems in Axiomatic Design 322
1. Axioms 322
2. Corollaries 322
3. Theorems in General Design 323
4. Theorems Related to Design and Decomposition of Large Systems 325
5. Theorems for Design and Operation of Large Organizations 326
6. Theorems Related to Software Design 326
7. Theorems Related to Complexity 327
References 328
Index 329