Proceedings of
The 1996 ASME Design Engineering Technical Conferences and
A REVERSE ENGINEERING AND REDESIGN METHODOLOGY FOR PRODUCT EVOLUTION
Kevin N. Otto
Engineering Design Research Laboratory
Massachusetts Institute of Technology
77 Massachusetts Avenue, Room 3-449
Cambridge, Massachusetts 02139
ABSTRACT
Consumer products drive business. To remain
competitive, industry is continually searching for new methods
to evolve their products. In this paper, we introduce a new
reverse engineering and redesign methodology to address this
need. Motivation is provided by an S-curve representation of
product improvement. Each phase, task, and technique of the
methodology is then presented. The redesign of an electric wok
provides illustrative examples of the methodology. Results of
the wok redesign are clearly superior to any product currently
on the market. The paper concludes with a discussion of the
methodologys impact, both on design education and industry.
INTRODUCTION
In the literature, a number of descriptive and prescriptive
design methodologies have been developed for general
engineering design problems (Pahl and Beitz, 1984; Pugh,
1991; Ullman, 1992; Ulrich and Eppinger, 1994; Asimow,
1962; Altschuller, 1984; Dixon and Finger, 1989). Basic phase
or waterfall models (Asimow, 1962) describe the entirety of
design as sequences of stages from needs analysis to conceptual
design to final manufacture. Rather than adopting this
universal view, other researchers consider different
combinations and types of design processes and methods. Pahl
and Beitz (1984) describe a very detailed design process which
works well for medium complexity systems. Ulrich and
Eppinger (1994) describe the formulation, evaluation, and
completion of design decisions, including customer and
manufacturing information. Clausing (1994) describes a total
quality approach. Papalambros and Wilde (1988) describe
methods to optimize product design models. Phadke (1989)
describes experimental methods to optimize designs.
While these methodologies are applicable to different types
of design problems, they tend to emphasize either design
Design Theory and Methodology Conference
August 18-22, 1996, Irvine, California
96-DETC/DTM-1523
Kristin L. Wood
Department of Mechanica Engineering
The University of Texas
ETC 5.160
Austin, TX 78712-1063
problems that seek original solutions or well-posed
parametric formulations. This emphasis provides a foundation
for teaching engineering design; it also provides a possible
approach for establishing corporate design processes in
industry. For the class of problems known as redesign
(adaptive, variant, etc.), however, an emphasis on original
design may be too general as a problem solving approach.
Sferro, Bolling, and Crawford (1993) argue the legitimacy of
this claim, based on an analysis of the current variant design
processes in the automobile industry. They develop a new
variant design methodology, referred to as Direct Engineering,
to replace more general original design methods.
As with original design, redesign problems include the
process steps of gathering customer needs, specification
planning and development, benchmarking, concept
generation, product embodiment, prototype construction
and testing, and design for manufacturing, but they also
focus on an additional step, referred to here as reverse
engineering (Ingle, 1994). Reverse engineering initiates the
redesign process, wherein a product is predicted, observed,
disassembled, analyzed, tested, experienced, and documented
in terms of its functionality, form, physical principles,
manufacturability, and assemblability. The intent of this
process step is to fully understand and represent the current
instantiation of a product. Based on the resulting representation
and understanding, a product may be evolved, either at the
subsystem (adaptive), configuration (adaptive), component
(variant), or parametric (variant) level.
In this paper, a reverse-engineering and redesign
methodology is presented, motivated and influenced, in part, by
the work of Sheppard and Tsai (1992) and Brereton and Leifer
(1993). This methodology focuses on the process steps needed
to understand and represent a current product. Extensions of
1 Copyright 1996 by ASME
contemporary techniques in engineering design are utilized at a
number of stages in the redesign process to meet this goal. A
number of new techniques are also developed to address the
unique characteristics of product evolution. The specific use of
the combined techniques provides a novel context for
application in industry and engineering-design education.
The next two sections describe our specific reverse-
engineering and redesign methodology, with application to an
electric wok product. Emphasis is placed on the salient and
unique features of our methodology, with relevant literature
providing supplemental details.
Metric
First market introduction of an individual product
New Technology
Level II Redesign
Initial Technology
Level I Redesign
Time
(Product Domain)
Figure 1. Product Evolution along S-Curve.
REVERSE ENGINEERING AND REDESIGN
To motivate the need for a redesign methodology, consider
a common abstraction of product evolution in the marketplace,
depicted in Figure 1. As shown in the figure, one can
determine a critical metric that is useful for evaluating a
product and its market competition, and plot the value of
performance for each product as a function of the time when
each product was introduced. The metric values will naturally
fall as an S-curve in time (Asthana, 1995). That is, at first a
new innovative product will enter a market domain as a new
concept. The plotted curve will remain somewhat flat for a
certain period of time, because it takes time for the competition
to respond. Next, a rapid profusion of innovation occurs, and
many products are launched in time. The lower leg of the S
is forming. The new technology, however, eventually tops out,
physical laws of the process dominate, and the engineers cannot
extract more performance. The slope of the S tops out again,
and the curve becomes flatter. All technological innovations
manifest themselves into the market along such an S-curve
timeline behavior.
Depending on the competitive environment, a product
development team must redesign their product at two levels
into the products future. The first level is as described along
an individual S-curve and includes parametric, variant, and
minor adaptive changes in the manufacturing, components,
materials, geometry, assemblies, and subassemblies. These
changes are a direct response to customer needs and feedback.
The second level, on the other hand, reflects a
discontinuous jump in the product characteristics.
Discontinuities of this type result from the introduction of new
technologies, new production processes, or a fundamental
change in product architecture. This creates a new
technological S-curve for the competition to compete against.
These types of change do not necessarily imply that each and
every subsystem of a product undergoes modifications; usually,
however, it does imply that at least one significant subsystem
undergoes a substantive transformation. For example, a leap in
S-curves occurred in the automobile industry due to the
introduction of ABS brakes. While the basic architecture of the
automobile remained the same, the brake subsystem underwent
a genesis due to the addition of feedback control.
A competitive company must understand these trends for
their industry. If the market is becoming more competitive, the
company must know to invest in R&D, or lose. One can
recognize this choice immediately as the point at which the
lower leg of the S starts to form. If the market technology is
topping out (the top of the S), the company should begin to
invest in a new technology, to jump to the next S-curve,
higher on the scale of the metric. Plotting trends provides all of
this information. Clearly trending of competitive data is a
necessary and culminating business consideration as a part of
product benchmarking.
To further illustrate product evolution, John Deere shows
the redesign of a rotary moco (Ashley, 1994). In this case
study, design models are used to improve the structural
integrity of the rotary cutterbar. Such improvements are typical
of evolution within the levels of a single S-curve. The same
basic technologies were maintained in the product, but new
parametric changes provided tremendous gains in product
performance.
The bottom line of product evolution with respect to S-
curves is that all products must change (both nonlinearly along
an S-curve and discontinuously between them) to remain
competitive. We propose that a systematic methodology will
lead to a better understanding of product evolution and how to
execute effective change with reduced cycle time. The next
subsection introduces the structure of such a methodology.
General Methodology
Figure 2 shows the general composition of our reverse
engineering and redesign methodology. Three distinct phases
embody the methodology: reverse engineering, modeling and
analysis, and redesign. The intent of the first phase, reverse
engineering, is twofold. First, a product is treated as a black
box and experienced over its operating parameters. Based on
the voice of the customer, we then predict and/or hypothesize
the function, product components, and physical principles. In
the case of prediction, the product is treated as a new design
wherein the ideal functionality, preferred design components,
and preferred physical principles are chosen to satisfy the
customer needs. On the other hand, in the case of hypothesis,
the design team attempts to recreate the actual product features
2 Copyright 1996 by ASME
and physical principles of the product before disassembly.
These unbiased results may be used after product disassembly
to compare the predicted design versus the actual product, and
then to choose appropriate paths for product redesign and
evolution.
The second step of the reverse engineering phase is to
experience the actual product in both function and form. This
subphase includes the full disassembly of the product, design
for manufacturing analysis, functional analysis, and the
generation of final design specifications. These data provide a
complete understanding of the actual product architecture,
manufacturability, and satisfaction (or not) of the design
specifications. Wielding these data, the actual product results
may now be compared with those that are predicted or
hypothesized.
Investigation,
Prediction, &
Hypothesis
Reverse
Engineering
Concrete Experience:
Function & Form
Design Models
Modeling &
Analysis
Design Analysis
Parametric Adaptive Original Redesign
Redesign Redesign Redesign
Figure 2. General Reverse Engineering and Redesign
Methodology.
In the second phase of the methodology, the product
information and design specifications are mapped to physical
models. These models may include mathematical (virtual)
representations or physical prototypes. Critical functions of the
product are modeled using balance relationships or
experimental design. These models are then analyzed to
determine the product performance over the range of operating
conditions.
In the third and final stage of the methodology, redesign of
a product commences based on the results of the reverse
engineering and modeling phases. Parametric redesign may be
pursued using optimization analysis of the design models.
Geometry, materials, tolerances, and other parameter changes
may result from this redesign effort. Alternatively or in
concert, adaptive redesign of the product may be pursued.
Using the identified customer needs, it may be apparent that
assemblies or product components need to be redesigned to
improve product quality. Morphological analyses or inventive
problem solving techniques may be used to synthesize new
subsystems to satisfy the design function. Design prototypes
will consummate the parametric or adaptive redesign steps to
validate the new design instantiations.
Beyond parametric or adaptive redesign, an original
redesign effort may be needed to satisfy the customer needs.
An original redesign, in this context, implies that a major
conflict exists between the customer needs and the current
product in the market. Because of this conflict, it is deemed
that an entirely new product architecture is needed. Functional
analyses from the reverse engineering phase will direct the
original redesign effort.
In summation, unbiased prediction, customer-driven
design, analysis using basic principles, and hands-on
experimentation are the philosophical underpinnings of the
redesign methodology. Three phases embody this philosophy:
reverse engineering, modeling and analysis, and redesign.
While these phases are presented sequentially in the above
discussion, the intent of the methodology is to be dynamic,
depending on the needed evolution for a product. The dashed
line in Figure 2 shows the global dynamic nature of the
methodology. For some product redesigns, it may be
appropriate to perform adaptive or original changes before
creating and optimizing a design model; similarly, the model
development of phase two may lead to a better understanding
of the product, bi-passing parametric redesign and leading
directly to adaptive. Alternatively, another product redesign
may call for simple parametric modifications to produce
dramatic S-curve response in quality and profit margin. The
proposed methodology may be used for any of these scenarios
or others.
The next section builds upon the general methodology of
Figure 2. Explanations of the tools and techniques for each
step in the methodology are provided. Without appropriate
techniques, the methodology would be relegated to a
philosophic goal without the foundation to be used in the reality
of industry or the university classroom. In addition, the
methodology is applied to the redesign of an electric wok
consumer product. Results of the wok redesign are shown at
each substep of the redesign process to provide needed
explanation and justification.
ELECTRIC WOK APPLICATION: ADAPTIVE AND
PARAMETRIC REDESIGN
Based on the general redesign methodology of Figure 2,
there are several tasks that must be completed to execute an
effective redesign of a consumer product. A succinct list of
tasks for each phase of the methodology is shown in Figure 3.
There exist a variety of techniques for completing the tasks.
Each task and associated technique is presented in this section
in the context of an electric wok redesign.
3 Copyright 1996 by ASME
Step 1: Reverse Engineering Investigation,
Prediction, Hypothesis
Two primary goals are intrinsic to the first step of the
methodology: (1) clarify the product domain, developing a
rigorous statement of the customer needs, and (2) treat the
product as a black box and either hypothesize the internal
functions and product features (solution principles), or choose
the design teams preferences for these items. Figure 4
schematically illustrates the redesign tasks, background
information (inputs), resulting knowledge, and potential impact.
After stating an initial problem statement, a black box
model is created, identifying the input and output flows of
materials, energies, and signals and the global function of the
product. These are documented in a single input-output block
model. The intent here is to understand the planned use of the
product over its full range of operating conditions, while
maintaining, figuratively and literally, very little knowledge of
the internal components of the product. By so doing, an
unbiased perception of possible product evolution is
maintained, in addition to avoiding psychological inertia when
generating concepts in later stages of the methodology.
1. Investigation, Prediction, and Hypothesis
Develop black box model
Use/Experience product
Gather and organize customer needs
Perform economic feasibility of redesign
State process description or activity diagram
Hypothesize refined functional decomposition
Hypothesize product features
List assumed working physical principles
2-5. Concrete Experience: Function & Form
Plan and execute product disassembly
Create BOM, exploded view, and parameter list
Execute and document Subtract/Operate Procedure
Experiment with product components
Develop Force Flow Diagrams
Create refined function structure of actual product
Create morphological matrix
Identify function sharing and compatibility
Transform to engineering specs. & metrics (QFD)
6. Design Models
Identify actual physical principles
Create balance relationships
Create engineering models and metric ranges
Example models: cost, heat transfer, stress,
strength, life-cycle (DFE), assembly, etc.
Alternatively or concurrently, build prototype model
7. Design Analysis
Calibrate Model
Create engr. analysis, simulation, optimization,
or spread sheet applications
Create prototype model with design of experiments
8. Parametric 9. Adaptive Redesign 10. Original
Redesign Recommend new subsystems Redesign
Search new effects,
Optimize design Develop new F.S.
principles, and TIPS trends
parameters Choose alternative
Perform sensitivity Augment morph. matrix
analysis/tolerance design Analyze Force Flow for
Build and test prototype
component combinations Alternatively, apply
Build and test prototype
Build and test prototype concepts in new field
Figure 3: Task list for the reverse engineering and
redesign methodology.
Based on the problem statement and black-box model,
customer needs are gathered and organized for the product.
The voice of the customer is the essential task in forming a
complete and usable product design specification. There are
several techniques that have been developed and applied to
gather a list of customer needs. These techniques include:
direct use of the product, circulating questionnaires, holding
focus group discussions, and conducting interviews. A more
complete discussion of the different methods is given in (Ulrich
and Eppinger, 1994; Urban and Hauser, 1992).
For the purposes of our methodology, the task of gathering
customer needs involves the subtasks of interviewing an
appropriate sample size of customers typically 9 or more for
small consumer products (Griffin and Hauser, 1993), recording
the customer statements in their words from prompted
questions or from spontaneous statements (such as product
likes, dislikes, and suggestions), interpreting the customer
needs into a noun-verb format, and finally subjectively rating
the importance of each customer need. After completing
Customer Need Collection forms with this information, each
interpreted need is copied onto an index card or post-it note,
listing the need, subjective importance rating, project title, and
customer ID. The index cards are then grouped into collective
customer need statements, and the relative importance of each
group is assigned using the number of index cards per group,
combined with the importance rating. The result of this
technique, as documented fully in (Otto, 1995), is a complete
customer need list, with both primary and secondary needs and
weightings.
The design team now has a clear indication of customer
needs for near-term and long-term evolution of the product.
This information must be supplemented with economic
feasibility to determine the potential return on investment, if it
exists. A number of techniques are available for completing an
economic feasibility. For example, product benchmarking
(Thornton and Meeker, 1995), activity-based costing (Miller,
1995), and product cost analysis (Ulrich and Eppinger, 1994)
are all viable approaches. The redesign methodology utilizes
any of these methods, depending on the information available.
It must be emphasized that only the level of detail necessary for
determining a go or no-go decision should be developed.
This level may be as simple as determining the history and
range of prices for the product domain, such as using consumer
advocate publications (e.g., Consumer Reports, 1995).
Alternatively, greater detail may be needed, such as
manufacturing, materials, and overhead or detailed activity
based costing, to determine a reasonable break-even analysis.
Assuming an adequate coverage of customer needs and
economic viability, the reverse engineering phase of the
redesign methodology transitions from investigation to
hypothesis and prediction. Three components distinguish the
new emphasis: functional analysis, product features, and
physical principles. If the product were to be immediately
disassembled at this point, there would exist a high risk of bias.
Prediction before disassembly provides an avenue for avoiding
this possible difficulty.
4 Copyright 1996 by ASME
 Prob. Defn.
Clarification Generate Aggregate
Black Box Model Function
Subfunctions,
Customer Reqs. Hierarchy Refine
Function
Create Structure
Process
Description
Create Label/
Task
Check
Listing Flows
Figure 4. Functional modeling and analysis process.
Functional analysis begins the prediction tasks. This
analysis includes the development of a process description, or
activity diagram, and the forming of a function structure, as
summarized in Figure 4. An important tool for analyzing the
function of a product is to specify the process by which the
product being designed will be functionally implemented. A
process or process description, in this sense, includes three
phases: preparation, execution and conclusion (Hubka, et al.
1988). Within each phase, high-level user and device functions
are listed to show the full cycle of a product, from purchase to
recycling or disposal. After listing the high-level functions in
each phase, a number of product characteristics are chosen,
including the products system boundary, parallel and
sequential paths through the function structure, process choices,
and interactions between user and device functions. These
choices are documented in a process description form.
Using the process description and customer needs, a
hypothesized function structure for the product is formulated
(Figure 4). Function structure modeling (Pahl and Beitz, 1984;
Miles, 1972; Hubka, et al. 1988; Ullman, 1993; Shimomura, et
al. 1995) has historically been used to create a form-
independent expression of a product design. We extend
common function structure modeling to include an approach for
mapping customer needs to subfunction sequences (called task
listing), a method for aggregating subfunctions, and a
comparison of a functional decomposition with customer needs
(Figure 4).
The first step is to identify major flows associated with the
customer needs of the product activities. A flow is a physical
phenomenon intrinsic to a product operation or subfunction.
For example, an operation may be to pressurize a fluid material.
Two critical flows for this operation are an energy to execute
pressure change and the fluid material being operated upon. A
list of common energy flows are given in Table 2 from
(Hundal, 1990).
For each of the flows, the next step (Figure 4) is to identify
a sequence of subfunctions that when linked represent the
hypothesized product functions or customer activities when
interfacing with the product. A subfunction, in this case, is an
Create
Compare Alternative
w/Customer Function
Needs
Structures
active verb paired with a noun that represents a product
operation. Miles (1972) provides lists of appropriate verbs and
nouns to use in functional analysis. A useful approach for
generating subfunctions during the hypothesis stage is to trace
the flow as it is transformed from it initial creation state to its
final expected state when it leaves the products system
boundary.
Table 2. Examples of common product energy flows.
displacement rotation force
power time stress
deflection/ density torque
strain
electricity magnetism heat
light sound pressure
For example, a customer need, expressed in the customers
voice, may exist for Easily cut a material. A suitable flow for
addressing this need is a force flow that ultimately acts on the
specified material flow. A sequence of subfunctions for this
flow may be of the form: capture force, apply force, transform
to larger force, transmit force as motion, guide motion, cut
material, stop motion, release force, dampen reaction to force,
etc.
Each sequence of subfunctions are aggregated (combined)
to represent the entire product. This step is accomplished by
appropriately connecting flows between each sequence and
adding subfunctions that interact or provide control states.
Aggregation and refinement of the function structure ends
based on two criteria: (1) are the subfunctions atomic, i.e.,
can they be replaced by a single, basic solution principle that
satisfies the function, and (2) is the level of detail sufficient to
address the customer needs? The first criterion provides a basis
for choosing the depth of functional analysis, e.g., a sub-
function of control motion in 3D should obviously be refined
to control in three rotations and translations since a single, basic
form solution does not provide 3D control. On the other hand,
the second criterion assures that time is not wasted refining a
function structure to the level of miscellaneous and secondary
product components, such as fastening.
5 Copyright 1996 by ASME
 product evolution and, subsequently, a concise statement of
Once the design team completes the subfunction quantified engineering requirements for evaluating potential
aggregation, functional modeling comes to a closure through improvements.
two verification steps. First, all major flows between the
subfunctions are labeled according to their state of Table 3 summarizes the tasks and subtasks of the
transformation. By labeling the flows, validity and continuity methodologys second step. Product disassembly (or tear
is ensured, perhaps leading to the addition of further functional down) initiates the tasks. A plan is first developed for the
representations. Second, the customer needs list is reviewed, disassembly activity, listing the order of disassembly,
and the subfunction or sequence of subfunctions are identified component or assembly to be removed, tool usage, access
that satisfy each customer need. Needs not covered by the direction, orientation of product (to prevent components from
function structure require further analysis, and sub-functions falling out), and any expected permanent deformation caused
not satisfying a need require confirmation of their by the disassembly. A plan, of this form, may need to be
incorporation. This verification typically adds more incrementally developed as more of the internal product is
subfunctions to the network, while simplifying or removing exposed; alternative plans may also be needed, depending on
others that really do not apply. the complexity of the product. However, in its entirety, the
plan provides a means for assessing the assemblability of the
A predicted process description and function structure product, as well as a means for returning the product to its
provide a sound basis for critically analyzing an actual product original form.
and for seeking avenues to improve quality. The customer ___________________________________________________
needs are related to a form-independent functional model of the ___________________________________________________
product. Two additional hypothesis tasks are now needed for Wok Redesign (Pan and Otto, 1995): Step 1 This
completion: directly matching the customer needs with product redesign project was initiated through the leading vision of the
features and working physical principles. Between these two financial backer. A need was perceived: the inadequacy of
matchings, a design team can determine which product features current electric woks to satisfy the demands of the young urban
or principles offer the best opportunity for redesign. dweller desiring to conveniently cook authentic Chinese food.
The original product is a West Bend 6 Quart Electric Wok,
A useful technique for hypothesizing the match between shown in Figure 6.
customer needs with features and principles is to apply cause
Human (setup),
and effect analysis (Ishikawa, 1992). Here, we consider the 110 V AC,
Gravity, Stirring
Motion Heat Heat Loss, Weight
level that each customer need is not satisfied as an effect, and to Food
Raw Food, Cooked Food,
treat the product features that produce this partial failure as Water, Oil in Steam,
Counter Top, Authentic Cooking
causes. A fishbone diagram (or cause-and-effect diagram) may Cooking Utensils
Heat Level Chinese
Utensils
On/Off Status
then be completed, where the backbone represents the product Cooking
Completion
Manner Food
Appearance

assembly that satisfies the sequence of subfunctions for the

customer need, major bones intersecting the backbone represent Figure 5: Wok Black Box Model.
important subassemblies or physical behavior. The fine bones
represent specific singular options that a design team can A competitive product is a traditional wok, used over a gas
choose among to attack the customer need partial failure. flame and heated by convective and radiative modes of heat
Typically, fine bones involve components satisfying individual transfer. Heating occurs uniformly across the entire wok
subfunctions. surface, rather than in a concentrated ring. This method thus
lends itself to uniformly cooking the food placed within it.
As discussed above and summarized in Table 1, the first
step of the redesign methodology provides us with the
necessary investigation, hypotheses, and predictions for a
successful product evolution. While this information is only
the preface to the redesign task, if properly wielded, it should
give us insights that far exceed our expectations and far exceed
the resources devoted to gathering and documenting the
information. A brief glance of example results is shown in the
wok application below.

Step 2: Reverse Engineering Concrete

Experiences
Concrete experience now becomes the emphasis of the
redesign methodology. The current product architecture must
be understood in detail. More importantly, however, the
customer needs must be compared with the current products
functionality, solution principles, and choices of design
parameters. This comparison ultimately leads to avenues for

6 Copyright 1996 by ASME

 Customer Data: Electric Wok
__________________________________________________________
Customer: CP Interviewer(s):
Address: MIT Date: 1/5/94
Willing to do Currently uses: Frying pan/pot
follow-up? Y Type of user: College student
______________________________________________________________________________
Question/Prompt Customer Statement Interpreted Need
______________________________________________________________________________
Typical uses Cooking stir-fry Chinese
food
Frying pan substitute

Quick, easy dishes

______________________________________________________________________________
Likes Bottom heats up quickly Bottom heats up quickly
Little to no smoke emitted Heats evenly/constant heat
when cooking Ears are covered in a type of
Ears remain cool (not hot) to insulating mat'l
touch Non-stick surface
Non-stick surface Wok is lightweight
Fairly lightweight Aesthetically pleasing
Attractive design/color Inside can be cleaned
Useful for college-age easily
students (w/out easy
access to stoves)
Easy to clean
_____________________________________________________________________________
Dislikes Sides slow to heat up Sides heat up at same rate
Need to stir food around a Rounded bottom to be able
lot to cook well to tilt/shake wok
Flat bottom: difficult to tilt Smaller bottom area
wok/move food Include off switch
Need to use more oil Heating unit is detachable/or
No off button/switch wok is watertight
Cumbersome to wash Long extension cord
Afraid to get bottom (heating
element) wet
Needed extension cord to
cook on table
_____________________________________________________________________________
Suggested One-sided handle (long) Handle that can be used to
Improvements "Flip-out" handle to con- flip food in the wok
serve shelf space Compact for storage
Include off button Can turn off heat w/out
Make bottom more round unplugging
Notch on rim for spatula/ Includes resting spot for
stirring utensil to rest on spatula/serving utensil
Longer cord (or include
extension?)
Figure 6: West Bend 6 Quart Electric Wok.
Figure 8a: Example Customer Interview
PROJECT: ELECTRIC WOK
Customer Requirements

Interviewer(s):
Date:
Number of Customers: 9
Weighting Scale: 1 - 10
Average Customer:
Male/Females, age 20-30, Attending college, Small apartment kitchen,
No automatic dishwashing equipment

Customer Requirement WT

Purchase
- Cost 7

Transport in package

Unpackage

Clean
- Non-stick surface 7
- Watertight 3
Detachable from the heating unit 3

Return to kitchen storage

- Compact for easy manipulation 8
- Heat contained in wok 2
- Impact resistant 5

Store in kitchen
- Compact for small storage 8

Remove from kitchen storage

Figure 7: Customer interview session. Transport to serving room
- Aesthetically pleasing 4
- Doesn't slide on tabletop 2

Turn on
- Heats and cools quickly 6
- Long extension cord 6
- Temperature switch readable 2
- Off switch included 2

Add raw food

- Large volume capacity 4
- Temperature indicator 3
- Temperature controls remain cool/don't get hot 2

Cook food
- Flat bottom for frying 3
- Small, rounded bottom for stir-fry MUST
- No ridges on inner surface 5
- Able to stand on own 7
- Detachable heating unit to remove heat when cooking 2
- Temperature uniform across inner surface MUST
- Steady-state temperature uniform 4
- Capable of high temperature 1
- Handles remain cool/don't get hot 3

Remove cooked food

- Contents can be poured out 4
- Easy to handle MUST

Throw out

Figure 8b: Partial Customer Need List

___________________________________________________
___________________________________________________

7 Copyright 1996 by ASME

 The disassembly plan is now systematically executed,
labeling each component as it is removed. Distinct assemblies
or sub-assemblies are also noted to understand the product
architecture. As the product tear down progresses, a bill-of-
materials (BOM) is constructed to investigate the abstract and
concrete features of the product. This BOM should list all
assemblies, sub-assemblies, and parts in the order they were
originally assembled. This makes DFA cost analysis easier.
Documentation for the bill-of-materials includes a table that
lists the assembly name, part number, quantity, part description,
part function(s), input-output flows (energy, material, or
signals), salient physical parameters, and predicted
manufacturing process(es).
In addition to the tabular BOM, concrete experiences with
the product calls for the creation of an exploded view or
assembly diagram. Construction of this graphical document
allows the design team to obtain a first-level understanding of
the product assemblability, based on the actual product tear
down. Degrees-of-freedom analysis, and other tools, may be
directly applied with this information. Overall, product
disassembly, carried out in this way, gives invaluable hands-on
experience with the product, while providing required data for
later steps in the redesign methodology.
and geometry of the nozzle may also be needed to further
understand the meaning of adequate suction. Recognition of
these physical parameters may not occur at this stage of the
redesign, but instead during the forming of engineering metrics
(step 5) or the construction of design models (step 6). In either
case, the design team iterates back to the experimentation task
to obtain the required data. Results of the task, independent of
when it is executed, are recorded on an updated BOM.
___________________________________________________
___________________________________________________
Wok Application: Step 2 The wok tear down revealed
the cause of the failure to deliver a uniform temperature
distribution across the bowl. The electric elements were housed
within a narrow circular channel, concentrating the heat
transfer. The non-uniform heating characteristics in time were
revealed to stem from a bimetallic temperature controller,
which also was the design driver for the poor power control
interface.

After or in concert with product tear down, a novel

subtract-and-operate (SOP) procedure (Table 3) is executed to
study the functional dependence of each product component
(Lefever and Wood, 1996; Lefever, 1995). A summary of the
procedure for an assembly or subassembly of a product is given
below:
Disassemble (subtract) one component of the assembly.
Operate the system through its full range.
Analyze effect through visual inspection or measurements.
Deduce the components subfunction; compare to BOM.
Replace component; repeat for all parts in assembly.
Using this procedure, construction of a SOP table occurs,
listing the part number, part description, and determined effect
of removal. Through this procedure and associated
documentation, a more refined understanding of component
functionality may be obtained; likewise, for those components
that are recorded as having no effect when subtracted,
redundant functionality exists in the product, implying that part
reduction may be directly pursued.

The final task of the second step is to experiment with the

overall product, its assemblies, and it components. Step one of
the redesign methodology generates a complete list of customer
needs, in addition to predicted product features and physical
principles. These data, in conjunction with the BOM, are now
used to direct the choice of physical parameters that must be
recorded for the product. For example, for a wet-dry portable
vacuum cleaner, a customer need may exist to provide
adequate suction. With the tear down revealing a motor,
centrifugal impeller, and nozzle assembly, the fishbone diagram
highlighted that volumetric flow rate and suction pressure
measurements (measured with manometer or other device) are
needed at the system level to address the customer need.
Torque-speed curves of the motor, geometry of the impeller,

8 Copyright 1996 by ASME

 Part # Quantity
Part DescriptionPart ColorFunction Physical Parameters Mfg. Process

A1Lid Assembly
001 1 Cover Red (top) Minimize oil splattering Stamped .030" alum. Stamped
Silver(bot)Steam and Enclose Food ...
002 Cover knob Black Lift support for wok lid Plastic
Insulate Temperature

A2Bowl Assembly
003 1 Wok bowl Black Hold food 14" diameter
Distribute heat .060" aluminum
Attached Handle Hard anodized surface
Attach Heating Assembly Rolled edge
Provides Non-stick SurfaceFlat, circular bottom
Contain liquid Raised ridge along
Prevent Stick bottom's perimeter
004 2 Handles Black Lift support for wok Plastic
Insulate Temperature
005 1 Wok stand Black Encase heat source; Shield Plastic
environ.
Support Container 8" circular diameter
Provide friction anti-skid 4 short legs
Display Temperature Settings
Support Cord Connection
006 2 Connector prongs
Steel Elec. connect wok to cord .13" diameter round
Provide Electrical shutoff .50" long, threaded
007 4 PEM studs Steel Connect bowl to stand & 2 short (1" from
heating sources bottom of bowl)
008 1 Metal Plate AluminumContain heating assembly Aluminum
for safety Embrossed lettering
Display customer information

A3Electrical Heating Assembly

009 1 Electrical Cord Black Connect wok to 2' long
electrical outlet
010 1 Thermostat Mtl/Crmc Regulate temperature (on/off)
Bimetallic strip
011 1 Heating Coil Black Convert elec. energy to 1000 W Cadmium Wire
radiation and convective heat
4" diameter ring
.38" hoop
012 1 String White Hold heat source in place
013 3 Insulated Wires White Connect heating source to Steel20 Guage hard wire
heat regulation Wrapped in thread insltn

A4Electical Heating Support

014 1 Radiation ShieldMetallic Shield thermostat from .01" millboard
radiant heat fireproofing Sheet
3.5" diam. ring
015 12 Coil Supports Off-white Hold heat source in place Ceramic
Electrically insulate coil
016 1 Element housingAluminumAttach heat source .030" aluminum
supports .75" U-channel ring
Reflect radiation into bowl4" mid-diameter
017 1 Spacer Silver Support for heating Aluminum
assembly attachment Elliptical shape
018 1 Slotted spacer Dark gray Hold temp. regulator in Indented, angled shape
place 2.63" on longest side
019 1 Square spacer Light grayCompress heat source supports
3.88" x 4.25"
of coil supports Square shape
Register assmbly process 2.88" diam. circle
cut through center

Figure 10: Wok Bill of Materials.

___________________________________________________
___________________________________________________

Step 3: Reverse Engineering Functional Analysis

Product disassembly provides detailed information
regarding component function, assemblability, physical
parameters, and manufacturing processes. It also provides an
intangible understanding of the product as a consequence of the
various hands-on experiences. These results must now be
abstracted to the level of the customer needs statements,
developed in step 1. By so doing, the design team may identify
and rank areas of focus for product improvement.
Figure 9: Wok Exploded View.
Functional analysis is the key instrument for building the
abstraction. Two primary tasks, as shown in Table 4, enable
functional analysis of the actual product. The first task is to
develop energy flow diagrams of the product and/or separate
product assemblies (Lefever and Wood, 1996; Lefever, 1995).
Energy flow diagrams are graphical aids that represent the
transfer of energy through a products components.

After or in concert with force flow analysis, a function

structure for the actual product is formulated. This task entails
the same approach as described in step 1 (Figure 4), except, in
this case, subfunctions are not predicted; they are derived from
the components in the product. This time we have the benefit
of tearing apart the actual product. We believe this two step
approach helps a design team understand different physical

9 Copyright 1996 by ASME

 ________________________________________________________________________________________________________
________________________________________________________________________________________________________

Wok Application: Step 3 A function structure was developed by first associating flows to each customer need. This produced
of electricity, and heat flow. These flows were then expanded into sequences of subfunctions as the flows traced through the wok. T

Clean Set Point

Use? or
Cook Show
or Elec. power
Store Connect Enable Regulate On/Off
Electric Power Elec. based
120 V AC to Wok On/Off on Temp.

Convert Heat Conduct heat Heat

Elec. to Heat bottom of Heat through loss
Radiation container Flow container
Sense
Heat

Heat
Container
Heat Wok
Surface

Heat Stir Contain Manipulate

Raw Food Food Food Wok
Food Poistion?
Cooked
Food

Positioned
Food
Prevent Surface
Skidding Load
Transmit Human Load Cooked
Remove
Weight to Food
Food
Human
Exposed Surfaces

Clean Compactify Stored

Wok Wok Wok

Figure 10: Wok Function Structure Actual Product.

________________________________________________________________________________________________________
________________________________________________________________________________________________________

principles by which the product could operation. Using the
flows for each customer need, as developed in step 1, a useful
approach to generating subfunctions for the actual product is to
examine the exploded view and bill-of-materials from step 2.
Each flow is traced through the product, recording the
subfunction(s) for a component as it is encountered by the flow.
This process creates a subfunction chain for each flow. The
next step is to connect the parallel flow chains together as a
network, adding subfunctions and flows for components that
link flow chains. The result of this process is the desired
function structure.
Step 4: Reverse Engineering Constraint
Propagation
Product disassembly and functional analysis, as completed
in steps 2 and 3, yield detailed design data for product
evolution. With these data, improvements in design function,
parameter choices, etc. may be approached knowledgeably for
assemblies, subassemblies, or components. Before attempting
such improvements, however, constraints between product
components must be well understood. With such
understanding, the ramifications and propagation of design
changes may be properly forecasted.
The first task in this step, as shown in Table 5, is to create
a morphological matrix (Pahl and Beitz, 1984; Ulrich and
Eppinger, 1994) of the solution principles (components) for the
significant functions. Each row of the matrix corresponds to a
subfunction from step 3, and each column represents a solution
principle. Labeled categories, such as energy domain, spatial
configuration, kinematics, or field type (Pahl and Beitz, 1984),
may also be included to group the solution principles. For the

10 Copyright 1996 by ASME

 ________________________________________________________________________________________________________
________________________________________________________________________________________________________

Wok Application: Step 4 A morphological matrix was developed for the electric wok, as an exercise in a structured approac
from step 9.)

Function Current Wok Possible Solutions

1. Connect to Wok Plug Direct
2. Switch Electric Plug Flip Switch "Off" Setting IC Control
Power on/off
3. Regulate ElectricityThermostat P-Control at PD-Control Open Loop
on/off Center Thermocouple
4. Convert Electricity Heating Coil Halogen Heat Washable Coil Silicon Rubber Inductive Coil Ceramic Disk
to Radiation Lamp Pad & Plate
5. Channel Heat Square U-Ring Parabolic U-Ring Dish-Shape
to Bottom of
Container
6. Heat Bottom Exposed Ring Larger Ring Circle
of Container on Bottom
7. Conduct Heat Change Mat'l Thicker Bowl Different Mat'l
Geometry
8. Sense Heat Thermostat at Thermocouple Thermistor IC Sensor None
Center
9. Prevent Skid 4 Dimple Pt. 3 Dimple Pt. Rubber Pad Flat Bottom
Contact Contact (No Legs)
10. Transmit to User Short tabs Full Handle
11. Clean Wok Attached Base; Detachable Bowl
Handwash
12. Compactify Wok None Base Attachmt. Detachable Pivot Handle
Fits Inside Bowl Handle

Figure 11: Wok Morphological Matrix.

________________________________________________________________________________________________________
________________________________________________________________________________________________________

actual product, only one column of the morphological matrix is
needed for this step since each subfunction is solved uniquely.
After completing the matrix, the design team is prepared to
seek alternative, adaptive solutions to chosen subfunctions, or
add functions to address specific customer needs. In addition,
the design team may identify function sharing of the product
components, simply by scanning the matrix for components
that are listed for more than one subfunction.
Function sharing and compatibility analysis comprise the
second task for understanding the product configuration. As
stated, the morphological matrix is a simple approach for
identifying function sharing within a product. Through such
identification, it is possible to plan for design changes without
violating functional requirements. For example, an adaptive
design change may call for the replacement of a product
component to improve product quality; however, if the said
component function shares, the design team must add the
shared functionality to the new component to maintain the
products integrity.
Compatibility analysis also provides important design
information before a product can be evolved. The concept of
compatibility simply entails the analysis of each critical product
component to identify its degrees-of-freedom, access directions
with respect to the product, relative motion with other
components, tribological properties, size tolerances, and
geometric tolerances. A matrix listing each component versus
these data may be constructed to document the analysis. By so
doing, design constraints at component interfaces are well
documented.
Step 5: Reverse Engineering Forming Engineering
Specifications
The last step of reverse engineering entails the forming of
specifications and choosing the product systems that will be
evolved, as shown in Table 6. The intent of the first task is to
define quantitative targets for the product (Otto, 1995). Having
established organized customer needs and a function structure
for the product, each subfunction must be associated to at least
one line item in a product Specification Sheet. For our
purposes, each specification item must come from a set of
possible elements/values, and these elements must collectively
be comprehensive and measurable.
To establish an initial set of engineering specifications, a
design team should start by listing each subfunction as rows of
a matrix. For each subfunction, a means to measure the input
and output flows should be conceived. These measures should
be listed for each subfunction row as the metrics for the
subfunction. For example, a subfunction might exist to
regulate temperature of a material. Possible measurements
include steady state temperature error, set point temperature

11 Copyright 1996 by ASME

 Specfications
error, and temperature variation across the material. Each of

MUST T variation across surface

these should be recorded as metrics for the subfunction.

Switch visibility angle

Compacted diameter

Steady state T error

Handle maximum T
Foot pad pressure
Compacted height

Switch provided
MUST Handle shape
Tipping force
Bowl volume

Sliding force
Next, the generated metrics must have target values

MUST Bowl shape

T rise time
Foot print
Diameter
Weight
Height
assigned to each. This subtask is accomplished by examining
the relevant customer needs and performing benchmarks with

9.0
9.0
9.0

3.0
5.0
5.0
3.0
3.0
5.0
3.0

5.0
3.0
5.0
3.0

5.0
WT.
related products or technologies. After these tasks, the results Return to kitchen storage
- Compact to manipulate 8 5 5 9 5
should be collected into a House of Quality matrix, creating the - Heat contained in wok 2 9 5

necessary importance rankings and relationship matrices. The Store in kitchen

- Compact for storage 8 9 9
result of this process is the forming of quantified specifications
Transport to serving room
with a clear link to the original customer statements. For more - Aesthetically pleasing 4
- Doesn't slide 2 5 9
details on the process, the reader is referred to (Otto, 1995).
Turn on
- Heats and cools quickly 6 9
- Switch readable 2
Quantified specifications provide clear goals for evolving - Off switch included 2 9 9

the current product. In turn, a complete House of Quality, with Add raw food
- Large volume capacity 4 5 5 9
this information, may be used to choose, preliminarily, which - Temperature indicator 3 9

components of the product should be evolved first. A question Cook food

- Flat bottom for frying 3 9
exists, however, concerning the type of redesign activity to - Small, rounded bottom MUST 9
- No ridges 5 9
pursue. Should parametric redesign be attempted first, or is - Able to stand on own 7 5 5 9
- Detachable heating unit 2 5 5 5
adaptive redesign required, followed by parametric efforts? - Bowl T uniform MUST 9
- Steady-state T uniform 4 9
This question may be straightforward to answer when obvious - Handles remain cool 3 9

component deficiencies exist in a product; however, in many Remove cooked food

- Contents can be poured 4 9
cases, an answer may not be easily forthcoming. For example, - Easy to handle MUST 5 5 5 9

in the redesign of a cordless, centrifugal vacuum cleaner, an

engineering specification may exist to increase flow rate by
500%. Such a large change in flow rate may seem to imply that
a technology change is needed in the drive system or pump
system for the vacuum. A simple mathematical model based on
turbomachinery theory might show, however, that changes in
impeller angles, thickness, and radii can easily produce a 500%
change. Thus, the creation of a design model is a necessary
step in the product evolution process, as presented in the next
section.
___________________________________________________
___________________________________________________
Wok Application: Step 5 A house of quality was
constructed to ensure all customer needs had proxy metrics that
could be measured and agreed upon by the design team.
Figure 12: Wok House of Quality.
___________________________________________________
___________________________________________________
Step 6: Modeling and Analysis Model
Development
Virtual and physical modeling of the product will provide
in-depth insights into its operation and possible improvements
that may be achieved parametrically. As listed in Table 7, three
tasks are needed to develop a virtual or mathematical, model.
Beginning with each important customer need or engineering
metric from the House of Quality, the product components that
affect the customer need should be listed. The governing
physical principles and associated modeling assumptions must
then be identified for each component, or the group of
components as a whole. For example, for a cordless vacuum
cleaner product, the customer need might exist to increase
flow rate. Components affecting the flow rate are the motor,
powertrain, impeller, and nozzle. The choice for the governing
physical principle might be centrifugal fluid flow (fluid
mechanics), assuming steady-state, incompressible, one-
dimensional, laminar flow.

After identifying the physical principles and assumptions

for each customer need, a balance relationship is created to
document a high-level physical model. As in step 1, a fishbone
diagram, or a failure modes and effects diagram (Clausing,
1994), may be used to document the balance relationship,
where the effect in the diagram is the customer need, and the
causes are the physical principles. The ultimate goal is to
refine the causes to the level of physical parameters or
variables.

The last task in formulating mathematical models for the

product is to convert the balance relationships into a set of

12 Copyright 1996 by ASME

 ________________________________________________________________________________________________________
________________________________________________________________________________________________________

Wok Application: Step 6 Mass, steady state temperature uniformity, temperature rise time, and volume equations were deriv
weight.

Material volume
K bowl
Bowl geometry Lid/no lid
Cp bowl Tf of food
Thermal mass h
Non-uniform SS Bowl Cond. Heat Trans. Cond. into food
Temperature
across diameter Radiation, Elem. -> Bowl Elements
of bottom of bowl Power
of elem. housing Size
Geometry of elem. housing Location

r dr

r r+dr

qrad qrad
qconv qconv

Region 1 Region 2 Region 3

rL rR R
qrad
qin qconv
q rad (r R2 rL 2 )(T M 4 T 4 )
q rad rL (T c T ) q rad 2 (rR r L ) (T o T )
2 4 4 2 2 4 4

qconv h (rR 2 r L 2 )(T M T )

qconv h r L2 (T c T ) qconv 2h (R rR )(T o T )
2 2

q L k 2 r Lt (T M T c )
q L k 2 r Lt (T M T c ) q R k 2 r Rt (T M T o )
q R k 2 r Rt (T M T o )

Middle Center Outer

Figure 13: Wok Heat Transfer Model.

________________________________________________________________________________________________________
________________________________________________________________________________________________________

mathematical equations. Basic engineering principles may be
used to choose the appropriate scaling law relationships (Miller
and Wood, 1996). Parameter ranges from the products bill-of-
materials should be used to augment the mathematical
relationships with appropriate parameter values and ranges. If
such parameter values are unavailable, the Experiment with
Product Components task of step 2 should be executed.
In some cases, cycle-time, economic, or product-
complexity considerations may prevent the development of a
mathematical model. The creation of a physical prototype can
be used as an alternative modeling approach. As listed in
Table 7, a prototype model should be designed in such
circumstances (Ulrich, 1994). The intent here is not to create a
prototype of the entire product; instead, a benchtop or other
experiment should be designed for a customer need, focusing
on the effected product components and variables that need to
be investigated. For instance, a customer need may exist for a
bottle cap remover to fit comfortably in the users hand during
operation. A mathematical model of this need is not directly
apparent; however, physical prototypes that vary shape, size,
and texture of the products handle may be designed to
investigate the customer need.

13 Copyright 1996 by ASME

Step 7: Modeling and Analysis Analysis Strategies 220

Models are developed for each of the important customer Ave Temp
needs in step 6. The next step is to develop analysis strategies +Sigma
-Sigma
for solving the models. The first task for developing an 200
analysis strategy, as listed in Table 8, is to calibrate the model

Temperature, F
for each customer need.
180
Model calibration entails the matching of the model to
the actual performance of the product. Two update procedures
are usually required for calibration: either changing estimates
of model parameters, or adding terms to the model to capture 160

important physical effects. For example, a model for the flow

rate of a cordless vacuum cleaner might be a linear function of
the impeller thickness, a square function of the impeller radius, 140
a linear function of the motor speed, and a trigonometric 0 2 4
Dist from Center
6
r, [in.]
8

function of the impeller angle. After testing the pressure in the

vacuums nozzle with a manometer, and converting to flow
rate, a discrepancy of over 100% might exist. To calibrate the
Figure 15: Wok Calibration.
model, new estimates for model parameters might be
considered. In this case, however, all parameters are measured minimize ||T|| (temp. var iation)
quantities. An alternative calibration approach is to increase
the order of the model. Assuming the original model subject to tr t (rise time)
considered the centrifugal flow at the center of the impeller, a
new model might be constructed to consider the average radius | T(t r ) Tss | (temp. at SS)
of flow within the inlet orifice. By so doing, increased T(t) f (t) 0 (transients)
accuracy will be achieved, perhaps within 5-10%.
W W (weight)
Once the model is calibrated, it must be converted into a Tc T c (min. center T )
form that is conducive for solution. Example formulations
include objective functions and constraints for optimization or Th T h (max. handle T )
constraint propagation, a set of simultaneous equations in a
Constants
spreadsheet, a state space formulation for simulation, or Boltzmann Constant 5.7E-08 W/m^2 K^4
Temp Environ T inf 25 C
combinations of these. Bowl Conductivity
Convection Coeff
k
h
200
4.40
W/mC
W/m^2
Wok Radius Xmax 0.18 m
Wok Height Ymax 0.09 m
Rmax 0.20 m
An alternative approach to the virtual model formulations Density
Emissivity
rho
eps
2800
0.80
kg/m^3

is the creation of a physical prototype strategy (Table 8). In Heat Capacity

Wattage
c_p
q_in
100
1000
J/kgm^3
W

this case, design of experiments must be developed, including Handle Conductivity

Duty Cycle
k_h
12%
20 W/mC
Handle Convect Cf h_h 4.40 W/m^2
the number of control factors, identification of noise factors, Design Variables

choice of response(s), number of experiments, and the Thickness

r_L r_L
t 0.0033 m
0.05 m
0.004
0.05
r_R r_R 0.13 m 0.13
experimental matrix. For statistically validity, it is also Handle
L 0.16 m 0.16
important to choose the number of replicates, the in-between s 0.03 m 0.03

tests for residual analysis, blocking (if needed), and the random Performance Metrics
Temp Rise Time t_r 3.25 min <-- NOTE: To within 1 C error of SS Temperatures
Steady State Temperatures 3.25
run order for the tests. Center
Mid
T_c
T_m
214 F
221 F
101 C
105 C
90

___________________________________________________ Outer
Steady State Temperature Errors
T_o 160 F 71 C

|| T_ij || 31 F
___________________________________________________ Weight
Bowl W 1.18 kg 1.5

Handle Temperature

Wok Application: Step 7 Experiments were executed to T_h 126 F 52 C 50

Intermediate Metrics
determine time constants and heat transfer coefficients of the Metal Volume
Center V_c 2.6E-05 m^3
wok. These were used to calibrate the previous metric Mid
Outer
V_m
V_o
1.5E-04
2.4E-04
m^3
m^3

equations and applied in an optimization. Subsequently, a Steady State Heat Flow Balance q_cond q_conv q_rad q_in
Center sum q 0.42 =0 7.21 -2.63 -4.16 0
designed experiment was performed about the new model Mid
Outer
sum q
sum q
-0.55
0.55
=0
=0
-78.92
71.70
-15.92
-30.01
-25.71
-41.15
120
0

optimum. Normed || sum q|| 0.78379 =0

Transcient Heat Flows T_s

Time Temperature, C Heat Flows, W T/dt Flag
sec Center Middle Outer Center Middle Outer Center Middle Outer
0 25 25 25 0.0 120.0 0.0 0.00 2.87 0.00 999999
6 25 42 25 31.1 45.1 36.3 4.28 1.08 0.53 999999
12 51 49 28 -5.6 69.8 38.9 -0.77 1.67 0.57 999999
18 46 59 32 21.2 24.6 48.1 2.92 0.59 0.70 999999
24 64 62 36 -5.5 49.4 40.6 -0.76 1.18 0.59 999999
192 100 104 70 -0.4 1.6 1.2 -0.05 0.04 0.02 192
198 100 104 70 0.6 0.3 1.3 0.08 0.01 0.02 198
204 101 104 70 -0.3 1.2 0.9 -0.04 0.03 0.01 204
210 100 104 71 0.5 0.2 1.0 0.07 0.00 0.01 210
216 101 104 71 -0.2 1.0 0.7 -0.03 0.02 0.01 216
222 101 105 71 0.4 0.1 0.8 0.05 0.00 0.01 222
228 101 105 71 -0.2 0.8 0.5 -0.03 0.02 0.01 228
234 101 105 71 0.3 0.1 0.6 0.04 0.00 0.01 234

14 Copyright 1996 by ASME

 Table 9. Representation of Redesign (Steps 8-10).

Phase: Task: Background Resulting Impact

Step Subtask Information Knowledge
Optimize Design, Calibrated design model; New design variable Evolved design
Iteratively design variable ranges; choices for quanified
customer needs
Perform SenstivityCalibrated design model; Possible directions for
Parametric

Evolved design, including

Analysis and optimization results; further improvement; effects of noise
Tolerance Design design variable ranges; robustness of new (uncertainties)
noise variable ranges solution
Build and Test Optimized design; Verified redesign or Demonstration of
Prototype experimental strategy identification of redesign evolution;
(DOE) remaining areas for hands-on feedback
improvement on customer satisfaction
Update Function Customer needs; Final function structure Novel functionality for
Structure comparison of predicted for redesign satisfying the customer
functions and actual needs
Search for Contradiction or Range of new solutions Conceptual leaps in
Inventive Solution conflict; chosen using TIPS approach product's S-curve
Apply new TIPS subsystem(s);
Redesign:

physical effects associated functions

Apply TIPS and customer needs;
design principles comparison of predicted
Apply TIPS vs. actual product
Adaptive

prevailing trends features and principles

Augment Chosen subsystem(s); Range of new solutions Conceptual leaps in
Morphological morphological matrix using team synthesis product's S-curve
.
Matrix for current product; methods
Add new funcs. new functions (if needed)
(if needed) comparison of predicted
Create solutions vs. actual product
for 2n columns features and principles
Analyze Force Force flow diagram(s); Component combinations Potential part count
Flows function structure that maintain force flows reduction
Build and Test Adapted design; Verified redesign or Demonstration of
Prototype experimental strategy identification of redesign evolution;
(DOE) remaining issues hands-on feedback
Develop New F.S. Predicted/actual F.S. Combined function struct.Abstract S-Curve Leap
Choose AlternativeNew F.S.customer needs New product concepts Revolutionary product
Original

Build and Test Original design; Verified design concept Demonstration of

Prototype experimental strategy risk level in new concept
Apply Product Engr. requirements; New product idea, Original solution in new
Technology to morphological matrix applying product's field
New Field effects in another field

Figure 16: Wok Optimization. Figure 17: Wok DOE Experiments.

___________________________________________________
___________________________________________________

Steps 8-10: Redesign: Parametric, Adaptive, or

Original

The data from steps 1-7 provide the design team with
immeasurable knowledge and capability. Customer needs are
gathered and organized. Product function is predicted,
experienced, and abstracted. Physical principles are
hypothesized, tested, and modeled. And engineering
specifications are quantified and ranked. The design team must
now employ these data in a successful redesign effort. Table 9
shows the tasks for the three types of redesign, i.e., parametric,
adaptive, and original.

15 Copyright 1996 by ASME

 Parametric redesign requires a model of the original
product or a model of a new product configuration following
adaptive redesign. The model should be calibrated and
reformulated according to the chosen solution technique.
Optimization, spread sheets, and/or simulation is then applied
to obtain new product parameters. Verification of the results
then commences using sensitivity analysis or tolerance
analysis, such as statistical tolerance stackup (Ullman, 1992) or
Taguchi tolerance design (Phadke, 1989). If satisfactory results
are obtained from the parametric redesign, building and
experimental testing of a beta prototype commences to verify
the recommended design improvements. If not, adaptive
solutions are investigated.

In the case of adaptive redesign, the design team seeks to

create alternative solution principles to chosen product
subsystems, replace subfunctions of the product, or add new
subfunctions to the product. The first task, then, is to update
the functional description of the product (Table 9), by either Figure 17: Final Alpha Prototype.
comparing the predicted function structure to the actual, or by ___________________________________________________
simply adding new functions prescribed by the customer needs. ___________________________________________________
Based on the new function structure, adaptive solutions may be
obtained in a number of ways. For example, the morphological
CONCLUSIONS: INTROSPECTION ON DESIGN
matrix of step 4 may be expanded to include a wide variety of
EDUCATION AND INDUSTRY
solution principles for the important subfunctions (Figure 11).
This paper presents a novel redesign methodology. It is
Brain storming techniques and discursive bias are directly
based on a ten-step process with three primary phases. Each
applicable for augmenting the morphological matrix.
phase provides a clear set of tasks to seek new product
Alternatively, or in concert, the Theory of Inventive Problem
configurations. Each phase also combines contemporary
Solving (TIPS) may be applied (Altschuller, 1984). This theory
design techniques with new applications and extensions
employs documented physical effects (over 1000), design
developed by the authors. These tasks and techniques provide a
principles (42), and prevailing trends in technology (eight so
unique forum for significantly evolving all types of consumer
called laws of evolution) to seek alternative solutions. For
products, as illustrated by the electric wok example. Over the
example, the customer needs and functional analysis of an
last three years, the methodology has been applied to over 100
electric iron product might show a conflict between
products at MIT and UT. The impact of these efforts on design
lightweight product and reliably remove wrinkles (which
education and industry is described below.
calls for a large mass). Adding the function of create
vibration, as suggested by TIPS principles, a large force may
Design Education
be imparted on the clothing material utilizing little product
We have conducted these methods both on industrial
mass.
applications and taught these techniques for three years running
at both MIT and UT: MIT as a single class project graduate
No matter what adaptive redesign technique is employed,
course, and UT as a two-person project freshman course, five-
new solution principles result. These solutions must be verified
person project junior/senior course (Bezdek and Wood, 1996),
with the compatibility analysis of step 4 of the methodology.
and single-person project graduate course. In general, we find
In addition, modeling and testing of a physical prototype must
the exercise of a structured design process has many benefits,
occur to verify the design changes, usually after a design model
basically including concrete experiences with hands-on
is executed.
products, applications with contemporary technologies, realistic
___________________________________________________
and fruitful applications of applied mathematics and science
___________________________________________________
principles, studies of systematic experimentation, exploration
of the boundaries of design methodology, and decision making
Wok Application: Steps 8-9 The final alpha prototype for
for real product development.
the redesigned wok includes many advances: a removable bowl
for washing, a large handle, an on/off switch, removable cord,
At MIT, the instruction focuses on exploring the strengths
understandable and visible power control, perfectly uniform
and deficiencies of the various structured design methods that
power control in time, compactable volume for storage, and a
have been developed in the community, as detailed above. The
wide view radiant surface. No electric wok on the market today
student population includes a large fraction of persons returning
yet incorporates all of these customer requested features.
to graduate school after having worked in industry on design
teams. They find that, for the most part, they did not have a full
appreciation for the theory and power behind many of the

16 Copyright 1996 by ASME

methods. Many are surprised at the comprehensiveness and
quality of results that the methods provide, and become
believers in a systems approach to a well posed design process.
At UT, the results are much the same as at MIT. The most
popular project in the freshman-level introductory course to
mechanical engineering is the reverse engineering of a
childrens toy or simple mechanical device. Students resonate
with the opportunity to learn the basics of design and apply
principles from their freshman physics and mathematics
courses. Junior- and senior-level students express their desire
for even more hands-on experiences. They also make it clear
that the redesign of a consumer product is a great forum for
learning design methodology and for preparing for their
capstone design class that focuses on design projects sponsored
by industry.
In general, we believe the application of scientific
principles to be a core guiding principle to continually
improving design methods. We continually ask why a method
is structured as it is, what it does, what it neglects, in search of
better ways. This approach has been inspiring.
Industrial Relevance
A common complaint lodged against design methodology
is that it is explanatory and thought provoking, but not relevant
to actual practice. We find this to becoming an antiquated
view. We find leading industrial companies to be constantly
seeking more structured approaches to their product
development processes, especially in the era of concurrent
development, intensive computing, and downsizing of
workforces. An effective structured method allows not just one
expert to understand and complete a task, but many other
persons.
These observations have led to most companies developing
internal product development processes, which they also tend to
guard as proprietary knowledge. Our experience is that, for the
most part, there is little intellectually unique within these
processes. Yet, as our industrial partners have remarked,
product development remains the key market battleground, and
simply the high stakes involved lead companies to these
measures of guarding structured design methods.
ACKNOWLEDGMENTS
The research reported in this document was made possible,
in part, by a Faculty Early Career Development Award and a
Young Investigator Award from the National Science
Foundation. The authors also wish to acknowledge the support
of the Leaders for Manufacturing Program, a collaboration
between MIT and U.S. industry, in addition to Ford Motor
Company, Texas Instruments, Desktop Manufacturing
Corporation, and the UT June and Gene Gillis Endowed
Faculty Fellow. Any opinions, findings, conclusions, or
recommendations are those of the authors and do not
necessarily reflect the views of the sponsors.
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