## MEC E 460 Design Project **Subject & Number:** MEC E 460 **Title:** Design Project **Course Career** **Units**: 4,5 **Approved Hours:** 2-1s-4 **Fee index:** 8 **Faculty:** [Faculty of Engineering]{.mark} **Department:** Mechanical Engineering **Typically Offered:** either term or Spring/Summer ### Calendar Description [Feasibility study and detailed design of a project which requires students to exercise creative ability, to make assumptions and decisions based on synthesis of technical knowledge, and in general, devise new designs, rather than analyse existing ones. Prerequisites: MEC E 200, 330 or 331, 340, 360, 362, 370 or 371, 380. Corequisite: ENG M 310 (or ENG M 401).]{.mark} ### Asynchronous & synchronous course content delivery All course material will be delivered synchronously on Tuesdays and Thursdays 12:30 - 13:50. Lecture notes and other resource material will be available asynchronously on eClass. ### Course Objectives & General Content This mechanical engineering capstone design course brings together design processes and engineering analysis techniques from earlier in the program into an open-ended, iterative, complex design experience in a team environment solving problems for real clients. Lectures include significant time for activities directly related to the design process throughout the term. Periodic reviews and reports follow a standard design project engineering framework, culminating in a design conference in which all teams showcase their design solutions. ### ### Learning outcomes 1. Apply engineering knowledge to a practical mechanical engineering design problem; 2. Generate design concepts and conduct feasibility analysis; 3. Work both individually and in a team to achieve design goals; 4. Appreciate and manage all stages of a design project; 5. Communicate the results of a design in both written document and oral presentation. ### Textbooks and References \- ### Assessment Details +-------------------------+----------------------+---------------------+--------------+ | > **Activity** | > **(A)Synchronous** | > **Due/Scheduled** | > **Weight** | +-------------------------+----------------------+---------------------+--------------+ | > Design activities and | > Synchronous | > throughout term | > 15% | | > peer feedback surveys | | | | +-------------------------+----------------------+---------------------+--------------+ | > Team dynamics | > Asynchronous | > end of term | > 10% | | > contribution | | | | +-------------------------+----------------------+---------------------+--------------+ | > Phase 1 report | > Synchronous | > 2023-10-02 | > 10% | +-------------------------+----------------------+---------------------+--------------+ | > Phase 2 report | > Synchronous | > 2023-11-02 | > 20% | +-------------------------+----------------------+---------------------+--------------+ | > Final design poster | > Synchronous | > 2023-12-02 | > 5% | +-------------------------+----------------------+---------------------+--------------+ | > Final design | > Synchronous | > 2023-12-02 | > 10% | | > presentation | | | | +-------------------------+----------------------+---------------------+--------------+ | > Final design report, | > Synchronous | > 2023-12-07 | > 30% | | > drawing package, | | | | | > ancillary | | | | | > deliverables | | | | +=========================+======================+=====================+==============+ ### ### Course Accreditation Units The current total and individual Accreditation Unit (AU) counts for this course are: ----------------------------------------------------------------- **Total** **Math** **NS** **ES** **ED** **CS** ------------- ------------- -------- -------- ---------- -------- 56.7 56.7 ----------------------------------------------------------------- ### ### Course Graduate Attributes The Graduate Attributes (GAs) developed in this course are: ------------------------------------------------------------ \# Graduate Attribute Level (I, D, A) ----- ------------------------------------------ ----------- 1 A knowledge base for engineering (KB): I 2 Problem analysis (PA): A 3 Investigation (IN): A 4 Design (DE): A 5 Use of engineering tools (ET): A 6 Individual and team work (TW): A 7 Communication skills (CS): A 8 Professionalism (PR): D 9 Impact of engineering on society and the D environment (IS): 10 Ethics and equity (EE): D 11 Economics and project management (EP): D 12 Life-long learning (LL): D ------------------------------------------------------------ ### ### Course Schedule Course Overview and Goals [Pre-Course Activity (0.5%)]{.underline}: Survey for Team Selection due Friday September 1, 2023 by 11 pm Resources: Team Selection Background Information Course Syllabus Learning Objectives Schedule of Lectures, Activities, and Deliverables ***Course Introduction*** Tuesday September 5, 2023 Lecture 01 Slide Deck Resources: A Short Video Preview of Lecture 01 Welcome Learning objectives and expected outcomes for the capstone design course How the Course Works: team formation, letter of intent, Phases 1, 2, and 3 deliverables How classes will work (pre-lecture material & quiz), in-class focus on design activities Team Formation and Project Selection Process Design Project Phases Planning a Design Project ***Becoming a Team & The Project Selection Process*** Thursday September 7, 2023 Lecture 02 Slide Deck Resources: A Short Video Preview of Lecture 02 The Value of Teams Roles and Responsibilities for Team Members Conditions for Project Success Group Dynamics Marking Rubric Team Charter Template Letter of Intent Template Work time to begin drafting team charter and letter of intent [Activity 01 (1%):]{.underline}The Team Charter & Letter of Intent Due Friday September 8 2023 at 5pm Teams receive their project selection prior to Lecture 03. Phase One: Planning ***Understanding the Client Need & Defining Requirements*** Tuesday September 12, 2023: Lecture 03 Slide Deck Resources: A Short Video Preview of Lecture 03 Stakeholder Analysis Establishing Design Requirements Functional Analysis System Block Diagrams Technical Performance Specifications (avoiding vague wording, and how to avoid Overspecifying the Solution) Performance, Durability, and Economic Measures Relevant Codes and Standards Ranking Importance Multi-Attribute Design Criteria Examples of Functional and Technical Specifications Information Resources for Stakeholder Requirements (On-Line Only) Resources: Trade Study Methodology Databases available through the Library Codes and Standards How to Look for Related Products and Patents [Activity 02 (1%):]{.underline} Preliminary Design Requirements, Technical and Functional Specifications, including Relevant Codes and Standards "one shall per requirement", and rationale (due at 5 pm Wednesday September 13, 2023) ***The Design Process, Project Plan*** Thursday September 14, 2023: Lecture 04 Slide Deck Resources: A Short Video Preview of Lecture 04 The Design Process and Statement of Work Work Breakdown Structure, Project Planning, and Scheduling, Suggestions for Load Leveling for Fair Contributions by All Team Members Sample Project Template Capturing the Rationale of Key Decisions in Project Documents Some Project Tracking Tools Meeting Agenda Template Meeting Minutes Template Action Log Template [Activity 03 (1%):]{.underline} Planning the Project & Estimating the Effort (due at 5 pm Friday September 15 2023) ***Requirements Review*** Tuesday September 19, 2023: Lecture 05 Slide Deck Resources: The Phase One Group Discussion Expectations Sign Up Schedule for Phase One Requirements Discussion Meeting Presentation Template for Requirements Review [Activity 04 (1.5%):]{.underline} Presentation Slides for Requirements Review Meeting & Participation (due Thursday September 21, 2023 by 5 pm) ***Delivering Phase One*** Thursday September 21, 2023: Lecture 06 Slide Deck Resources: A Short Video Preview of Lecture 06 What's Expected in the Phase One Report The Report Outline Marking Rubric for Phase One Report Examples of Phase One Reports Time to work on Phase One Review presentation ***Phase One Requirements and Project Plan Presentation and Feedback*** Tuesday September 26 to Thursday September 28: Phase One Review Meetings (20 minutes per team, some to be scheduled outside of regular class time, all team members are expected to attend and contribute to presenting) [Deliverable (10%)]{.underline}: Phase One Report (due Monday October 2, 2023 at 5 pm) [Peer Feedback Activity (0.5%):]{.underline} Team Phase 1 Survey (due Tuesday October 3, 2023 at 5 pm) [Phase Two: Conceptual Design]{.underline} ***Conceptual Design*** Tuesday October 3, 2023: Lecture 07 Slide Deck Resources: A Short Video Preview of Lecture 07 How to Come Up with Pretty Good Ideas Principles for Creative Thinking (Individual and Team-based) Crazy Eights and Other Creative Games Brainstorming versus directed problem understanding Recognizing a Potentially Good Idea Examples of Conceptual Design *[Activity 05 (1%)]{.underline}*: *Individual Ideation Exercise (due Wednesday October 4, 2023 at 11 pm)* ***Creative Thinking for Design -- From Ideas to Concepts*** Thursday, October 5, 2023: Lecture 08 Slide Deck Resources: Bring your individual ideas!! A Short Video Preview of Lecture 08 Approaches to Creative Thinking [Activity 06 1%:]{.underline} Team Design Charette (due Thursday October 5 at 5 pm - end of the class preferred) ***Combining and Modifying Ideas to Create Concepts*** Tuesday October 10, 2023: Lecture 9 Slide Deck Resources: A Short Video Preview of Lecture 9 SCAMPER Work Session on Combining and Modifying Ideas ***Critical Thinking for Design*** Thursday October 12, 2023: Lecture 10 Slide Deck Resources: A Short Video Preview of Lecture 10 Principles for Critical Thinking Six Thinking Hats Presenting a reasoned, evidence-based argument Thinking ahead to what kind of analysis would help decide the feasibility of a concept Expectations for the Phase Two Group Presentation Template for Preliminary Design Review (PDR) Signup Schedule for PDR *[Activity 07 (1.5%)]{.underline}*: *Preliminary Design Review Slide Deck & Participation (due Monday October 16, 2023 by 11 pm)* [Phase Two Preliminary Design Presentation and Feedback]{.underline} Tuesday October 17 to Thursday October 19: Phase Two Review Meetings (20 minutes per team, some to be scheduled outside of regular class time, all team members are expected to attend and contribute to presenting) ***Preliminary Engineering Analysis of Concepts*** Tuesday October 24, 2023: Lecture 11 Slide Deck Resources: A Short Video Preview of Lecture 11 System Level Processes Working Individually on Concepts Preliminary Analysis for Performance (Appropriate Complexity: Focus on the important stuff) Preliminary Analysis for Durability and Reliability (FMEA, Fault Tree, RCA) Preliminary Cost Estimation Preliminary Drawings and Mockups to Represent the Concepts (the role of sketches and Solidworks) Intro to Team-Based Evaluation Based on Functional and Technical Specifications Se***lecting the Concept for Detail Design*** Thursday October 26, 2023: Lecture 12 Slide Deck Resources: A Short Video Preview of Lecture 12 Working as a Team to Decide on Workable Concepts, Agreeing on Figures of Merit and Applying Them to Make the Decision Keeping Some Contingency Ideas How the conceptual design affects what will need to be done in detailed design [Activity 08 (1%):]{.underline} Updating the Project Plan (due Monday October 30 2023 by 5 pm) ***Completing Phase Two and Preparing for Detailed Design*** Tuesday October 31, 2023 Lecture 13 In-class guest lecture by Prof D. Nobes on using simulation tools with SolidWorks for design engineering analysis Students can individually review the posted lecture material of What's Expected in the Phase Two Report (Packaging the Activities): The Report Outline Client Endorsement expectations Marking Rubric for Phase Two Report Examples of Phase Two Reports [Deliverable (20%):]{.underline} Phase Two Report (due Thursday November 2, 2023 at 5 pm) [Peer Feedback Activity (0.5%):]{.underline} Team Phase 2 Survey (due Sunday November 5, 2023 at 11 pm) [Phase Three: Detailed Design]{.underline} ***Addressing the Important Technical Uncertainties through Engineering Analysis, and Producing the Detailed Design Package*** Thursday November 2, 2023 Lecture 14: Phase 3 & Design for Performance Additional Resources: Design of Mechatronic and Dynamic Mixed-Physics Systems (hydraulic systems, robots...) [Activity 09 (1%):]{.underline} Update Functional and Performance Specs due Monday November 6, 2023 at 5 pm ***Design for Durability and Reliability*** Tuesday November 7, 2023 Lecture 15: Design for Durability and Reliability Failure Modes and Effects Analysis Work session Additional Resources: Design for Impact and Wear Failure Modes and Effects Analysis work session [Activity 10 (1%):]{.underline} FMEA, and Potential Design Risks, Potential Project Risks due Thursday, November 9, 2023 at 5 pm ***Design for Manufacturability*** Thursday, November 9, 2023 Guest Lecture 16: Design for Manufacturability (by David deJong, a local manufacturing engineer and instructor) Some Additional resources on-line: Materials Selection and Material indices Monday November 13, 2023 is a Statutory Holiday November 14-17, 2023 Fall Break, no lectures and no seminar ***Manufacturing Cost Estimation*** Tuesday November 21, 2023 Guest Lecture 17: Manufacturing Cost Estimation (D DeJong) ***Design for Sustainability*** Thursday November 23, 2023 Lecture 18: Designing for quality and durability Noneconomic costs of engineering design [Activity 11 (1%)]{.underline}: Sustainability Design Report (basically the section of your Phase 3 report on designing for environmental factors and sustainability) due Friday November 24, 2023 at 5 pm ***Design Integration & the Drawing Package*** Tuesday November 28, 2023 Lecture 19 Slide Deck Resources: A Short Video Preview of Lecture 19 Producing Detailed Subsystems That Fit the Overall System Pivoting When There's a Bust The Detailed Design Drawing Package What's Expected in the Drawing Package Example Drawing Packages *[Activity 12 (1%)]{.underline}*: *Preliminary Drawing Tree and list of Key Assemblies and Detailed Drawings (due Tuesday November 28, 2023 at 5 pm)* ***The Critical Design Review -- Design Conference and Report*** Thursday November 30, 2023 Lecture 20 Slide Deck Resources: A Short Video Preview of Lecture 20 Critical Design Review Effective Technical Presentations What's Expected in The Phase Three Group Presentation Marking Rubric for the Presentation Effective Technical Posters What's Expected in the Poster Marking Rubric for the Poster Example Posters What's Expected in the Phase Three Report How to Provide Detailed Calculations Marking Rubric for Phase Three Report Examples of Phase Three Reports ***Design Conference*** Saturday December 2, 2023 Interesting talks, camaraderie, food, prizes! Attendance is *[mandatory]{.underline}* [Phase 3 Deliverables:]{.underline} Presentation Slide Deck & Group Presentation (10%) December 2, 2023 submitted by 11 pm) Group Poster (5%) Morning of December 2, 2023 hard copy posted by 9 am Electronic version of poster submitted electronically by Thursday December 7, 2023 by 5 pm Electronic copy of each team member log book (individual penalty if not submitted), by Thursday December 7, 2023 at 5 pm Phase Three Report, including drawing package, meeting agendas, meeting minutes (30%), Thursday December 7, 2023 at 5 pm [Peer Feedback Activity (0.5%):]{.underline} Team Phase 3 Survey by Friday December 8, 2023 at 5 pm ***After Phase 3: Going from Design to Final Product Tuesday*** December 5, 2023: Lecture 21 Slide Deck Course Summary Resources: Demonstration, Integration, Analysis, and Test Why Going from Prototype to Product Is Hard Some Thoughts on Engineering Design in the 21^st^Century