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| Foreword | |
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| Preface | |
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| Journeys in Product Development | |
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| Chapter Roadmap | |
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| An Introduction to Product Design | |
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| Thoughts for the Reader and Student of Product Design | |
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| Product Development versus Design | |
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| Types of Design and Redesign | |
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| What is Engineering Design? | |
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| Modern Product Development | |
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| A Modern Product Development Process | |
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| A Reverse Engineering and Redesign Product Development Process | |
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| Examples of Product Development Processes | |
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| Systems: Xerox Corporation | |
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| Industrial Design: Design EDGE, Austin TX Product Design Firm | |
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| Rapid: Microsoft Corporation | |
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| Research Intensive: Raychem Corporation | |
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| Complex: Ford Motor Company | |
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| Technical: Raytheon Corporation | |
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| Theories and Methodologies in Design | |
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| Summary and "Golden Nuggets" | |
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| References | |
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| Product Development Process Tools | |
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| Chapter Roadmap | |
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| Product Development Teams | |
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| The Basics of Teams | |
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| Team Composition: Seeking Synergy, Unity, Competence, and Consensus | |
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| Strategies: Team Structures | |
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| Team Building (Basic Activities) | |
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| Team Evaluation | |
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| Closing: Product Development Teams | |
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| Product Development Planning | |
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| Planning Process | |
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| Basic Planning and Scheduling Tools | |
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| Summary and "Golden Nuggets" | |
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| References | |
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| Scoping Product Developments: Technical and Business Concerns | |
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| Chapter Roadmap | |
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| Determining What to Develop | |
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| S-Curves | |
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| S-Curves and New Product Development | |
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| Comments on S-curves and Technology Forecasting | |
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| Basic Method: Mission Statement and Technical Questioning | |
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| Technical Questioning | |
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| Mission Statements | |
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| Finger Nail Clipper: Clarification and Mission Statement | |
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| Advanced Method: Business Case Analysis | |
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| Harvard Business Case Methodology: Product Evolution | |
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| Product Development Economic Analysis | |
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| Advanced Method: Design Drivers | |
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| Design Drivers | |
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| Example: Finger Nail Clipper | |
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| Summary and "Golden Nuggets" | |
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| References | |
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| Understanding Customer Needs | |
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| Chapter Roadmap | |
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| Customer Satisfaction | |
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| Voice of the Customer | |
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| Customer Populations | |
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| Types of Customer Needs | |
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| Customer Need Models | |
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| Gathering Customer Needs | |
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| Need Gathering Methods | |
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| Conducting Interviews: Like/Dislike Method | |
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| Conducting Interviews: Articulated-Use Method | |
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| Customer Interviews: Product Feel and Industrial Design | |
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| Organizing and Prioritizing Customer Needs | |
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| Grouping Interpreted Needs | |
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| Grouping the Needs--Affinity Diagram Method | |
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| Determining Need Importance | |
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| Customer Use Patterns | |
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| Customer Needs Documentation | |
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| Summary and "Golden Nuggets" | |
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| References | |
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| Establishing Product Function | |
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| Chapter Roadmap | |
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| Why Functional Decomposition? | |
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| Motivation | |
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| Function Modeling Basics | |
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| Functions and Constraints | |
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| Modeling Process | |
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| A Simple Approach: Function Trees | |
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| The FAST Method | |
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| The Subtract and Operate Procedure | |
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| Establishing System Functionality: Creating a Function Structure | |
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| The Basics of Function Structures: Black Box and Definitions | |
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| The Function Structure Modeling Process | |
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| Develop Process Descriptions as Activity Diagrams | |
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| Formulate Subfunctions Through Task Listing | |
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| Aggregate Subfunctions into a Refined Function Structure | |
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| Validate the Functional Decomposition | |
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| Establish and Identify Product Architecture and Assemblies | |
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| Augmentation: From Simple Function Trees to Complete Models | |
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| An Example of Hierarchical Function Structure Decomposition | |
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| Bringing Flows into the Functional Hierarchical Decomposition | |
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| Aggregation Revisited: Simplicity of Shooting Darts | |
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| A Functional Common Basis | |
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| The Common Basis | |
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| Transforming Functional Models | |
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| Uses of a Common Basis | |
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| Aggregate Function Study | |
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| Critique of Functional Modeling Methods | |
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| Summary and "Golden Nuggets" | |
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| References | |
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| Product Teardown and Experimentation | |
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| Chapter Roadmap | |
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| Teardown Process | |
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| Overview | |
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| List the Design Issues | |
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| Prepare for Product Tear Downs | |
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| Examine the Distribution and Installation | |
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| Disassemble, Measure, and Analyze Data by Assemblies | |
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| Form a Bill of Materials | |
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| Teardown Methods | |
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| Subtract and Operate Procedure | |
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| SOP Examples | |
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| Force Flow (Energy Flow Field) Diagrams | |
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| Measurement and Experimentation | |
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| Post Teardown Reporting | |
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| Disassembly Plan and BOM | |
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| Exploded Views with Highlighted Features | |
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| Actual Product Function Structure (Network) | |
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| Applications of Product Teardown | |
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| Application: Slide-Out Auxiliary Visor | |
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| Case Study of an Automatic Iced Tea Maker | |
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| Summary and "Golden Nuggets" | |
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| References | |
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| Benchmarking and Establishing Engineering Specifications | |
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| Chapter Roadmap | |
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| Background: Know Your Enemy to Know Yourself | |
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| A Benchmarking Approach | |
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| Form a List of Design Issues | |
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| Form a List of Competitive or Related Products | |
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| Conduct an Information Search | |
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| Teardown Multiple Products in Class | |
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| Benchmark by Function | |
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| Establish Best in Class Competitors by Function | |
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| Plot Industry Trends | |
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| Benchmarking Example: Coffee Mills | |
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| Support Tools for the Benchmarking Process | |
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| Indented Assembly Cost Analysis | |
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| Function--Form Diagrams | |
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| Trend Analysis | |
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| Proposal on Opportunities for Re-design | |
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| Thoughts on Benchmarking the Competition | |
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| Setting Product Specifications | |
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| Specification Process | |
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| Basic Method: The House of Quality | |
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| Advanced Method: Value Analysis | |
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| Summary and "Golden Nuggets" | |
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| References | |
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| Product Portfolios and Portfolio Architecture | |
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| Chapter Roadmap | |
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| Product Portfolio Architecture | |
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| Background | |
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| Portfolio Architecture Types | |
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| Choosing an Architecture Type | |
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| Theory | |
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| Market Basis for Architecture Decisions | |
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| Platform Architecture | |
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| Negotiating a Modular Family Platform | |
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| Basic Method: Charts | |
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| Advanced Method: Functional Architecting | |
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| Advanced Method: Optimization Selection | |
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| Summary and "Golden Nuggets" | |
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| References | |
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| Architecture | |
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| Chapter Roadmap | |
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| Product Architectures | |
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| Introduction | |
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| Architecture Types | |
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| Architecture Examples | |
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| Product Modularity: Background | |
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| Types of Modularity | |
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| Modular Design: Basic Clustering Method | |
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| Create a Function Structure of the Product | |
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| Cluster the Elements into Module Chunks | |
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| Create a Rough Geometric Layout(s) | |
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| Define Interactions and Detail Performance Characteristics | |
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| Modular Design: An Advanced Functional Method | |
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| Function Dependencies | |
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| Module Heuristics | |
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| Process: Application of the Module Heuristics | |
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| Summary | |
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| Architecture-Based Development Teams | |
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| A Method of Forming Module Based Development Teams | |
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| Application of Module-Based Development Teams | |
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| Summary of the Development Team Method | |
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| Summary and "Golden Nuggets" | |
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| References | |
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| Generating Concepts | |
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| Chapter Roadmap | |
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| Concept Generation Process | |
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| Basic Methods: Information Gathering and Brainstorming | |
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| Information Gathering: Conventional Aids | |
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| Traditional Brainstorming | |
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| Brain-Ball | |
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| C-Sketch/6-3-5 Method | |
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| Idea Generators for Intuitive Techniques | |
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| Advanced Methods: Directed Search | |
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| Systematic Search with Physical Principles | |
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| Systematic Search with Classifying Schemes | |
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| Theory of Inventive Problem Solving | |
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| Morphological Analysis | |
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| Develop Concepts for Each Product Function | |
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| Combining Solution Principles (Concept Variants) | |
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| Digression/Caution: Function Sharing | |
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| Product Application: Fingernail Clipper | |
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| Product Application: Bilge Water Removal Product | |
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| Product Application: Smart Spoon to Assist Persons with Disabilities | |
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| Summary and "Golden Nuggets" | |
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| References | |
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| Concept Selection | |
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| Chapter Roadmap | |
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| Introduction | |
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| Factors that Determine Effective Decision Making | |
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| Design Evaluations | |
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| Information Quality | |
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| Estimating Technical Feasibility | |
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| Estimation | |
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| Example: Air Conditioning for an Electric Vehicle | |
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| Estimating Hints | |
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| A Concept Selection Process | |
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| Forming Consensus on the Criteria | |
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| Forming Consensus on the Alternatives | |
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| Ranking | |
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| Assessment | |
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| Attacking the Negatives | |
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| A Basic Method: Pugh Concept Selection Charts | |
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| Establish the Criteria and Alternatives | |
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| Select a Datum | |
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| Ranking and Assessment | |
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| Alternative Rank Ordering | |
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| Attacking the Negatives | |
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| Iteration and Solution | |
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| Example: Coffee Mill | |
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| Advanced Discussion: Measurement Theory | |
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| Set Structure of Evaluation | |
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| Ordinal Scales | |
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| Interval Scales | |
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| Ratio Scales | |
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| Extensively Measurable Scales | |
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| Advanced Method: Numerical Concept Scoring | |
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| Scoring with Interval Scales | |
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| Selection Error Analysis | |
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| Concept Selection with Error Analysis: Design of a Cat Litter Box Product | |
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| A Critique of Design Evaluation Schemes | |
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| Chapter Summary and "Golden Nuggets" | |
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| References | |
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| Concept Embodiment | |
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| Chapter Roadmap | |
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| Overview and Context | |
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| Basic Methods: Refining Geometry and Layout | |
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| General Process of Product Embodiment | |
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| Embodiment Checklist | |
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| Advanced Methods: Systems Modeling | |
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| Systems Modeling | |
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| Mechanical Embodiment Principles | |
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| FMEA Method: Linking Fault States to Systems Modeling | |
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| Case Study: Computer Monitor Stand for a Docking Station | |
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| Summary | |
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| Summary and "Golden Nuggets" | |
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| References | |
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| Modeling of Product Metrics | |
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| Chapter Roadmap | |
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| Introduction: Model Selection by Performance Specifications | |
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| Model Preparation and Selection Method | |
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| Product Application: Model Preparation and Selection | |
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| Mathematical Modeling versus Physical Prototyping | |
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| Example | |
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| Advanced Topic: What is a Product Model? | |
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| Informal Models | |
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| Formal Models | |
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| Constructing Product Models: basic Method | |
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| A Basic Modeling Approach | |
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| A Product Application in Constructing Basic Models: Iced Tea Maker | |
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| Constructing Product Models: Advanced Method | |
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| Approach | |
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| Method | |
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| Product Models: Cases | |
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| Electric Wok Product | |
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| Handle Temperature | |
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| Other Metrics to Integrate a Complete Model | |
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| Comments on Design Model Validation | |
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| Summary and "Golden Nuggets" | |
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| References | |
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| Design for Manufacture and Assembly | |
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| Chapter Roadmap | |
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| Overview and Motivation | |
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| Basic Method: Design Guidelines | |
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| Design for Assembly | |
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| Design for Piece Part Production | |
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| Advanced Method: Manufacturing Cost Analysis | |
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| Cost Driver Modeling | |
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| Manufacturing Cost Analysis | |
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| Critique of Design for Assembly Methods | |
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| Chapter Summary and Golden Nuggets | |
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| References | |
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| Design for the Environment | |
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| Chapter Roadmap | |
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| Why DFE? | |
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| Environmental Objectives | |
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| Global Issues | |
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| Regional and Local Issues | |
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| Basic DFE Methods: Design Guidelines | |
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| Application: Paper Carrier Design | |
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| Life Cycle Assessment | |
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| Overview | |
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| Basic Method: ATandT's Environmentally Responsible Product Assessment | |
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| Weighted Sum Assessment Method | |
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| Life Cycle Assessment Method | |
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| Techniques to Reduce Environmental Impact | |
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| Design to Minimize Material Usage | |
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| Design for Disassembly | |
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| Design for Recyclability | |
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| Design for Remanufacturing | |
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| Design for High-Impact Material Reduction | |
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| Design for Energy Efficiency | |
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| Design to Regulations and Standards | |
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| Chapter Summary and "Golden Nuggets" | |
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| References | |
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| Analytical and Numerical Model Solutions | |
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| Chapter Roadmap | |
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| Overview and Strategy | |
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| Solution Definition | |
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| Pareto Optimality | |
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| Basic Method: Spreadsheet Search | |
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| Product Application: Spreadsheet Search for a Toy Rocket Product | |
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| Summary | |
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| Fundamental Concepts in Optimization | |
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| Constraints | |
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| Objective Functions | |
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| Standard Null Form | |
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| Advanced Topic: A Discussion of Analytical Formulations | |
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| Unconstrained Problems | |
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| Lagrangians | |
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| Practical Optimization | |
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| Numerical Search | |
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| Stopping Criteria | |
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| Sensitivity Analysis | |
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| Global Optimality | |
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| Solution Method: Matlab | |
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| Solution Method: Spreadsheet Solvers | |
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| Product Applications | |
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| Application: Redesign of a TOMY "Push-n-Go" Train | |
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| Application: Electric Wok Product | |
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| Summary and "Golden Nuggets" | |
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| References | |
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| Physical Prototypes | |
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| Chapter Roadmap | |
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| Prototyping Essentials | |
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| What Are Physical Models/Prototypes | |
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| Types of Prototypes | |
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| Prototypes Goals | |
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| Uses of Prototypes | |
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| Mock-up Materials and Processes | |
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| Prototyping Processes | |
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| Rapid Prototyping Techniques | |
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| Rapid Prototyping: A Historical Prespective | |
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| Commercial Rapid Prototyping Processes | |
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| Choosing Rapid Prototyping for a Product? | |
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| Scale, Dimensional Analysis, and Similitude | |
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| Buckingham II Theorem and Scaled Testing | |
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| Buckle Design Example | |
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| Basic Method: Physical Prototype Design and Planning | |
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| Guidelines for Prototype Design | |
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| Sample Prototype Application | |
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| Summary and "Golden Nuggets" | |
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| References | |
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| Physical Models and Experimentation | |
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| Chapter Roadmap | |
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| Design of Experiments | |
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| Basics of Designed Experiments | |
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| Basic Method: Two Factorial Experiments | |
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| Extended Method: Interactions | |
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| A Basic Product Application: Redesign of a Toy Solar Car | |
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| Design of Experiments: Reduced Tests and Fractional Experiments | |
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| Full Factorial Inefficiencies | |
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| Orthogonality | |
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| Base Design Method | |
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| Higher Dimensions Fractional Factorial Designs | |
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| Statistical Analysis of Experiments | |
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| Degrees of Freedom | |
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| Correlation Coefficient | |
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| Standard Error of the Residual | |
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| t-Test | |
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| ANOVA: F-ratio Test | |
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| Other Indicators: Residual Plots | |
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| Summary: Advanced DOE Method for Product Testing | |
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| Product Applications of Physical Modeling and DOE | |
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| Product Application I: Nerf Missilestorm (Norrell, 1995) | |
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| Blender Panel Display Evaluation | |
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| Coffee Grinder Experimental Optimization | |
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| Summary and "Golden Nuggets" | |
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| References | |
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| Physical Models and Experimentation | |
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| Chapter Roadmpa | |
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| Quality Design Theory | |
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| General Robust Design Model | |
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| Robust Design Model Construction | |
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| Basic Method: Taguchi's Method | |
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| Noise Variable Matrix | |
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| Design Variable Matrix | |
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| Experimental Matrix | |
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| Signal to Noise Ratios | |
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| Selection of a Target Design | |
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| Parameter Design and the Taguchi Philosophy | |
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| Advanced Analysis: Probability Theory | |
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| Sizing the Variation | |
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| General Robust Design Problem Formulation | |
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| Chapter Summary and "Golden Nuggets" | |
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| Robust Design as a Design Philosophy | |
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| Golden Nuggets | |
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| References | |
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| Function Structure Definition | |
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| Flow Definitions | |
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| Material | |
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| Energy | |
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| Signal | |
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| Function Definitions | |
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| Channel | |
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| Support | |
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| Connect | |
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| Branch | |
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| Provide | |
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| Control Magnitude | |
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| Convert | |
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| Signal | |
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| Function Structures for Example Products | |
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| DOE Tables | |
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| Base Design Tables | |
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| L-Array Tables | |
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| TRIZ Relationship Table | |
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| Eco-Indicator Environment Assessment | |
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| Index | |