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- All Subjects: Product Design
- All Subjects: engineering
Description
In the three phases of the engineering design process (conceptual design, embodiment design and detailed design), traditional reliability information is scarce. However, there are different sources of information that provide reliability inputs while designing a new product. This research considered these sources to be further analyzed: reliability information from similar existing products denominated as parents, elicited experts' opinions, initial testing and the customer voice for creating design requirements. These sources were integrated with three novels approaches to produce reliability insights in the engineering design process, all under the Design for Reliability (DFR) philosophy. Firstly, an enhanced parenting process to assess reliability was presented. Using reliability information from parents it was possible to create a failure structure (parent matrix) to be compared against the new product. Then, expert opinions were elicited to provide the effects of the new design changes (parent factor). Combining those two elements resulted in a reliability assessment in early design process. Extending this approach into the conceptual design phase, a methodology was created to obtain a graphical reliability insight of a new product's concept. The approach can be summarized by three sequential steps: functional analysis, cognitive maps and Bayesian networks. These tools integrated the available information, created a graphical representation of the concept and provided quantitative reliability assessments. Lastly, to optimize resources when product testing is viable (e.g., detailed design) a type of accelerated life testing was recommended: the accelerated degradation tests. The potential for robust design engineering for this type of test was exploited. Then, robust design was achieved by setting the design factors at some levels such that the impact of stress factor variation on the degradation rate can be minimized. Finally, to validate the proposed approaches and methods, different case studies were presented.
ContributorsMejia Sanchez, Luis (Author) / Pan, Rong (Thesis advisor) / Montgomery, Douglas C. (Committee member) / Villalobos, Jesus R (Committee member) / See, Tung-King (Committee member) / Arizona State University (Publisher)
Created2014
Description
This dissertation is to address product design optimization including reliability-based design optimization (RBDO) and robust design with epistemic uncertainty. It is divided into four major components as outlined below. Firstly, a comprehensive study of uncertainties is performed, in which sources of uncertainty are listed, categorized and the impacts are discussed. Epistemic uncertainty is of interest, which is due to lack of knowledge and can be reduced by taking more observations. In particular, the strategies to address epistemic uncertainties due to implicit constraint function are discussed. Secondly, a sequential sampling strategy to improve RBDO under implicit constraint function is developed. In modern engineering design, an RBDO task is often performed by a computer simulation program, which can be treated as a black box, as its analytical function is implicit. An efficient sampling strategy on learning the probabilistic constraint function under the design optimization framework is presented. The method is a sequential experimentation around the approximate most probable point (MPP) at each step of optimization process. It is compared with the methods of MPP-based sampling, lifted surrogate function, and non-sequential random sampling. Thirdly, a particle splitting-based reliability analysis approach is developed in design optimization. In reliability analysis, traditional simulation methods such as Monte Carlo simulation may provide accurate results, but are often accompanied with high computational cost. To increase the efficiency, particle splitting is integrated into RBDO. It is an improvement of subset simulation with multiple particles to enhance the diversity and stability of simulation samples. This method is further extended to address problems with multiple probabilistic constraints and compared with the MPP-based methods. Finally, a reliability-based robust design optimization (RBRDO) framework is provided to integrate the consideration of design reliability and design robustness simultaneously. The quality loss objective in robust design, considered together with the production cost in RBDO, are used formulate a multi-objective optimization problem. With the epistemic uncertainty from implicit performance function, the sequential sampling strategy is extended to RBRDO, and a combined metamodel is proposed to tackle both controllable variables and uncontrollable variables. The solution is a Pareto frontier, compared with a single optimal solution in RBDO.
ContributorsZhuang, Xiaotian (Author) / Pan, Rong (Thesis advisor) / Montgomery, Douglas C. (Committee member) / Zhang, Muhong (Committee member) / Du, Xiaoping (Committee member) / Arizona State University (Publisher)
Created2012
Description
This dissertation presents methods for addressing research problems that currently can only adequately be solved using Quality Reliability Engineering (QRE) approaches especially accelerated life testing (ALT) of electronic printed wiring boards with applications to avionics circuit boards. The methods presented in this research are generally applicable to circuit boards, but the data generated and their analysis is for high performance avionics. Avionics equipment typically requires 20 years expected life by aircraft equipment manufacturers and therefore ALT is the only practical way of performing life test estimates. Both thermal and vibration ALT induced failure are performed and analyzed to resolve industry questions relating to the introduction of lead-free solder product and processes into high reliability avionics. In chapter 2, thermal ALT using an industry standard failure machine implementing Interconnect Stress Test (IST) that simulates circuit board life data is compared to real production failure data by likelihood ratio tests to arrive at a mechanical theory. This mechanical theory results in a statistically equivalent energy bound such that failure distributions below a specific energy level are considered to be from the same distribution thus allowing testers to quantify parameter setting in IST prior to life testing. In chapter 3, vibration ALT comparing tin-lead and lead-free circuit board solder designs involves the use of the likelihood ratio (LR) test to assess both complete failure data and S-N curves to present methods for analyzing data. Failure data is analyzed using Regression and two-way analysis of variance (ANOVA) and reconciled with the LR test results that indicating that a costly aging pre-process may be eliminated in certain cases. In chapter 4, vibration ALT for side-by-side tin-lead and lead-free solder black box designs are life tested. Commercial models from strain data do not exist at the low levels associated with life testing and need to be developed because testing performed and presented here indicate that both tin-lead and lead-free solders are similar. In addition, earlier failures due to vibration like connector failure modes will occur before solder interconnect failures.
ContributorsJuarez, Joseph Moses (Author) / Montgomery, Douglas C. (Thesis advisor) / Borror, Connie M. (Thesis advisor) / Gel, Esma (Committee member) / Mignolet, Marc (Committee member) / Pan, Rong (Committee member) / Arizona State University (Publisher)
Created2012
Description
Functional or dynamic responses are prevalent in experiments in the fields of engineering, medicine, and the sciences, but proposals for optimal designs are still sparse for this type of response. Experiments with dynamic responses result in multiple responses taken over a spectrum variable, so the design matrix for a dynamic response have more complicated structures. In the literature, the optimal design problem for some functional responses has been solved using genetic algorithm (GA) and approximate design methods. The goal of this dissertation is to develop fast computer algorithms for calculating exact D-optimal designs.
First, we demonstrated how the traditional exchange methods could be improved to generate a computationally efficient algorithm for finding G-optimal designs. The proposed two-stage algorithm, which is called the cCEA, uses a clustering-based approach to restrict the set of possible candidates for PEA, and then improves the G-efficiency using CEA.
The second major contribution of this dissertation is the development of fast algorithms for constructing D-optimal designs that determine the optimal sequence of stimuli in fMRI studies. The update formula for the determinant of the information matrix was improved by exploiting the sparseness of the information matrix, leading to faster computation times. The proposed algorithm outperforms genetic algorithm with respect to computational efficiency and D-efficiency.
The third contribution is a study of optimal experimental designs for more general functional response models. First, the B-spline system is proposed to be used as the non-parametric smoother of response function and an algorithm is developed to determine D-optimal sampling points of a spectrum variable. Second, we proposed a two-step algorithm for finding the optimal design for both sampling points and experimental settings. In the first step, the matrix of experimental settings is held fixed while the algorithm optimizes the determinant of the information matrix for a mixed effects model to find the optimal sampling times. In the second step, the optimal sampling times obtained from the first step is held fixed while the algorithm iterates on the information matrix to find the optimal experimental settings. The designs constructed by this approach yield superior performance over other designs found in literature.
First, we demonstrated how the traditional exchange methods could be improved to generate a computationally efficient algorithm for finding G-optimal designs. The proposed two-stage algorithm, which is called the cCEA, uses a clustering-based approach to restrict the set of possible candidates for PEA, and then improves the G-efficiency using CEA.
The second major contribution of this dissertation is the development of fast algorithms for constructing D-optimal designs that determine the optimal sequence of stimuli in fMRI studies. The update formula for the determinant of the information matrix was improved by exploiting the sparseness of the information matrix, leading to faster computation times. The proposed algorithm outperforms genetic algorithm with respect to computational efficiency and D-efficiency.
The third contribution is a study of optimal experimental designs for more general functional response models. First, the B-spline system is proposed to be used as the non-parametric smoother of response function and an algorithm is developed to determine D-optimal sampling points of a spectrum variable. Second, we proposed a two-step algorithm for finding the optimal design for both sampling points and experimental settings. In the first step, the matrix of experimental settings is held fixed while the algorithm optimizes the determinant of the information matrix for a mixed effects model to find the optimal sampling times. In the second step, the optimal sampling times obtained from the first step is held fixed while the algorithm iterates on the information matrix to find the optimal experimental settings. The designs constructed by this approach yield superior performance over other designs found in literature.
ContributorsSaleh, Moein (Author) / Pan, Rong (Thesis advisor) / Montgomery, Douglas C. (Committee member) / Runger, George C. (Committee member) / Kao, Ming-Hung (Committee member) / Arizona State University (Publisher)
Created2015
Description
Healthcare operations have enjoyed reduced costs, improved patient safety, and
innovation in healthcare policy over a huge variety of applications by tackling prob-
lems via the creation and optimization of descriptive mathematical models to guide
decision-making. Despite these accomplishments, models are stylized representations
of real-world applications, reliant on accurate estimations from historical data to jus-
tify their underlying assumptions. To protect against unreliable estimations which
can adversely affect the decisions generated from applications dependent on fully-
realized models, techniques that are robust against misspecications are utilized while
still making use of incoming data for learning. Hence, new robust techniques are ap-
plied that (1) allow for the decision-maker to express a spectrum of pessimism against
model uncertainties while (2) still utilizing incoming data for learning. Two main ap-
plications are investigated with respect to these goals, the first being a percentile
optimization technique with respect to a multi-class queueing system for application
in hospital Emergency Departments. The second studies the use of robust forecasting
techniques in improving developing countries’ vaccine supply chains via (1) an inno-
vative outside of cold chain policy and (2) a district-managed approach to inventory
control. Both of these research application areas utilize data-driven approaches that
feature learning and pessimism-controlled robustness.
innovation in healthcare policy over a huge variety of applications by tackling prob-
lems via the creation and optimization of descriptive mathematical models to guide
decision-making. Despite these accomplishments, models are stylized representations
of real-world applications, reliant on accurate estimations from historical data to jus-
tify their underlying assumptions. To protect against unreliable estimations which
can adversely affect the decisions generated from applications dependent on fully-
realized models, techniques that are robust against misspecications are utilized while
still making use of incoming data for learning. Hence, new robust techniques are ap-
plied that (1) allow for the decision-maker to express a spectrum of pessimism against
model uncertainties while (2) still utilizing incoming data for learning. Two main ap-
plications are investigated with respect to these goals, the first being a percentile
optimization technique with respect to a multi-class queueing system for application
in hospital Emergency Departments. The second studies the use of robust forecasting
techniques in improving developing countries’ vaccine supply chains via (1) an inno-
vative outside of cold chain policy and (2) a district-managed approach to inventory
control. Both of these research application areas utilize data-driven approaches that
feature learning and pessimism-controlled robustness.
ContributorsBren, Austin (Author) / Saghafian, Soroush (Thesis advisor) / Mirchandani, Pitu (Thesis advisor) / Wu, Teresa (Committee member) / Pan, Rong (Committee member) / Arizona State University (Publisher)
Created2018
Description
A quantitative analysis of a system that has a complex reliability structure always involves considerable challenges. This dissertation mainly addresses uncertainty in- herent in complicated reliability structures that may cause unexpected and undesired results.
The reliability structure uncertainty cannot be handled by the traditional relia- bility analysis tools such as Fault Tree and Reliability Block Diagram due to their deterministic Boolean logic. Therefore, I employ Bayesian network that provides a flexible modeling method for building a multivariate distribution. By representing a system reliability structure as a joint distribution, the uncertainty and correlations existing between system’s elements can effectively be modeled in a probabilistic man- ner. This dissertation focuses on analyzing system reliability for the entire system life cycle, particularly, production stage and early design stages.
In production stage, the research investigates a system that is continuously mon- itored by on-board sensors. With modeling the complex reliability structure by Bayesian network integrated with various stochastic processes, I propose several methodologies that evaluate system reliability on real-time basis and optimize main- tenance schedules.
In early design stages, the research aims to predict system reliability based on the current system design and to improve the design if necessary. The three main challenges in this research are: 1) the lack of field failure data, 2) the complex reliability structure and 3) how to effectively improve the design. To tackle the difficulties, I present several modeling approaches using Bayesian inference and nonparametric Bayesian network where the system is explicitly analyzed through the sensitivity analysis. In addition, this modeling approach is enhanced by incorporating a temporal dimension. However, the nonparametric Bayesian network approach generally accompanies with high computational efforts, especially, when a complex and large system is modeled. To alleviate this computational burden, I also suggest to building a surrogate model with quantile regression.
In summary, this dissertation studies and explores the use of Bayesian network in analyzing complex systems. All proposed methodologies are demonstrated by case studies.
The reliability structure uncertainty cannot be handled by the traditional relia- bility analysis tools such as Fault Tree and Reliability Block Diagram due to their deterministic Boolean logic. Therefore, I employ Bayesian network that provides a flexible modeling method for building a multivariate distribution. By representing a system reliability structure as a joint distribution, the uncertainty and correlations existing between system’s elements can effectively be modeled in a probabilistic man- ner. This dissertation focuses on analyzing system reliability for the entire system life cycle, particularly, production stage and early design stages.
In production stage, the research investigates a system that is continuously mon- itored by on-board sensors. With modeling the complex reliability structure by Bayesian network integrated with various stochastic processes, I propose several methodologies that evaluate system reliability on real-time basis and optimize main- tenance schedules.
In early design stages, the research aims to predict system reliability based on the current system design and to improve the design if necessary. The three main challenges in this research are: 1) the lack of field failure data, 2) the complex reliability structure and 3) how to effectively improve the design. To tackle the difficulties, I present several modeling approaches using Bayesian inference and nonparametric Bayesian network where the system is explicitly analyzed through the sensitivity analysis. In addition, this modeling approach is enhanced by incorporating a temporal dimension. However, the nonparametric Bayesian network approach generally accompanies with high computational efforts, especially, when a complex and large system is modeled. To alleviate this computational burden, I also suggest to building a surrogate model with quantile regression.
In summary, this dissertation studies and explores the use of Bayesian network in analyzing complex systems. All proposed methodologies are demonstrated by case studies.
ContributorsLee, Dongjin (Author) / Pan, Rong (Thesis advisor) / Montgomery, Douglas C. (Committee member) / Wu, Teresa (Committee member) / Du, Xiaoping (Committee member) / Arizona State University (Publisher)
Created2018
Description
The purpose of this research project is to outline the design process and to uncover some of the considerations that designers must keep in mind in an effort to design more empathetically. These will include a focus on appropriate aesthetics, user experience design, and designing for innovation. These findings are then applied to a three-part design project to illustrate the importance of these guidelines.
ContributorsTerminel Iberri, Carlos Martin (Author) / Boradkar, Prasad (Thesis director) / McDermott, Lauren (Committee member) / McVey, Patrick (Committee member) / Barrett, The Honors College (Contributor) / The Design School (Contributor)
Created2014-05
Description
Game design and product design are natural partners. They use similar tools. They reach the same users. They even share the same goal: to provide great user experiences.
This thesis asks, "Can game design build better product learning experiences, and if so, how?" It examines the learning situations created by and necessary for product design. It examines the principles of game learning. Then it looks for opportunities to apply game learning principles to product learning situations. The goal is to create engaging and successful product learning experiences, without turning products into games.
This study uses an auto-ethnographic evaluation of a gameplay session as well as participant observation and interviews with gamers to gather qualitative data. That data is sorted with an A(x4) framework and used to create user experience profiles.
The final outcome is a toolkit that identifies areas where game design could improve the design of product user experiences, especially for product learning.
This thesis asks, "Can game design build better product learning experiences, and if so, how?" It examines the learning situations created by and necessary for product design. It examines the principles of game learning. Then it looks for opportunities to apply game learning principles to product learning situations. The goal is to create engaging and successful product learning experiences, without turning products into games.
This study uses an auto-ethnographic evaluation of a gameplay session as well as participant observation and interviews with gamers to gather qualitative data. That data is sorted with an A(x4) framework and used to create user experience profiles.
The final outcome is a toolkit that identifies areas where game design could improve the design of product user experiences, especially for product learning.
ContributorsReeves, James Scott (Author) / Boradkar, Prasad (Thesis advisor) / Gee, Elisabeth (Committee member) / Herring, Donald (Committee member) / Arizona State University (Publisher)
Created2016
Description
This thesis is developed in the context of biomanufacturing of modern products that have the following properties: require short design to manufacturing time, they have high variability due to a high desired level of patient personalization, and, as a result, may be manufactured in low volumes. This area at the intersection of therapeutics and biomanufacturing has become increasingly important: (i) a huge push toward the design of new RNA nanoparticles has revolutionized the science of vaccines due to the COVID-19 pandemic; (ii) while the technology to produce personalized cancer medications is available, efficient design and operation of manufacturing systems is not yet agreed upon. In this work, the focus is on operations research methodologies that can support faster design of novel products, specifically RNA; and methods for the enabling of personalization in biomanufacturing, and will specifically look at the problem of cancer therapy manufacturing. Across both areas, methods are presented attempting to embed pre-existing knowledge (e.g., constraints characterizing good molecules, comparison between structures) as well as learn problem structure (e.g., the landscape of the rewards function while synthesizing the control for a single use bioreactor). This thesis produced three key outcomes: (i) ExpertRNA for the prediction of the structure of an RNA molecule given a sequence. RNA structure is fundamental in determining its function. Therefore, having efficient tools for such prediction can make all the difference for a scientist trying to understand optimal molecule configuration. For the first time, the algorithm allows expert evaluation in the loop to judge the partial predictions that the tool produces; (ii) BioMAN, a discrete event simulation tool for the study of single-use biomanufacturing of personalized cancer therapies. The discrete event simulation engine was designed tailored to handle the efficient scheduling of many parallel events which is cause by the presence of single use resources. This is the first simulator of this type for individual therapies; (iii) Part-MCTS, a novel sequential decision-making algorithm to support the control of single use systems. This tool integrates for the first-time simulation, monte-carlo tree search and optimal computing budget allocation for managing the computational effort.
ContributorsLiu, Menghan (Author) / Pedrielli, Giulia (Thesis advisor) / Bertsekas, Dimitri (Committee member) / Pan, Rong (Committee member) / Sulc, Petr (Committee member) / Wu, Teresa (Committee member) / Arizona State University (Publisher)
Created2023