0000 invention machine

8/18/2019 0000 Invention Machine

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A User’s Perspective:

Innovating Smarter withInvention Machine Goldfire

William Hessler, Mechanical Engineer Leader

CSC, Computer Sciences Corporation

Aberdeen Proving Ground, MD


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WHAT IS GOLDFIRE?!

http://inventionmachine.com/Portals/56687/html/tour/tour.html?source=hesslerhttp://inventionmachine.com/Portals/56687/html/tour/tour.html?source=hessler


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What is Goldfire?


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What is Innovation?

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MarketAnalysis

New ProductDevelopment

RiskManagement

ProductImprovement

LeverageIP

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• Technology / market landscaping

• Understand trends and evolutions

• Design a new product or system

• Design a hybrid system

• Diagnose and fix product defects

• Improve product to achieve a specific goal

• Identify potential failure points

• Develop risk mitigation strategies

• Patent strategies

• Find new markets for existing IP

Innovation Activities

New ProductDevelopment

Risk

Management

ProductImprovement

LeverageIP

MarketAnalysis

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THE MAIN EVENT


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My Background with Invention Machine & TRIZ

• Ingersoll-Rand Power Tools, 1989 - 1998•

1997 trained as a trainer for TRIZ problem solvingand on Invention Machine software• Trained engineers/designers how to do more

effective problem solving and cost savings for handtools

• Dade Behring, 1998 - 2004•

Medical diagnostics blood analysis company• Formerly DuPont Medical Products, now SiemensDiagnostics

• GE Energy, 2004 - 2009• 3 years as a combustion Design Engineer• Introduced TRIZ and Goldfire to engineers, scientists

and IP personnel• 1.5 years for Solar Technologies

• Spring Life Device Manufacturer, 2009 - 2010• CSC, Computer Sciences Corporation, 2011 -

Present• Supporting ARMY Research & Development test labs


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Applications of Goldfire

•

Problem Statement:How to apply Goldfire to company problems using RootCause Analysis, Function Models and TRIZ basics forsolution creation

• Contradiction:Psychological inertia-“there is NO WAY software and aprocess is going to help you be more creative.”

• Ideal Final Result:More engineers have access to Goldfire & understandbasics of TRIZ principals to solve future problems


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APPLICATIONS OF INNOVATIONSOFTWARE


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1st Use-Project:

Create a Unique Patent-able Torque Tool Solution: Team developed a function model describing nuts

vibrating loose over time; air motor and mechanism manufacturingwere major concern issues.

Benefits:• Goldfire identified vibration as key feature and suggested

removing air motor and swinging mechanism.

•

Goldfire said eliminate air powered motor and swingingmechanism device for tightening lug nuts.

Results:• Everyone said this was impossible, UNTIL software suggested

using a high vibration source to eliminate the air motor andswinging mechanism TO TIGHTEN the nuts.

• The software recognized this as a potential solutioncontradiction since we documented nuts come loose

due to vibrations caused during driving.

WOW!!!

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2nd Use-Project:

Why are these holes cracking?

Challenge: RCAs & FMEAs get directed by the loudestspeakers in the room, usually the RCA champions, whousually think they are the expert.• When you use Goldfire, it is the expert in the room and more

issues are uncovered that would have been most likely ignoredor missed due to the Human Expert not having the world's

domain expertise at their fingertips.• Team initially came up with a Fishbone diagram with only 11

ribs for why holes crack in hot parts.

• 11 ribs… and not one mention of any manufacturing cause!

Solution: Used Goldfire to create a Fishbone diagram with 97ribs; everyone wanted to know where I “FOUND” it. The teaminvestigated shot peening of the holes to improve residual stressesat the machine surfaces of the holes.

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3nd Use-Project:

How to wash clothes & dishes more efficiently?

Challenge: How to wash (clothes or dishes) moreefficiently?

• I did a DEMO for the Appliance team in late 2007and asked, “What problem if it were solved wouldmake you Engineer of the Year in your group?”

Results: Goldfire in 10 minutes said solution wascentered around STEAM, STEAM, STEAM and moreSTEAM.

• Within 10 minutes I had the complete R&D team’s

attention and they saw the evolution of high

efficiency appliances and their competitors capturingeven more market share.

• All major competitors had the patents and whitepapers on cleaning with steam for residentialappliances.

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5th Use-Project:

Eliminate Solar Frame Assembly & Field Issues

Solution:

Trim “un-needed” parts using Goldfire & evaluate whatcould be eliminated in solar panel design and packaging.

Built a simple solar panel function model. Goldfire asked ifthe frame could be integral to another part.. like the $$ flatglass AND showed that packaging boxes had many potential

improvement areas in the past 35 years. Results: Eliminated aluminum frame, tape, screws, ergonomics

issues, module assembly issues (>$51.00) & new formed glass$42.00. Shipping waste also eliminated and still gives customerfunctions of eliminated parts Box $13.00 and landfill waste, BUT

Lego like corners $10.00 & CAN BE RE-USED!.


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6th Use-Project:

Why are all these springs breaking? Challenge: Spring lifting

devices with main springsbreaking in a weird tearingshape.When I heard the cause wasspring overload and onlyoverload, I knew this was a job for Goldfire.

Results: Team was amazed to see this MANY common spring failuremodes. RCA in Goldfire has ability to link causes and effects withrelated improvement Patents. Goldfire showed this type of failure wasCAUSED by twisting and pulling, so we redesigned spring ends.


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Using Goldfire for Patent Disclosures & Filings

Challenge: How to grow business, not lose market

share, come up with new product ideas faster andfind ways to make existing products more efficient.How do you find information, no matter what form it is in or where it is stored. How do you do MUCHmore with less resources, better, faster andcheaper.

Corporate agenda: Innovation is key to staying ontop. Senior leadership searching for REPEATABLEmethods and consistent processes to generate newproducts. Engineering managers trying to accelerate

the number of patents per year as one of their“number one” high priority measurable metrics.

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Results: 28 Patent Disclosures at Gas Turbine & 3 at Solar:

in less than 4 years

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Reaction to the Software

People at first do not believe any software could actuallyhelp you be more innovative and creative.

• How can a software package help you think by generatingideas, looking for causes and effect relationships and breakingfundamental concepts down into simplified functions?

•

It asks you what you are trying to solve, and what the causesand effects are that you know about..

I did a demo in 2007 for the research team in India.

• Were very surprised to see it suggest solutions to one of theirresearch problems to making LEDs brighter.

• I had JUST created a function model and within a few minutesit was suggesting unique solution directions.

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What is TRIZ, how is Goldfire related, & isTRIZ experience required?

Recommended Book: “ And suddenlythe inventor appeared: TRIZ, thetheory of inventive problem solving” byGenrich Altshuller (2004)

Origin: USSR by Altshuller after WWII

Theory: Innovation can be taught; stepby step methodology that can lead to arepeatable process.

Basis: Exhaustive patent searchconducted by Altshuller

Today: Considered an empiricalmethod of innovation

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http://en.wikipedia.org/wiki/TRIZ


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Knowledge Based Problem Solving

Definition ProblemFormulation

ConceptIdeation

ConceptDevelopment

Design

QFD

Market

Research

Axiomatic

Design

FMEA

DOE

Robust

Design

Computer

Modeling

DFMA

Trial & Error

Brainstorming

6 Hats

Morphological Analysis

Osborn’s Checklists

Stages of Product Development

T o o l E f f e c t i v e n e s s

TRIZ

Six Sigma

Value Engineering

Innovation Labs

Definition ProblemFormulation

ConceptIdeation

ConceptDevelopment

Design

QFD

Market

Research

Axiomatic

Design

FMEA

DOE

Robust

Design

Computer

Modeling

DFMA

Trial & Error

Brainstorming

6 Hats

Morphological Analysis

Osborn’s Checklists

Stages of Product Development

T o o l E f f e c t i v e n e s s

TRIZ

Six Sigma

Value Engineering

Innovation Labs

Goldfire is the most complete TRIZ tool available.

Definition DesignProblemFormulation

ConceptIdeation

ConceptDevelopment


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Impact of TRIZ on an organization

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The Problem Statement

Analysis Approach to Current Solution Road Blocks:Define your Roadblocks based on 5W’s and H.

Answer the 6 basic questions of journalism: 1. Who? Who has the problem?

2. What? What does the problem seem to be?What are the resources?

3. When? When does the problem occur? All the time?Under certain circumstances?

4.Where? Where does the problem occur?

5. Why? Why does the problem occur?

6. How? How does the problem occur?

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ENGINEERING


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The Problem Statement – Asking Why5

Ask "Why" Five Times

Ask "Why" a problem occurred and then ask "Why" four more times.

For example...

1. Why has the machine stopped?

A fuse blew because of an overload

2. Why was there an overload?There wasn't enough lubrication for the bearings

3. Why wasn't there enough lubrication?

The pump wasn't pumping enough

4. Why wasn't lubricant being pumped?

The pump shaft was vibrating due to damaged impeller5. Why was the impeller damaged?

Chips of foreign material entered into the pump

Problem Statement: Foreign material chips are damaging the pump impeller.

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Problem Definition to Solving the Problem

2) Create Ideal Final Result (IFR)Eliminate the deficiencies

Preserve the advantagesNot more complicatedNo new disadvantages

1) Define the problem

List all requirements and constraints We want this but we can’t becauseof this. We get this because of this.

3) Determine the differencesCompare original system with IFR

4) Create Ideality EquationList differences as Benefit, Cost,

Harmful

5) Determine Contradictions

Technical or Physical contradictions

6) Determine Input ParametersUse 2 of 39 or other parameters

7) Physical or Technical ContradictionConvert between the two contradictions

If Technical then use ContradictionMatrix

9) Examine SolutionsConvert generic solutions to specific

Does solution increase Ideality?No – go to step 5

Does solution solve the problem?Yes – IMPLEMENT

8) Determine General SolutionUse 40 Inventive Principles


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Typical Goldfire Project Focus:

Reduce part cost Reduce size

Reduce temperature

Reduce weight Increase speed

More efficient

Improve alignment

Reduce assemblytime

Increase strength

Reduce vibration

Reducestress/pressure

Improve

manufacturability

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1. Weight of moving object

2. Weight of nonmoving object

3. Length of moving object

4. Length of nonmoving object

5. Area of moving object

6. Area of nonmoving object

7. Volume of moving object

8. Volume of nonmoving object

9. Speed

10. Force

11. Tension, pressure, stress

12. Shape

13. Stability of object

14. Strength

15. Durability of moving object

16. Durability of nonmoving object

17. Temperature

18. Brightness

19. Energy spent by moving object

20. Energy spent by nonmoving object

21. Power

22. Waste of energy

23. Waste of substance

24. Loss of information

25. Waste of time

26. Amount of substance

27. Reliability

28. Accuracy of measurement

29. Accuracy of manufacturing

30. Harmful factors acting on object

31. Harmful side effects

32. Manufacturability

33. Convenience of use

34. Reparability

35. Adaptability

36. Complexity of device

37. Complexity of control

38. Level of automation

39. Productivity

Select which parameternumber is improving, andwhich is getting worse.

TRIZ 39 Parameters

When facing a contradiction, begin with identifying the 39 engineering parameters.

Which parameter improves and which parameter worsens as a result?


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TRIZ 40 Principles

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1. Segmentation

2. Taking out

3. Local quality

4. Asymmetry

5. Merging

6. Universality

7. "Nested doll"

8. Anti-weight

9. Preliminary anti-action

10. Preliminary action

11. Beforehand cushioning

12. Equipotentiality

13. 'The other way round'

14. Spheroidality - Curvature

15. Dynamics

16. Partial or excessive actions

17. Another dimension

18. Mechanical vibration

19. Periodic action

20. Continuity of useful action

21. Skipping

22. "Turn Lemons into Lemonade"

23. Feedback

24. 'Intermediary'

25. Self-service

26. Copying

27. Cheap short-living objects

28 Mechanics substitution

29. Pneumatics and hydraulics

30. Flexible shells and thin films

31. Porous materials

32. Color changes

33. Homogeneity .

34. Discarding and recovering

35. Parameter changes

36. Phase transitions

37. Thermal expansion

38. Strong oxidants

39. Inert atmosphere

40. Composite materials

Note: All 40 principles may apply to solving the contradiction, though statically the top levelsolutions for resolving this conflict are identified in a matrix grid. More than one set of

parameters may apply to the contradiction.

Use the Contradiction Matrix to generate ideas using the 40 Principles


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KEY - Building and Using Function Models

1. What is a Function Model?

A visual flowchart that breaks a problem down to its key component features and then linksrelationships of one feature to other features.

2. When and where should you use Function Models?Product Design, Competitive analysis, Value analysis, cost savings, understanding steps in

current Systems or Process or Product RCAs, FMEAs, problem solving, DFA, DFM, LEAN andProject Management.

3. Why should you use Function Models?Break problem down to solve-able pieces and use digital public domain and existing

corporate knowledge to help you find cause and effect relationships.

4. Who should use Function Models?

Engineers, managers, designers, marketing, manufacturing

5. How much could companies save using Function Models in dailyproblem solving?10-20% of Research analysis and problem solving could = $millions per year

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Analyze the Problem – Functional Analysis

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Understand the Function of your System and its Components

What does the system do? What does each element of the system do?

• What is the object being acted on?

What is the energy in the system

• How is the energy being transmitted?

• What tool is delivering the energy andhow is it being controlled?

Are the actions:

• Useful?

• Harmful?

• Necessary?• Adequate?

• Inadequate?

Where are there idle resources? Space Shuttle TileFunctional Diagram

Space

ShuttleSurfaceTile

Ice

AluminumSkin

Silicone

Bonding Agent

Reentry Air


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Function Model Goal and Objective

Function Models will become much more important as groups startto focus on cost savings, value analysis, and how to makeimprovements to existing systems. Function models can also becreated for your competitors parts/designs and used to compare aswell as understand competitive differences.

Functions (components) are listed in flow diagram form (or table

form) then both good and bad relationships (action words) arelinked between those functions.

Once Function Models are created in Goldfire, it can then start toevaluate functions for being most valuable and least valuable. Thewhole time the software is able to suggest how to eliminate

combine or design out functions and link to Knowledge Bases,Patents, data or key Scientific effects.

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GOLDFIRE


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Root Cause Applications

Root Cause Analysis

• Construct & analyze a cause-&-effect graph with all causes• Lead users to question their assumptions & think beyond their

initial problem statement

• Eliminate “symptomatic” or phantom problems from furtherconsideration

•

Identify critical paths

Device Analysis

• Analyze a system’s configuration & behavior at an abstract level

• Apply disciplines of Value Engineering Analysis & TRIZ to identify

• The highest value problem areas• The most effective points for change

• Prioritize or justify problems based on accepted (or user-defined)metrics

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INNOVATOR


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Today’s RCA Situation without Goldfire

Without a structured software process:

• The loudest speaking person in the room drives the directionand action of what he perceives to be the important issues.

• Often times solving the wrong problem or missing the rootcause of the problem leaving it to re appear in the future.

•

Psychological inertia, “We tried that once and it did not work”attitude are big issues.

With a structured software process:

• The function model and the interactions between the functions

will help to automatically drive solutions to the problem.• It is crucial that function models properly expand the real

problem areas and interactions be understood for good problemsolving to occur. True even if you don’t use Goldfire.

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Recommendations

Implement Goldfire innovation software Lunch-n-Learns

Find and use Champions & successes to spread the word

Break problems down to functions and list relationshipsbetween components

Conduct more internal specific Function Modelingrelated training and/or from Invention Machine

Create detailed function models & accurate componentinteractions: list helpful and harmful actions

Identify Action Words used in your industry Identify Functions that are reoccurring issues, then

start with BOM of components around that problemcomponent

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APPENDIX


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polarizespolarizes

filters transmissionfilters transmission

drainsdrains

producesproduces

decreasesdecr eases

does not stickdoes not stick

holdsholds

oxidizesoxidizes

protectsprotects

weldedwelded

difficult to attachdifficult to attach

weldedwelded

protectsprotects

holdsholds

glassglass

silicon chipsilicon chipwirewire

solder solder

adhesiveadhesive

voltage output

(out)

voltage output

(out)

light (in)light (in)

Solar Cell


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weights downweights down

powerspowers

drainsdrains

supportssupports

heatsheats

Harmful ActionHarmful Action

vibratesvibrates

heatsheats

supposrtssupposrts

enclosesencloses

reduces speedreduces speed

reduces speedreduces speed

increases speedincreases speed

vibratesvibrates

creates torquecreates torque

spinsspins

vibratesvibrates

loadsloads

loadsloads

supportssupports

held byheld by

wearswearsslipsslips

centerscentersdrill bitdrill bitchuckchuck

gear packgear pack dc motor dc motor handlehandle

battery packbattery pack

Battery Power Tool


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41

Inventive Principle # 14– Spheroidality-

Curvature

a. Replace linear parts

or flat surfaces with

curved ones; replace

cubical shapes with

spherical shapes

b. Use rollers, balls

spirals

c. Replace a linear

motion with rotatingmovement; utilize a

centrifugal force


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42

InventivePrinciple #35 –

Parameter

Change -Transformation of

the physical orchemical states

of an object

Change an object's

aggregate state,

density distribution,

degree of flexibility,temperature


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Invention Machine Customers

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http://inventionmachine.com/about-us/customers/


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Invention Machine Customers

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“With Goldfire we did 6

months worth of dataanalysis in 5 hours withbetter results.”

- Oil & Gas Enterprise

Received a patent for a newtransistor design expectedto generate $8M annually

- Electronics Manufacturer

Used Goldfire to develop anew tooth whitening solution

and captured 70% of a $400Mmarket.

- Health & Beauty Company

Using Goldfire developed a

new foam with over 40product applicationsgenerating $21.5M.

- Chemical Producer

Reduced research

time by over 60%.- Medical Device Maker

Reduced component costs by38%, which translated into $77M

in savings over 3 years.- Technology Provider

Reduced analysistime by 75%- Auto Parts Maker

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R GIST R NOW:

PowerToInnovate.com

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Questions?

Contact Information• Web: InventionMachine.com •

Email Allison at:[email protected]

• Phone: +1.617.305.9250

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