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Engineering DesignSystems Engineering
Lecture 02Engineering Design and Systems Engineering
Through the Lens of Decision Making
Jitesh H. Panchal
ME 597: Decision Making for Engineering Systems Design
Design Engineering Lab @ Purdue (DELP)School of Mechanical Engineering
Purdue University, West Lafayette, INhttp://engineering.purdue.edu/delp
August 27, 2019ME 597: Fall 2019 Lecture 02 1 / 46
Engineering DesignSystems Engineering
Objectives for Today
1 To provide an overview of the engineering design and systemsengineering processes.
2 To identify the decisions made within systematic engineering designprocesses.
3 To understand the nature of design decisions.
ME 597: Fall 2019 Lecture 02 2 / 46
Engineering DesignSystems Engineering
Recall: Basic Elements of a Decision
Decision
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O11
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O1k
O21
O22
O2k
On1
On2
Onk
U(O11)
U(O12)
U(O1k)
U(O21)
U(O22)
U(O2k)
U(On1)
U(On2)
U(Onk)
Select Ai
p11
p1k
p21
p1k
pn1
pnk
Alternatives Outcomes Preferences Choice
ME 597: Fall 2019 Lecture 02 3 / 46
Engineering DesignSystems Engineering
Example: A Lottery
Cost: $2Odds of winning the jackpot: 1 in
259 Million!
What are the
alternatives?
outcomes?
preferences?
information?
choice?
ME 597: Fall 2019 Lecture 02 4 / 46
Engineering DesignSystems Engineering
a. Pahl and Beitz Systematic Design Methodb. Four Phases of Pahl and Beitz Approach
Design as Decision Making
Let us start with a simple decision-based view of design.
??? Design = Choosing the best alternative (solution) ???
Decision
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O21
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O2k
On1
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Onk
U(O11)
U(O12)
U(O1k)
U(O21)
U(O22)
U(O2k)
U(On1)
U(On2)
U(Onk)
Select Ai
p11
p1k
p21
p1k
pn1
pnk
Alternatives Outcomes Preferences Choice
Is this an accurate (complete) view of design? Why / Why Not?
...
...
...
ME 597: Fall 2019 Lecture 02 5 / 46
Engineering DesignSystems Engineering
a. Pahl and Beitz Systematic Design Methodb. Four Phases of Pahl and Beitz Approach
Design as a Decision-making Process
Is this an accurate (complete) view of design? Why / Why Not?
Design is typically not a single decision. It is a network of decisions.
Outcomes are only clear at the end of the process.
Not all alternatives are available. Need to generate alternatives.
Not all information is available. Need to generate information.
Not all information about preferences is directly available. Need tounderstand preferences (gradually).
Resources are always limited.
There may be multiple decision makers involved in the design process.
...
Design methods provide guidance in navigating these decisions.
ME 597: Fall 2019 Lecture 02 6 / 46
Engineering DesignSystems Engineering
a. Pahl and Beitz Systematic Design Methodb. Four Phases of Pahl and Beitz Approach
The Process of Design Thinking
Design thinking is a process by which designers approach problem solving.
Image Source:https://i.pinimg.com/originals/bb/19/c2bb19c2522081dad7f682c10d99a07903.jpg
ME 597: Fall 2019 Lecture 02 7 / 46
Engineering DesignSystems Engineering
a. Pahl and Beitz Systematic Design Methodb. Four Phases of Pahl and Beitz Approach
(Some) Principles of Design Thinking
Empathize and understand what users need; Find the latent needs
Prototype early, and prototype often
Work quickly: do not wait for the final design
Test ASAP; Launch Beta
Iterate, Iterate, Iterate
“Fail fast to succeed sooner” - David Kelley
ME 597: Fall 2019 Lecture 02 8 / 46
Engineering DesignSystems Engineering
a. Pahl and Beitz Systematic Design Methodb. Four Phases of Pahl and Beitz Approach
A systematic engineering design process
Consider an example of a systematic design process.
ME 597: Fall 2019 Lecture 02 9 / 46
Engineering DesignSystems Engineering
a. Pahl and Beitz Systematic Design Methodb. Four Phases of Pahl and Beitz Approach
The Pahl and Beitz Systematic Design Method
Concept
Preliminary Layout
Definitive Layout
Documentation
Specification
Clarification of Task
Conceptual Design
Embodiment Design
Detail Design
Phase 0 - Start
Upg
rade
and
Impr
ove
Solution
Customer
ME 597: Fall 2019 Lecture 02 10 / 46
Engineering DesignSystems Engineering
a. Pahl and Beitz Systematic Design Methodb. Four Phases of Pahl and Beitz Approach
Phase 1: Clarifying the Task
An engineer’s first problem in any design situation is to discover what theproblem really is.
What objectives must the intended solution satisfy?What properties must it have?What properties must it not have?
Clarifying the Task
Analyze market / company Find and select product ideas Formulate a product proposal
Task
Specification
Clarify the task Elaborate a requirements list
Product Proposal
Phase 1
Product Planning
ME 597: Fall 2019 Lecture 02 11 / 46
Engineering DesignSystems Engineering
a. Pahl and Beitz Systematic Design Methodb. Four Phases of Pahl and Beitz Approach
Need for Planning and Clarification of Task
what the customer said
what marketing understood
what engineering designed
what manufacturing realized
what the customer really wanted
how customer service solved the problem
ME 597: Fall 2019 Lecture 02 12 / 46
Engineering DesignSystems Engineering
a. Pahl and Beitz Systematic Design Methodb. Four Phases of Pahl and Beitz Approach
Clarification of Task
What is the problem really about?
What implicit wishes and expectations are involved?
Do the specified constraints actually exist?Avoid
fixed solution ideas / solution-specific considerationsfictional constraints and concrete implications
The outcome is a requirements list.
ME 597: Fall 2019 Lecture 02 13 / 46
Engineering DesignSystems Engineering
a. Pahl and Beitz Systematic Design Methodb. Four Phases of Pahl and Beitz Approach
Example Requirements List
Problem Statement:
Develop a device that, upon demand, conveniently provides cool, clean water for human consumption. The device must fit in a particular building space (see schematic) and function appropriately in an office environment.
Requirements List for Water-Dispensing Device Page: 1
Requirements Changes DW Responsibility
Schematic:
* Modified
8/2/00
D D D D
1. Water Characteristics Flow rate should be < 35 mL/s Flow velocity should be 20 - 40 cm/s Water temperature (dispensed) should be 5 - 8 ºC Water quality (dispensed) must meet EPA guidelines, e.g.,
Contaminant Threshold Arsenic < 0.05 mg/L Fluoride < 4.0 mg/L Lead < 0.015 mg/L Copper < 1.3 mg/L Mercury < 0.002 mg/L
as specified in Safe Drinking Water Act (1996)
Design Team Members
ME 597: Fall 2019 Lecture 02 14 / 46
Engineering DesignSystems Engineering
a. Pahl and Beitz Systematic Design Methodb. Four Phases of Pahl and Beitz Approach
Example Requirements List (cont.)
Requirements List for Water-Dispensing Device Page: 2
Requirements Changes DW Responsibility
* Adjusted 8/2/00
* Added 8/2/00
D D D W D D W D D D W D
2. Ergonomics Must be easy to use Must be accessible to all (esp. those in wheelchairs) Must be attractive Should be free of splattering Must be safe Must be quiet Must remain sanitary 3. Cost Total cost (installed) < $450 US Operating cost < $200 per year 4. Production, Installation, & Maintenance Must be manufactured from standard parts/assemblies Should be installed < 35 minutes by 2 skilled laborers Must be easily maintained over 12 week service intervals
Design Team Members
ME 597: Fall 2019 Lecture 02 15 / 46
Engineering DesignSystems Engineering
a. Pahl and Beitz Systematic Design Methodb. Four Phases of Pahl and Beitz Approach
Outcome of the Clarification of Task Phase
A decision to proceed to Phase 2 is predicated on answers in the affirmativeto the following questions:
Has the task been clarified sufficiently to allow development of a solutionin the form of a design?
Must further information about the task be acquired?
ME 597: Fall 2019 Lecture 02 16 / 46
Engineering DesignSystems Engineering
a. Pahl and Beitz Systematic Design Methodb. Four Phases of Pahl and Beitz Approach
What is the nature of these decisions?
Decision
A1
A2
An
O11
O12
O1k
O21
O22
O2k
On1
On2
Onk
U(O11)
U(O12)
U(O1k)
U(O21)
U(O22)
U(O2k)
U(On1)
U(On2)
U(Onk)
Select Ai
p11
p1k
p21
p1k
pn1
pnk
Alternatives Outcomes Preferences Choice
ME 597: Fall 2019 Lecture 02 17 / 46
Engineering DesignSystems Engineering
a. Pahl and Beitz Systematic Design Methodb. Four Phases of Pahl and Beitz Approach
Phase 2: Conceptual Design
In conceptual design the basicsolution path is laid down in the formof a solution principle, through thefollowing steps:
1 identification of the essentialproblems through abstraction,
2 establishment of functionstructures, and
3 search for appropriate workingprinciples and their combination.
Specification
Abstract to identify essential problems
Establish function structures
Search for working principles
Combine working principles into working structures
Select suitable combinations
Firm up into principle solution variants
Concept
Evaluate against technical and economic criteria
ME 597: Fall 2019 Lecture 02 18 / 46
Engineering DesignSystems Engineering
a. Pahl and Beitz Systematic Design Methodb. Four Phases of Pahl and Beitz Approach
Abstraction of Requirements
Abstraction is
ignoring what is particular or incidental and emphasizing what is general,and
identifying fictitious constraints and eliminating all but genuinerestrictions.
Steps in abstraction:
1 Eliminate personal preferences from the requirements list.2 Consider only requirements that affect function and essential constraints.3 Transform quantitative into qualitative data, reducing them to essential
ideas.4 Broaden essential ideas systematically (generalize).5 Formulate the design problem in solution-neutral terms.
ME 597: Fall 2019 Lecture 02 19 / 46
Engineering DesignSystems Engineering
a. Pahl and Beitz Systematic Design Methodb. Four Phases of Pahl and Beitz Approach
Abstraction: Example of Motor Vehicle Fuel Gauge
Eliminate personal preferences.
Consider only requirements that affect function and essential constraints
Transform quantitative into qualitative data
Broaden essential ideas systematically
Formulate in solution-neutral terms as an overall function
ME 597: Fall 2019 Lecture 02 20 / 46
Engineering DesignSystems Engineering
a. Pahl and Beitz Systematic Design Methodb. Four Phases of Pahl and Beitz Approach
Phase 2: Function Structures
A function
specifies the relationship between inputs and outputs in terms of energy,material (matter), signal (information).
ME 597: Fall 2019 Lecture 02 21 / 46
Engineering DesignSystems Engineering
a. Pahl and Beitz Systematic Design Methodb. Four Phases of Pahl and Beitz Approach
Function Structure – Example
Develop a device that, upon demand, conveniently provides
cool, clean water for human consumption.
Control Delivery
Deliver Water
Deliver Water
Purify Water
Cool Water
Dispose Water
Hold Liquid
Dispense Liquid
Function structures allow clear definition of existing or necessary subsystemsso that they can be dealt with separately (reducing complexity!).
ME 597: Fall 2019 Lecture 02 22 / 46
Engineering DesignSystems Engineering
a. Pahl and Beitz Systematic Design Methodb. Four Phases of Pahl and Beitz Approach
Search for Solution Principles
Solution (working) principles represent a physical effect and preliminaryembodiment (e.g., “cartoon” sketch). Use ideation techniques, searches, andanalysis of known or existing systems to determine solution principles. Foreach subfunction, identify as many working principles as possible.
Morphological matrix:
Force Cycle
Change Signal
Display Time
Store Energy
Principal Solution Alternatives
Sub-Functions
Oscillating crystal
Stroke magnet Electrical motor Meter
ME 597: Fall 2019 Lecture 02 23 / 46
Engineering DesignSystems Engineering
a. Pahl and Beitz Systematic Design Methodb. Four Phases of Pahl and Beitz Approach
Combine Solution Principles into Working Structures
Select a working structure.
ME 597: Fall 2019 Lecture 02 24 / 46
Engineering DesignSystems Engineering
a. Pahl and Beitz Systematic Design Methodb. Four Phases of Pahl and Beitz Approach
What is the nature of concept selection decisions?
Decision
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U(O11)
U(O12)
U(O1k)
U(O21)
U(O22)
U(O2k)
U(On1)
U(On2)
U(Onk)
Select Ai
p11
p1k
p21
p1k
pn1
pnk
Alternatives Outcomes Preferences Choice
ME 597: Fall 2019 Lecture 02 25 / 46
Engineering DesignSystems Engineering
a. Pahl and Beitz Systematic Design Methodb. Four Phases of Pahl and Beitz Approach
Phase 3: Embodiment Design
Concept
Develop preliminary layouts and form designs
Refine and evaluate against technical and economic criteria
Select best preliminary layouts
Preliminary Layout
Eliminate weak spots
Check for errors & cost effectiveness
Prepare preliminary parts list and production documents
Definitive Layout
Complexity!! Many simultaneous,interdependent activities!
Analysis and synthesis alternateand complement each other!Optimization and error ID +solution search and evaluation.
Proceed from qualitative toquantitative, from abstract toconcrete, from rough to detailed,with provisions for checks andcorrections (i.e., iterations!).
Outcome of Phase 3
A definitive layout for which production documents can be prepared withminimal detail design.
ME 597: Fall 2019 Lecture 02 26 / 46
Engineering DesignSystems Engineering
a. Pahl and Beitz Systematic Design Methodb. Four Phases of Pahl and Beitz Approach
Examples of Preliminary and Definitive Layout
Definite layout
Principal Solution
Preliminary layout
8 working elements 20 form elements (0.04%)
50 working elements 2000 form elements (4%)
280 working elements 50000 form elements (100%)
Adapted from Prof. H. Birkhofer’s lecture “Produktentwicklung”, TU-Darmstadt, 2004.
ME 597: Fall 2019 Lecture 02 27 / 46
Engineering DesignSystems Engineering
a. Pahl and Beitz Systematic Design Methodb. Four Phases of Pahl and Beitz Approach
What is the nature of these decisions?
Decision
A1
A2
An
O11
O12
O1k
O21
O22
O2k
On1
On2
Onk
U(O11)
U(O12)
U(O1k)
U(O21)
U(O22)
U(O2k)
U(On1)
U(On2)
U(Onk)
Select Ai
p11
p1k
p21
p1k
pn1
pnk
Alternatives Outcomes Preferences Choice
ME 597: Fall 2019 Lecture 02 28 / 46
Engineering DesignSystems Engineering
a. Pahl and Beitz Systematic Design Methodb. Four Phases of Pahl and Beitz Approach
Phase 4: Detail Design
Solution
Documentation
Definitive Layout
Finalize details
Complete all documents
Check all documents
Finalize detailed drawings ofcomponents, detailedoptimization of shapes, materials,surfaces, tolerances and fits.
Integrate individual componentsinto assemblies and assembliesinto overall product. Includeassembly drawings, part lists.
Complete production documents(manufacturing, assembly,transport, operating instructions).
Outcome of Phase 4
Final production documents (tolerances, assembly processes, materials,tooling, etc.)
ME 597: Fall 2019 Lecture 02 29 / 46
Engineering DesignSystems Engineering
a. Pahl and Beitz Systematic Design Methodb. Four Phases of Pahl and Beitz Approach
What is the nature of these decisions?
Decision
A1
A2
An
O11
O12
O1k
O21
O22
O2k
On1
On2
Onk
U(O11)
U(O12)
U(O1k)
U(O21)
U(O22)
U(O2k)
U(On1)
U(On2)
U(Onk)
Select Ai
p11
p1k
p21
p1k
pn1
pnk
Alternatives Outcomes Preferences Choice
ME 597: Fall 2019 Lecture 02 30 / 46
Engineering DesignSystems Engineering
a. Pahl and Beitz Systematic Design Methodb. Four Phases of Pahl and Beitz Approach
In Summary: Nature of Engineering Design Decisions
ME 597: Fall 2019 Lecture 02 31 / 46
Engineering DesignSystems Engineering
a. What is Systems Engineering?b. Systems Engineering Processes
Systems and Systems Engineering
System
a collection of hardware, software, people, facilities, and proceduresorganized to accomplish some common objectives.
a collection of components organized to accomplish a specific functionor set of functions. (IEEE STD 610.12)
Systems Engineering
An interdisciplinary approach and means to enable the realization ofsuccessful systems. (INCOSE, 1999)
The application of the system analysis and design process and theintegration and verification process to the logical sequence of thetechnical aspect of the product life cycle. (Forsberg and Mooz, 1992)
ME 597: Fall 2019 Lecture 02 32 / 46
Engineering DesignSystems Engineering
a. What is Systems Engineering?b. Systems Engineering Processes
Example of a Human Designed System
(Adapted from Wertz and Larson, 1999)
Subject of Study
Orbit and Constellation
Command, Control and Communications
Payload
Spacecraft Bus
Launch Element
Ground Element
Mission Operations
ME 597: Fall 2019 Lecture 02 33 / 46
Engineering DesignSystems Engineering
a. What is Systems Engineering?b. Systems Engineering Processes
Systems Engineering goes Beyond the Product
WeightStress
Hydraulics
Engine
Wings
Empennage
Fuselage
Armament
Lof t
Service
Production
Equipment
STRUCTUREGROUP
PROPULSIONGROUP
CONTROLGROUP
MANUFACTUREGROUP
PAYLOADGROUP
Cabling
Electronics
AEROGROUP Streamline
System Organization
Hierarchy is an effective way of managing complexity! The driving principle isnear-decomposability (Simon, 1961).
ME 597: Fall 2019 Lecture 02 34 / 46
Engineering DesignSystems Engineering
a. What is Systems Engineering?b. Systems Engineering Processes
The VEE model of Systems Engineering
Understand User Requirements, Develop
System Concept and Validation Plan
Develop System Performance Specification and System Validation Plan
Expand Performance Specifications into CI
“Design-to” Specs and CI Verification Plan
Fab, Assemble and Code to “Build-to” Documentation
Evolve “Design-to” Specifications into “Build-
to” Documentation and Inspection Plan
Inspect to “Build-to”
Documentation
Assemble CIs and Perform CI Verification
to CI “Design-to” Specifications
Integrate System and Perform System Verification to
Performance Specifications
Demonstrate and Validate System to User Validation Plan
Inte
grat
ion
and
Qualif
icatio
n Decom
position
and Definition
Systems Engineers
Domain Engineers
Time
ME 597: Fall 2019 Lecture 02 35 / 46
Engineering DesignSystems Engineering
a. What is Systems Engineering?b. Systems Engineering Processes
Examples of Decisions in Systems Engineering (1)
DevelopmentPhase
Examples of Decisions in Systems Engineering
1. ConceptualDesign
* Should a conceptual design effort be undertaken?* Which system concept (usually a mixture of technolo-gies) should be the basis of the design?* Which technology for a given subsystem should be cho-sen?* What existing hardware and software can be used?* Is the envisioned concept technically feasible, based oncost, schedule and performance requirements?* Should additional research be conducted before a deci-sion is made?
Buede, D.M, 2009, The Engineering Design of Systems: Models and Methods, Wiley.ME 597: Fall 2019 Lecture 02 36 / 46
Engineering DesignSystems Engineering
a. What is Systems Engineering?b. Systems Engineering Processes
Examples of Decisions in Systems Engineering (2)
DevelopmentPhase
Examples of Decisions in Systems Engineering
2. Preliminarydesign
* Should a preliminary design effort be undertaken?* Which specific physical architecture should be chosenfrom several alternatives?* To which physical resource should a particular functionbe allocated?* Should a prototype be developed? If so, to what level ofreality?* How should validation and acceptance testing be struc-tured?
Buede, D.M, 2009, The Engineering Design of Systems: Models and Methods, Wiley.ME 597: Fall 2019 Lecture 02 37 / 46
Engineering DesignSystems Engineering
a. What is Systems Engineering?b. Systems Engineering Processes
Examples of Decisions in Systems Engineering (3)
DevelopmentPhase
Examples of Decisions in Systems Engineering
3. Full-scaledesign
* Should a full-scale design effort be undertaken?* Which configuration items should be bought instead ofmanufactured?* Which detailed design should be chosen for a specificcomponent given that one or more performance require-ments are critical?
Buede, D.M, 2009, The Engineering Design of Systems: Models and Methods, Wiley.ME 597: Fall 2019 Lecture 02 38 / 46
Engineering DesignSystems Engineering
a. What is Systems Engineering?b. Systems Engineering Processes
Examples of Decisions in Systems Engineering (4)
DevelopmentPhase
Examples of Decisions in Systems Engineering
4. Integrationand qualifica-tion
* What is the most cost-effective schedule for implemen-tation activities?* What issues should be tested?* What equipment, people, facilities should be used to testeach issue?* What models of the system should be developed oradapted to enhance the effectiveness of integration?* How much testing should be devoted to each issue?* What adaptive (fallback testing in case of a failure) test-ing should be planned for each issue?
Buede, D.M, 2009, The Engineering Design of Systems: Models and Methods, Wiley.ME 597: Fall 2019 Lecture 02 39 / 46
Engineering DesignSystems Engineering
a. What is Systems Engineering?b. Systems Engineering Processes
Examples of Decisions in Systems Engineering (5)
DevelopmentPhase
Examples of Decisions in Systems Engineering
5. ProductRefinement
* Should a product improvement be introduced at thistime?* Which technology or technologies should be the basis ofthe product improvement?* What redesign is best to meet some clearly defined de-ficiency in the system?* How should the refinement of existing systems be imple-mented given safety, performance and cost criteria?
Buede, D.M, 2009, The Engineering Design of Systems: Models and Methods, Wiley.ME 597: Fall 2019 Lecture 02 40 / 46
Engineering DesignSystems Engineering
a. What is Systems Engineering?b. Systems Engineering Processes
Hierarchy of Objectives
Start with the fundamental objective (e.g., maximize safety) . . . objectivesthat are important to the system’s stakeholders in a value sense, i.e., thestakeholders would be willing to pay for improved performance.
The fundamental objective can be subdivided into value objectives that moremeaningfully define the fundamental objective, thereby forming afundamental objectives hierarchy or value structure.
Maximize
Safety
Minimize
Loss of Life
Minimize
Serious Injuries
Minimize
Minor Injuries
Adults Children Adults Children
ME 597: Fall 2019 Lecture 02 41 / 46
Engineering DesignSystems Engineering
a. What is Systems Engineering?b. Systems Engineering Processes
Example of Objectives Hierarchy with Value Curves
ME 597: Fall 2019 Lecture 02 42 / 46
Engineering DesignSystems Engineering
a. What is Systems Engineering?b. Systems Engineering Processes
Issues in Systems Engineering
Multi-disciplinary teams: Different disciplines must work together in anintegrated manner.
Distributed enterprises: need to understand interdependencies in theprocess.
Processes, methods, and tools in the process are highly integrated.Over-the-wall method is no longer efficient.
Engineering decisions must be based on an evaluation of the behavior ofproduct when it is used in the holistic environment (hardware,software, people, production, installation, transportation, maintenance,recycling, etc.)
P. Wiese and P. John, 2003, Engineering Design in the Multi-Discipline Era. A SystemsApproach, Professional Engineering Publishers.
ME 597: Fall 2019 Lecture 02 43 / 46
Engineering DesignSystems Engineering
a. What is Systems Engineering?b. Systems Engineering Processes
Interactions Among Design Teams
V-8 Engine Design
ME 597: Fall 2019 Lecture 02 44 / 46
Engineering DesignSystems Engineering
a. What is Systems Engineering?b. Systems Engineering Processes
Summary
Objectives for Today:1 To provide an overview of the engineering design and systems
engineering processes.2 To identify the decisions made within systematic engineering design
processes.3 To understand the nature of design decisions.
ME 597: Fall 2019 Lecture 02 45 / 46
Engineering DesignSystems Engineering
a. What is Systems Engineering?b. Systems Engineering Processes
References
G. Pahl, W. Beitz, J. Feldhusen, K.H. Grote, 2007, Engineering Design:A Systematic Approach, 3rd Edition, Springer London.
P. Wiese and P. John, 2003, Engineering Design in the Multi-DisciplineEra. A Systems Approach, Professional Engineering Publishers, 2003.
D.M. Buede, 2000, The Engineering Design of Systems: Models andMethods, John Wiley & Sons.
C. Paredis, “Systems Engineering”, ME8813: Modeling and Simulation inDesigns, Lecture 2 Notes, Spring 2004, Georgia Tech, Atlanta
F. Mistree, W. F. Smith, et al., 1990, “Decision-Based Design: AContemporary Paradigm for Ship Design.” Transactions, Society of NavalArchitects and Marine Engineers 98: 565-597.
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