A User's Perspective: Innovating Smarter with Invention Machine Goldfire
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Transcript of A User's Perspective: Innovating Smarter with Invention Machine Goldfire
A User’s Perspective:
Innovating Smarter with
Invention Machine Goldfire
William Hessler, Mechanical Engineer Leader
CSC, Computer Sciences Corporation
Aberdeen Proving Ground, MD
WHAT IS GOLDFIRE?!
What is Goldfire?
What is Innovation?
Page 4
Market Analysis
New Product Development
Risk Management
Product Improvement
Leverage IP
• 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 Product Development
Risk Management
Product Improvement
Leverage IP
Market Analysis
THE MAIN EVENT
My Background with Invention Machine & TRIZ
• Ingersoll-Rand Power Tools, 1989 - 1998 • 1997 trained as a trainer for TRIZ problem solving
and on Invention Machine software • Trained engineers/designers how to do more
effective problem solving and cost savings for hand tools
• Dade Behring, 1998 - 2004 • Medical diagnostics blood analysis company • Formerly DuPont Medical Products, now Siemens
Diagnostics • 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
Applications of Goldfire
• Problem Statement:
How to apply Goldfire to company problems using Root Cause Analysis, Function Models and TRIZ basics for solution creation
• Contradiction:
Psychological inertia-“there is NO WAY software and a process is going to help you be more creative.”
• Ideal Final Result:
More engineers have access to Goldfire & understand basics of TRIZ principals to solve future problems
APPLICATIONS OF INNOVATION
SOFTWARE
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 manufacturing were 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 swinging mechanism device for tightening lug nuts.
Results:
• Everyone said this was impossible, UNTIL software suggested using a high vibration source to eliminate the air motor and swinging mechanism TO TIGHTEN the nuts.
• The software recognized this as a potential solution contradiction since we documented nuts come loose
due to vibrations caused during driving.
WOW!!! 10
2nd Use-Project:
Why are these holes cracking?
Challenge: RCAs & FMEAs get directed by the loudest speakers in the room, usually the RCA champions, who usually 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 ignored or 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 97 ribs; everyone wanted to know where I “FOUND” it. The team investigated shot peening of the holes to improve residual stresses at 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) more
efficiently?
• I did a DEMO for the Appliance team in late 2007
and asked, “What problem if it were solved would
make you Engineer of the Year in your group?”
Results: Goldfire in 10 minutes said solution was
centered around STEAM, STEAM, STEAM and more
STEAM.
• Within 10 minutes I had the complete R&D team’s
attention and they saw the evolution of high
efficiency appliances and their competitors capturing
even more market share.
• All major competitors had the patents and white
papers on cleaning with steam for residential
appliances.
12
5th Use-Project:
Eliminate Solar Frame Assembly & Field Issues
Solution:
Trim “un-needed” parts using Goldfire & evaluate what could be eliminated in solar panel design and packaging.
Built a simple solar panel function model. Goldfire asked if the frame could be integral to another part.. like the $$ flat glass 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 customer
functions of eliminated parts Box $13.00 and landfill waste, BUT
Lego like corners $10.00 & CAN BE RE-USED!.
6th Use-Project:
Why are all these springs breaking? Challenge: Spring lifting
devices with main springs breaking in a weird tearing shape.
When I heard the cause was spring overload and only overload, I knew this was a job for Goldfire.
Results: Team was amazed to see this MANY common spring failure modes. RCA in Goldfire has ability to link causes and effects with related improvement Patents. Goldfire showed this type of failure was CAUSED by twisting and pulling, so we redesigned spring ends.
Using Goldfire for Patent Disclosures & Filings
Challenge: How to grow business, not lose market
share, come up with new product ideas faster and
find 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 MUCH
more with less resources, better, faster and
cheaper.
Corporate agenda: Innovation is key to staying on
top. Senior leadership searching for REPEATABLE
methods and consistent processes to generate new
products. Engineering managers trying to accelerate
the number of patents per year as one of their
“number one” high priority measurable metrics.
15
Results: 28 Patent Disclosures at Gas Turbine & 3 at Solar:
in less than 4 years
Reaction to the Software
People at first do not believe any software could actually
help you be more innovative and creative.
• How can a software package help you think by generating
ideas, looking for causes and effect relationships and breaking
fundamental concepts down into simplified functions?
• It asks you what you are trying to solve, and what the causes
and 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 their
research problems to making LEDs brighter.
• I had JUST created a function model and within a few minutes
it was suggesting unique solution directions.
16
BEST PRACTICES
What is TRIZ, how is Goldfire related, & is
TRIZ experience required?
Recommended Book: “And suddenly
the inventor appeared: TRIZ, the
theory of inventive problem solving” by
Genrich Altshuller (2004)
Origin: USSR by Altshuller after WWII
Theory: Innovation can be taught; step
by step methodology that can lead to a
repeatable process.
Basis: Exhaustive patent search
conducted by Altshuller
Today: Considered an empirical
method of innovation
18
Knowledge Based Problem Solving
DefinitionProblem
Formulation
Concept
Ideation
Concept
DevelopmentDesign
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
Tool Ef
fect
iven
ess
TRIZ
Six Sigma
Value Engineering
Innovation Labs
DefinitionProblem
Formulation
Concept
Ideation
Concept
DevelopmentDesign
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
Tool Ef
fect
iven
ess
TRIZ
Six Sigma
Value Engineering
Innovation Labs
Goldfire is the most complete TRIZ tool available.
Definition Design Problem
Formulation
Concept
Ideation
Concept
Development
Impact of TRIZ on an organization
20
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
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 impeller
5. Why was the impeller damaged?
Chips of foreign material entered into the pump
Problem Statement: Foreign material chips are damaging the pump impeller.
22
23
Problem Definition to Solving the Problem
2) Create Ideal Final Result (IFR) Eliminate the deficiencies
Preserve the advantages
Not more complicated
No new disadvantages
1) Define the problem
List all requirements and constraints We want this but we can’t because
of this. We get this because of this.
3) Determine the differences Compare original system with IFR
4) Create Ideality Equation List differences as Benefit, Cost,
Harmful
5) Determine Contradictions Technical or Physical contradictions
6) Determine Input Parameters Use 2 of 39 or other parameters
7) Physical or Technical Contradiction Convert between the two contradictions
If Technical then use Contradiction
Matrix
9) Examine Solutions Convert generic solutions to specific
Does solution increase Ideality?
No – go to step 5
Does solution solve the problem?
Yes – IMPLEMENT
8) Determine General Solution Use 40 Inventive Principles
Typical Goldfire Project Focus:
Reduce part cost
Reduce size
Reduce temperature
Reduce weight
Increase speed
More efficient
Improve alignment
Reduce assembly
time
Increase strength
Reduce vibration
Reduce
stress/pressure
Improve
manufacturability
24
Benefits of a Confident Decision Point ?
Innovative solutions with more proposals- better, cheaper,
faster
Enhances credibility and exposes past knowledge.
Reduces # of trial and error solutions. Saves time, money and
reduces risks
Easy software to use and follows repeatable process
Works on any type of problem in any industry
Used Goldfire on Power Tools, Medical Devices, Gas Turbines,
Solar Modules, Ergonomic Lifting Products. Can be applied to
existing designs, new products, failure prediction, RCA’s,
cost savings, liability redesigns, process improvements and
product enhancements.
25
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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 parameter
number is improving, and
which 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?
TRIZ 40 Principles
27
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 level
solutions 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
Please click here to access the
full presentation deck and
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this session:
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innovating-smarter-with-invention-machine-goldfire/