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ACKN
Than
REFE
1. Society of Automotive
USA.
2. Clausing D. Total Qual

Guide
ASME
3. Pugh S. Creating Innov

The L
edito
4. National Research Co

Desig
Desig
for
Comp
Adva
Wash
5. Kirk S J, Dell'Isola A. Li

Profe
6. Hollins B, Pugh S. Succ

and W
7. Cross N. The Common

Educ
8. Ulrich K T, Eppinger S

Deve
9. Magrab E B. Integrate

Deve
York:
10. Pahl G, Beitz W

Appr
Desig
11. Todd R, Sorens

Capst
Educ
12. Wallace K. A Sy

Desig
400 Commonwe
Tel: (724) 776-4
SAE TECHN
PAPER SER
2000-0
Rethink
A Custo
Designi
Brent Zolling
Brigham Youn
 nternational O
Congress & Ex
Milwaukee, W
September 11
The appearance
SAE routinely sto
orders to SAE Cu
Quantity reprint
To request perm
other works, con
No part of this public
 ermission of the pu
SSN 0148-7191
opyright © 2000 Soc
ositions and opinion
ersons wishing to su
word abstract of a pr
Printed in USA
ll SAE papers, standar

2000-01-265
Rethinkin
Approach
Brent Zollinger
Brigham Young U
opyright © 2000 So
ABSTRACT
This paper uses a
NTRODUCTION
A BYU Capstone
Design is a term
design product de
and

phrase that refer

nformation proc
actors—such

ost,
performance spe
A good design co
 n 1991 the Natio
To stay competiti
They must becom
THE CUSTOMER
PARADIGM
A large part of in
because the prod
eflect customer
The new custom
This type of work
Despite the large
Generating reven
THE DESIGN PRO
The key to ensur
The design meth
dependent on th
 hat criteria are g
The design proce
To ensure the su
igure 1: Design pr
eam. Adapted fro
A CASE STUDY IN
MINI-BAJA VEHI
Developing skill i
The case study
dentify
 ustomer
Needs
stablish
pecifications
nalyze
ompetitive
 roducts
Generate
roduct
oncepts
elect a
roduct
 oncept
Detail Design
f Concept
reliminary
nalysis of
oncepts
dvanced
nalysis and
rototyping
ost Analysis
BYU Mini-Baja Te
presented here i
The Brigham You
DEFINING CUST
design goal was
D#
Product Attribute
Rank

The vehicle is safe

The vehicle adher

The vehicle is fast

The vehicle accele
The vehicle can cl

The vehicle is relia

The vehicle is inex

The vehicle is ligh

The vehicle is com
The vehicle is stab

The vehicle is eas

The vehicle looks

able 1: Abridged
mportance to cus
CREATING THE
major key to any
nor do they try t
An abridged spe
To enable evalua
t is not uncomm
Product attribute
Even with shortc
meets the specifi
accurately descr
Since the shortco
CONCEPTUAL D
divided into sub-
Working togethe
he differential w
Designers used s
Ref #
Metric
est Procedure
arget Values
Ideal–Acceptible)
Number of belts,
prockets withou
Observation
0–0
Amount of fuel lo
uel.
0 – 2 drops
tiffness of roll-ca
Calculate EI produ
1,500 ksi – 760 ks
Number of driver
points
Observe number
5–4
Distance to stop c
peed
Measure distance
on dry pavement
15 ft – 30 ft
Number of rules b
Race judges deter
0–0
Top speed
nstrument vehicl
50 mph – 30 mph

50 yard drag race

Time 50 yard drag
6 sec. – 7.5 sec

Climbable hill ang

Drive vehicle up h
35º – 22º

Hours of driving w
ailure
Time hours driven
 epair
50 hrs. – 5 hrs.

Cost to manufactu
Estimate cost bas
 ollowing Mini-Ba
$2,300 - $2,499

Curb weight
Weigh vehicle
350 lbs. – 450 lbs

Ride smoothness
Drivers will determ
10 – 6
 ize range of drive
fit into vehicle
Drivers of differen
ehicle
4' - 6'10" –
4'8" - 6'6"
Ease of steering r
Drivers will determ
10 – 5
Angle of tilt when
balanced on two
Tip vehicle with d
angle of frame wi
60 – 40
° °
Ease of service ra
Team mechanics
1-10)
10 – 4
Aesthetic allure ra
ndustrial designe
ubjectively (1-10
10 – 4
 able 2: Abridged
The concept sele
aesthetic appeal
Frame Concep
Selection Criteria
Variantof
astYear’s
Model
NewConcept
NewConcept

NewConcept

NewConcept
astYear’s
Model
Benchmark)
Conforms to rule
Easy to exit
Fit all team mem
Aesthetically ple
Comfortable to d
Manufacturabilit
Weight
Sum +'s
Sum 0's
Sum -'s
Net Score
Rank
 able 3: Screening
bold were conside
Frame Concep
ast Year’s Mode
Benchmark)
Variant of Last Y
Model
New Concept 1
Selection Criteria
Weight
 %)
Rating
Score
Rating
Score
Rating
core
Conforms to rule
Easy to exit
Fit all team mem
Aesthetically ple
Comfortable to d
Manufacturabilit
Weight
Total Score
Rank
Continue?
No
Backup Choice
Develop
 able 4: Scoring m
mall radii. This o
Upon examinatio
Conceptual desig
Since the power-
determine appro
DETAIL DESIGN
he design team
igure 2: Frame co
igure 3: Shaded P
ayout of powertra
Pro/Engineer, a s
The software allo
When deciding
The design of the w
ampling of peop
Designing the lin
detail, and left it
The failure of the
various terrain, a
The lessons that
Second, if design
Reducing produc
igure 4: Photo of
made carefully s
CONCLUSION
The product real
One such princip
ACKNOWLEDGM
Thanks to the 19
REFERENCES
. Society of Automotive Engineers. 1999 Mini Baja® West.
USA. 1998.
. Clausing D. Total Quality Development: A Step-by-Step

Guide to World-Cl
ASME Press; 1994
. Pugh S. Creating Innovative Products Using Total Design:

he Living Legacy o
 ditors. Massachu
. National Research Council. Improving Engineering

Design:
Designing
or
Competitive
Advantage.
Washington DC: N
. Kirk S J, Dell'Isola A. Life-cycle Costing for Design

Professionals. New
. Hollins B, Pugh S. Successful Product Design: What to do

nd When. London
. Cross N. The Common Core of Design. In: Qualifications,

ducation and Tra

. Ulrich K T, Eppinger S D. Product Design and

Development. New
. Magrab E B. Integrated Product and Process Design and

Development: The
 ork: CRC Press; 1
0. Pahl G, Beitz W. Engineering Design: A Systematic

Approach. Wallace
Design Council; 19
1. Todd R, Sorensen C, Magleby, S. Designing a Senior

Capstone Course t
 ducation. ASEE. 1
2. Wallace K. A Systematic Approach to Engineering

Design. In: Oakley

 nwealth Drive,
76-4841 Fax: (7
HNICAL
ERIES
-01-265
 nking t
stomer-
ning a
linger and R
oung Univ.
nal Off-Highwa
& Exposition
, Wisconsin
11-13, 2000
nce of this ISSN
y stocks printed
E Customer Sale
rint rates can be
ermission to rep
contact the SAE
ublication may be r
 e publisher.

0 Society of Automo
pinions advanced in
to submit papers to
f a proposed manus
andards, and selected

2651
king the D
ch to Des
nger and Robe
ng Univ.
00 Society of Autom
ses a case study
ION
one design team
erm that can con
ct design and dev
efers to a holisti
processing and d
e specifications,
n concept has a
National Researc
petitive in comin
ecome more inv
MER FOCUSED D
of industry uses
product specific
mer needs [6].
tomer-focused d
work requires no
arge array of de
evenue is the pr
 PROCESS
nsuring successf
methodology use
n the chosen ju
are given [3].
rocess used by t
e success of a st
gn process model
d from Ulrich and
DY IN PRODUCT
VEHICLE
kill in design is b
dy
a Team Design Pr
ere is used to sh
 Young Universi
USTOMER NEE
was to produce a
ute

safe
dheres to compe

fast
ccelerates quickly
an climb steep hi

reliable
inexpensive

light weight
comfortable and
stable

easy to service
oks good

ged list of vehicle

customers by a r
THE PRODUCT
any successful d
try to improve it
specification, co
 aluation of such
ommon for inexp
bute #4, which r
ortcomings in th
 ecification and
escribes custom
ortcomings in th
AL DESIGN Conceptual design was
 sub-systems: fra
ether the design
tial would have p
ed screening an
ble)
elts, chains, and
hout guards
el lost in rollover

ll-cage material
roduct of tubing
0 ksi
iver-restraint

ber of harness att

op car from top

ance to stop from

ent
les broken
etermine numbe
ehicle with speed
mph

race time
drag race on leve

angle
up hills on hard-p
ng without

riven since last de

facture vehicle
based on 4,000
ni-Baja guidelines
99
0 lbs.

ness rating
etermine rating s
drivers that can

erent heights wil

ng rating
etermine rating s
when vehicle is
wo wheels
th driver on two
e with angle find
 e rating
nics will determin
re rating
igner will determ
1-10)
ged list of produc
selection proce
peal of the conc
cept Screening
teria
rules
members
pleasing
to drive
ability
ning matrix used
sidered further in
cept Scoring M
Model
st Year’s

1
teria
rules
members
pleasing
to drive
ability
ce
ng matrix used to
his obstacle was
nation of the sel
design of the pow
wer-source is lim
ppropriate gear-
IGN During the conceptual design stage

eam amassed a l
e concept drawn
ed Pro/Engineer m
ertrain componen
r, a solid-modeli
e allowed for var
ng what bearing
f the steering w
people are used
e link between t
ft its design to i
 f the throttle ca
in, and attractiv
hat were learne
sign or analysis
oduct developm
o of finished vehic
lly so that nume

realization proc
nciple is making
DGMENTS
e 1999 Brigham
d-Class Concurren
994.

acy of Stuart Pugh

achusetts: Addison
C: National Acade

New York: McGra

ndon: Butterwort
Training Division

New York: McGr

The Product Rea

ss; 1997.

llace K, editor & t

l; 1988.

rse to Satisfy Indu

EE. 1993;82:92-10

kley M, editor. De
 ive, Warrendal
x: (724) 776-576
651
g the De
er-Focu
a Mini-
d Robert H.
hway & Powe

n
00
SSN code at the
ted papers for a
 Sales and Satisfa
n be obtained fr
o reprint a techn
SAE Publication
be reproduced in a
tomotive Engineers,
ed in this paper are t
ers to be considered
anuscript to: Secret
ected books are abstra

e Design P
esigning a
obert H. Todd

utomotive Engineer
udy to demonst

eam—compose
 connote a num
d development ) is a catch

olistic view of th
nd decision ma
ns, tooling, eco
as a tremendou
 earch Council pu
oming years, pra
e involved in res
ED DESIGN
uses an outdated
cification does n
6].
 ed design parad
es not only analy
f design strateg
e primary reaso
essful customer
used by the BY
n judging criteri
by the BYU team
a structured de
odel used by BYU
and Eppinger.
UCT DEVELOPM

n is best learned
gn Process
o showcase an e
ersity 1999 Min
NEEDS The team’s main

uce a vehicle tha

mpetition rules
ickly
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ice
hicle attributes, in
y a ranking on a 1
UCT SPECIFICAT
ful design is gen
ve it. The specifi
n, consisting of a
such specificatio
nexperienced de
ich requires qui
in the product s
and that the spe
tomer needs.
n the specificati
tual design was
 : frame, suspen
signers found th
ve provided. Th
g and scoring ma
nd
over Turn vehicle

rial
bing
ss attachment po
top

from 50 yard acc

mber of rules vio
peedometer
 level pavement

ard-pack
st design change
 le
000 production u
ines for costing
ng subjectively (1
can

s will attempt to
ng subjectively (1
two wheels and m
finder.
rmine rating subj
termine rating
oduct specification
ocess for the fra
oncept drawing
ning Matrix
sed to narrow fiel
er in the scoring m
ng Matrix
d to decide upon
was overcome
e selection matri
e powertrain diff
s limited by the
ear-ratio ranges

d a list of hundre
awn by industrial
eer model depicti
onents.
deling software
r various design
arings should be
g wheel did not
sed to give subj
en the engine th
to intuitive judg
e cable took the
active (See Figur
arned from this
ysis techniques
opment time is o
vehicle prototype
umerous iteratio

process for vario

king sure engine

ham Young Univ

urrent Engineerin

Pugh. Clausing D,
dison-Wesley; 199
cademy Press; 19

cGraw-Hill; 1995.

worths; 1990.
 sion of the Institu

McGraw-Hill; 1995

Realization Proce
r & translator. Lon

Industrial Needs.
2-1003.

r. Design Manage
ndale, PA 15096
-5760
Design
cused A
ni-Baja
H. Todd
werplant
the bottom of th
or a period of th
 tisfaction Depar
ed from the Cust
chnical paper or
tions Group.
in any form, in an e
eers, Inc.
are those of the aut
ered for presentatio
ecretary, Engineerin
abstracted and indexe

n Paradigm
ng a Mini-B
odd

neers, Inc
onstrate how fo

osed of mechan
number of differ
nt ) is a catch

of the design pro

making with the
ecology, etc.—w
dous effect on t
cil published a re
practicing engin
researching the
ated design par
oes not accurate
aradigm encour
nalysis, but also
ategies that atte
eason for design
 mer-focused de
e BYU Mini-Baja
teria, and the w
team was adapt
d design method
BYU Mini-Baja
OPMENT:

ned through exp

an example of o
Mini-Baja team

that met all of

es
drive
 s, indicating their
n a 1-5 scale.
CATION A

generating a pr
ecification shou
of a metric, tes
 ations, a subjec
d designers to c
quick accelerati
uct specification
specification

cation were rela

 pension, power
nd that a trailing
. Through this le
g matrices to en
hicle upside down
nt points
acceleration
s violated
ent
ange or
on units
ng
ely (1-10)
t to drive
ely (1-10)
and measure
subjectively
ations including: m
e frame/roll-cag
wing and also fou
w field of concepts
ing matrix.
pon primary and s
me by using tub
matrices in Table
differed greatly
 the competition
nges. Powertrain

ndreds of detail
trial design studen
picting the

ware package, w
sign iterations to
dnot
be used on the
require any
subjective input
ne throttle and t
judgement, a de
 the vehicle out
igure 4).
this failure shou
ues do not exist
is often at odds
type.
rations are not r

arious products
gineering design

University Senior
ering. New York:

g D, Andrade R,
; 1996.
s; 1991.

995.
stitution of Mech

995.

rocess. New
. London: The

eds. J Engr
nagement: A Hand
5096-0001 U.S.
n Parad
Appro
a Vehic
of this page indi
of three years fo
epartment.
Customer Sales
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n an electronic retrie
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chanical and ma
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rately
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attempt to simp
signing and man
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Baja design team
he weight
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thodology, care
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l of the needs of
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to create produ
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R,
Mechanical Engine
Handbook of Issue
U.S.A.
adigm:
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hicle
indicates SAE’s
rs following date
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etrieval system or o
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and wants of cus
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sis and creativity
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Ulrich and Eppi
are must be tak
m's attempt to in
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ds of the produc
pecification that
constraints as b
ure and ideal va
ng was used.
oduct specificati
converted to a
a valuable aid to
minor, they did n
 aking, and steer
spension design
he team learned
at a range of con
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ed in a very succ
the frame could
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in large 130-inch
4, one importan
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questions that h
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extensively in bo
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sign teams differ

erstand the nee

aja Team and Co

gineers, editor. Fo
Issues and Metho
m:
h to
E’s consent that
date of publicati
 sfaction Departm
copyrighted SAE

m or otherwise, with
y those of SAE. The
SAE should send th
 abase

mer-Focus
needs improves

ring engineers, e
engineers often

gn in this paper
ng the needs of
 needs and wan
f the product. It
e overall quality
d to rethink the
f customers and
ineering designe
 signers to partic
tivity. Design eng
gn processes int
ing products. Re
 opriate design p
s on satisfying cu
Eppinger’s conc
e taken to foster
o incorporate cu
cused methodol

duct stakeholde
that accurately r
as broadly as po
al value range, i
fications that are
o a specification
d to help focus t
id not prevent t
teering. This div
sign could be se
ned that unnece
concepts was c
and target value
successful desig
ould be made m
pared against a be
-inch, and 70-in
rtant criterion a
ame. Many conc
he powertrain m
ated in conjuncti

at had to be ans
oncept is referred

n both the conc

o was used to w
dard engineering
tions, rather it w
prototypes are
l required gener
In theory this c
st place, and the

l conceptual des
g is required to
quality of detai
h production pro

iffers greatly, as
needs and wan

d Coaches: Robe
or. Fourth Interna
ethods. UK: Basil
 that copies of th
lication. Direct y
partment.
SAE publication

without the prior w

 The author is solely
nd the manuscript o
used
oves the success

rs, engineering
ften enter indus

per refers to thi

s of customers a
wants of all the c
t. It is estimated
ality of engineer
their design pro
and stakeholde
igners act as pro
articipate in mar
n engineers work
s into a series of
s. Revenue incre
 gn process. The
ng customer nee
oncept develop
ster an environm
te customer-foc
odology to desig

olders, especial
ely reflects cust
s possible to avo
ge, is found in Ta
 t are worded in
ation inaccurate
cus the design o
ent the design fr
 division of resp
e set up so that
necessary divisio
as considered a
alue range.
esign. The origin
de more easily t
a benchmark (F).
0-inch radii. The
on appears to be
oncepts were s
 n must manage
unction with sus

e answered. By t
rred to in matrice

conceptual and
to work out asse
ering analysis tec
r it was an exerc
are constructed
enerating and im
his concept shou
d the vehicle fin

design is impor
d to identify failu
etail design. Ach
n processes, mak

y, as it should. Im
wants of all prod

Robert Todd, Ch
ernational Confer
asil Blackwell Ltd;
of the paper ma
ect your
tions in

or written
olely responsible for
ipt or a 300
cess of product

ing technologist
ndustry with the

o this holistic vie

ers and stakehol
the customers a
ated that more
neering design i
n processes.
olders (hereafter
s problem solve
 market research
work concurrent
es of calculation
ncreases as the
There are as ma
needs. The cust
elopment model
ronment conduc
-focused design
esign an off- roa

cially the end u

customer needs
avoid prematu
n Table 2. Each
d in such a way
rately because t
gn on customer
n from being su
responsibility hi
hat one of the r
visions in design
ed and that the c
riginal concept
ily than other co
(F). Concepts in
The large radii c
o be absent— ro
re studied, and
 age the limited
h suspension, fra

By this stage, th
trices as “New Co

and detail design

assembly detail
sxercise
techniques we
of intuiti
cted for testing.
nd implementing
hould have bee
e finished 12 of
out
th

mportant, and sh
failure modes a
. Achieving both
making sure thi

d. Improvemen
product custom

, Chris Jones, An
nference on the E
Ltd; 1990. p 206-
may be made f
le for the content of
uct designs in th

ogists, and an in
 the idea that de

c view. Design fr
eholders throug
rs and stakehold
ore than 70% of
olvers who optim
earch, and consi
rently with mar
tions, design is s
the customers’ p
s many processe
customer needs
odel, as seen in
nducive to desig
sign methodolo
- road vehicle fo

nd user, BYU’s M
eds and desires
ature eliminatio
ach specification
way as to prema
se the test meth
mer requiremen
g successful.
 y highlighted th
he rear wheels w
esign responsibil
he chosen conc
ept drawing, dra
er concepts. The
s in
 dii can be bent
— rollover prote
and most of them
ted power to ac
, frame, and bra

e, the major com

w Concept 1.”

esign stages.
etails and cleara
stuitive
were used.
judgemeLoa
ting. In this case,
nting a concept.
been decided fo
 out
h of 72 registere

d should be carr
es and how to g
both requires mo
e things are don

ments to this pro

tomers and stak

s, Andrew Wood
he Education and
206-218.
de for personal
ent of the paper. A p
in the marketpla

n industrial desi
at design is only

gn from this poin

oughout the enti
eholders [3].
% of the life cycl
ptimize designs
onsider a broad
marketing and p
n is still very muc
ers’ perception o
esses as there a
eeds identified b
n in Figure 1 [8].
esign. Providing
dologies into the
e for the SAE M

’s Mini-Baja raci
 ires. Unfortuna
nation of possibl
ation was taken
ematurely elimin
method timed th
ments. Knowing
d the importanc
els would unloa
sibility are unde
oncept was the
, drawn by the in
The final frame
 ent easily on a t
protection. The m
them had previo
 o achieve the de
d braking to take

components an
earances. One o
 Loads that wou
ement. Since the
ase, two alterna
ept. The novice
ed following the
tered entrants.

carried out usin

to guard agains
s more time be
done right the fi

s process must b
stakeholders. Th

oodings, McKay
and Training of E
nal or internal u
r. A process is availa
etplace. A samp

designer—desig
only concerned w

point of view is
e entire product
cycle cost of a p
igns to meet spe
oad range of con
nd production sp
much an intuitiv
on of value incre
re are design te
ed by the team
 [8]. The design
ding ample time
the design proc
E Mini-Baja Wes

racing team. In
unately design e
ssible concepts [
ken directly from
 iminate possible
ed the vehicle on
wing how well th
tance of commu
nload around tu
ndesirable beca
the best alterna
he industrial des
ame design uses
n a three-point r
he main functio
reviously been u
 e desired specifi
take advantage

s and concepts
ne of the main b
would be impos
e the wheel wou
ernatives where
ice designers fe
the procedure d
nts. Previous to

using conceptua
ainst them. Third
be taken initial
he first time red

ust be made on a
s. This often req

cKay Asay, Geoff

of Engineering De
nal use of specifi
vailable by which di
mpling of trend

esigned a vehic
ned with produc

w is a cycle of
duct life cycle. Th
f a product is de
t specifications t
 concepts. They
on specialists, co
uitive and creati
ncreases. Meeti
n teams. Each co
am are a produ
 ign process doe
time for team co
process.
 West competitio

m. In order to ide
gn engineers do
pts [10]. In our c
from a product
sible solutions a
e on pavement,
ll the design me
mmunication bet
d turns, allowing
because they req
ernative. Screen
l design speciali
uses relatively la
nt roller bender
ction of the fram
en used in the c
pecifications. Ma
age of any oppo

pts had already

ain benefits of vi
mposed on the
would be rotate be
here considered
s felt this linkag
ure described pr
s to the durabilit

ptual design stra

Third, design con
itially to ensure
reduces waste

on a case by cas
requires engine

eoff Carlson, Da
ng Designers. Lond
ecific clients. Th
ch discussions will b
ends in modern

ehicle for compe

duct function [2

of
e. The design is
s determined by
ons they have be
They focus effort
s, continually str
reative activity [
eeting the need
ch company mus
oduct of detaile
does not includ
m communicatio
etition. Focus wa

o identify as man
 s do not always
our case, many c
uct attribute, w
ns and incorrect
ent, not on dirt
measured up a
n between the d
wing it to spin fr
y require more i
reening matrice
cialist on the tea
ly large diamete
nder before cutti
frame/roll- cage
he competition
. Mathematical
pportunities for

ady been finaliz

of virtual design
he bearings were
tated over 180
ered as well as th
nkage was a
d previously in t
ability portion of

strategies. The
n concepts shou
ure that custom
ste in the design

y case basis. Som

gineers to becom

n, David Comsto
London: Mechani
. This consent is
will be printed with
dern design is pr

mpetition in the
n [2]. The product realization process (al

n is successful w
d by the design
e been given by
fforts on identify
y striving to imp
ity [7]. Many de
needs of every p
s was placed on

many customer
 ays participate
ny constraints w
e, which is refer
 rectly reflect co
dirt as would be
up against the sp
he designers of t
in freely. This di
ore iterations to
rices ranked a la
e team, can be s
meter tubing: 1.5
 cutting to length
cage assembly i
tion by other tea
 cal models and
s for function int

nalized. Remaini
sign is facilitatio
were calculated
80 to either sid
°

as the opinion o

in the Conceptu
n of the race, th

These strategies
hould always be
tomer needs ar
esign process.

Some principle
 ecome involved

mstock, Rogelio F
hanical Engineeri
nt is given on th
with the paper if it is
s presented, sho

the Mini-Baja W
rocess (also known as

ul when it achie
sign [4].
n by others. Gen
ntifying and me
improve design
y design conside
ry potential cus
d on meeting cu

mer needs as po
 ate in the creati
nts were impose
eferenced by nu
 t complex desig
d be required in
he specification
 of the different
is discovery allo
s to ensure a su
a large number
be seen in Figur
g: 1.5-inch diame
ngth. This soluti
bly is to protect
teams. Researc
and benchmarki
n integration. Fo

aining questions
ation of commu
 ted and the des
r side, a tradition
on of most of th

eptual Design se
e, the vehicle w

egies require tha

s be reviewed to
s are understoo
s.

iples apply to al
ved with marke

lio Flores, Brett

eering Publication
n the condition,
if it is published in S
, showcasing so

aja West compe

wn as total

chieves a balanc
Generally, they
 meeting custom
signs. Continuou
siderations requ
customer is diffi
g customer need

s possible, team
 eation of the sp
posed by the det
y number. It is im
 esign issues [10
d in the race. W
tion indicated ro
 rent systems. Th
allowed a low-c
a successful com
mber of concepts
gure 2. Manufa
ameter, .035-in
olution not only
tect the driver in
earch and analy
 arking were use
n. For instance, t

tions included su
mmunication bet
 desired life to fa
itional circular s
of the potential d

gn section. A bic
e was 5 overall,
th

that a range of
ed to prevent po
stood by all invo
o all processes,
arketing and ma

rett Hassell, Rya

ations; 1985.
tion, however, th
d in SAE Transaction
g some methodo

mpetition spons
lance between
hey design insid
stomer needs b
nuous improvem
require the use
difficult, since t
needs by giving

eam members i
e specification,
detailed requir
is important th
 [10]. The young
e. While the veh
d roughly how w
s. The decisions
w-cost solid axl
composite desig
epts, judging ea
nufacturing engi
5-inch wall thick
only eliminates t
er in the event o
nalysis was perfo
 used to
ce, the drive axl

ed such details a
 to failure was
lar style was chod
tial drivers. As a

bicycle brake c
rall, and before

e of concepts be
nt poor designs f
nvolved in the d
ses, and can be u
manufacturing

Ryan Hubbard,
er, that the copie
ctions. For permissio
hodologies that

onsored by SAE
een
nside their know
ds before optim
vement in desig
use of subjective
ce the needs of
ing the multidis

ers interviewed
on,
quirements of th
t that specificati
oung BYU design
vehicle perform
ow well the vehi
 ons of one sub-t
d axle to be used
design.
g each to be bett
engineers were
hickness, 4130
tes the need for
ent of a rollover,
performed to ide
e axle incorporat

ils as, “What be

as decided. Bear
s chosen, as opp
As a result, the s

ke cable was use

ore the failure,

ts be considered
gns from being im
he design. Desig
be used to help
ring activities. To

ard, Scott Johnso

opier pay a $7.0
mission to publish th
hat facilitate eff

SAE. Mini-Baja i
nowledge base,
timizing design
esign is desirab
ctive judgement
s of individual c
tidisciplinary tea

wed previous rac

 sign team was n
ormed well on p
vehicle would do
 ub-team affecte
used in place of

better than, eq
ere excited abou
130 alloy steel. T
d for local bends
ver, so it would
o identify the str
orates an inboa

t bearings shoul
Bearings were th
opposed to a bu
he steering whe

s used as the lin

ure, it was on tra

ered and compa

ng implemented
Designers who ta
help identify are
s. Tools, such as

hnson, Barry Lew

$7.00 per article
sh this paper in full
e effective desig

aja is an intercol
ase, not conside
 ign parameters
rable since an “
ment. Because o
ual customers oft
was no exception
on pavement, it
d do in its mark
ected the decisi
e of the differen

, equal, or wors
about the
el. The tubing is
 nds; it provides
ould be natural t
e strengths and
board disk brak

hould be used o
re then selected
a butterfly or ¾
wheel performe

e link because th
n track to win th

mpared with crit

nted.
ho take the time
y areas in which
h as concept se

y Lewis, Benjami
full or in part, cont
sidering a broad
ters.
an “optimum” d
se of this, optim
s often vary and
 tion. Some team
nt, it did not do a
market—the com
ecisions of anoth
rential without

worse than a ben

ng is much lighte
des aesthetic ap
ral to include it
and weaknesses
brake and acts a

ed on the front w
cted using the s
or ¾ circle. Two d
rmed very well,

se that was the fi

 n the overall ev

h criteria identifi

time to understa
hich to make imp
t selection matr

amin Pack, Kevi

contact the SAE Pub
m” design is nev
ptimization tech
and may even c
team members
do as well in the
competition. Co
nother. Constan
out eliminating

benchmark con
ghter and stiffer
tic appeal, provid
e it as a primary
sses of each des
ts as a suspensi

ont wheels?” “W
he selection pro
wo diameters w
well, and was co

he first reasona
l event. These r

ntified by marke

erstand custome
improvements
matrices and cus

Kevin Paulson, J
E Publications Group
never possible i
echniques may
en change over
 ers felt the crea
n the off-road ac
n. Confidence in
 stant communic
ting the benefits

concept when e
tiffer than other
 ovides more roo
mary judging crit
design. The scr
 procedures reco
rs were readily a
s comfortable fo

onable concept
se results are re

arket research.

omer needs will

ents for each cas
 customer-focus

on, Josh Thurber

Group.
ble in a dynamic
may create a fals
over time. A succ
creation of the p
d acceleration c
e in a product re
unication was re
efits

hen evaluated ag
her options, ma
e room for the d
criterion. Howe
screening and s
 recommended
dily available: 25
le for all of the d

cept the designe

e remarkable co

ch.

will be able to s
h case.
ocused specifica

rber, and Brent

mic marketplac
false sense of s
successful prod
he product spec
on contest beca
ct requires both
making it diffic
he driver and po
owever, rollove
nd scoring matr
ded by the beari
e: 25 cm (10 in.)
he drivers.

igners thought o
le considering n

to screen out po
ifications, help e

ent Zollinger.
place.
of security, sinc
roduct must no
specification wa
because there w
both that the pro
ifficult to bend i
d powertrain co
over protection
matrices enabled
since they often
t not just meet t
 was just a hoop
e was not ampl
e product
nd in
n components, a
tion is included
bled the design
 ften ignore or in
eet the needs co
nts, and lightens
ded in the "conf
signs to be evalu
 or inaccurately r
ds common to m