Page 1

A Users 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?

Market Analysis Leverage IP New Product Development

Product Improvement

Risk Management

Page 5

Innovation Activities
Market Analysis New Product Development Product Improvement Risk Management 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

THE MAIN EVENT

My Background with Invention Machine & TRIZ

Ingersoll-Rand Power Tools, 1989 - 1998

Dade Behring, 1998 - 2004

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
Medical diagnostics blood analysis company Formerly DuPont Medical Products, now Siemens Diagnostics 3 years as a combustion Design Engineer Introduced TRIZ and Goldfire to engineers, scientists and IP personnel 1.5 years for Solar Technologies

GE Energy, 2004 - 2009

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!!!
11

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.

12

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 teams 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.
13

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.

Results: 28 Patent Disclosures at Gas Turbine & 3 at Solar: in less than 4 years
16

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.

17

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

19

Knowledge Based Problem Solving

Six S igma Value Engineering

TRIZ
FMEA DOE Robust Design Computer Modeling DFMA Concept Concept Development Development

Tool Effectiveness

Innovation Labs Market Research QFD

Trial & E rror Brainstorming 6 Hats Morphological Analysis Osborns C hecklists

Axiomatic Design Definition Definition Problem Problem Formulation Formulation

Concept Concept Ideation Ideation

Design Design

Stages of Product Development

Goldfire is the most complete TRIZ tool available.

Impact of TRIZ on an organization

21

The Problem Statement

Analysis Approach to Current Solution Road Blocks: Define your Roadblocks based on 5Ws and H. Answer the 6 basic questions of journalism:
1.

2.
3.

Who? What? When?

4.
5. 6.

Where? Why? How?

ENGINEERING Who has the problem? What does the problem seem to be? What are the resources? When does the problem occur? All the time? Under certain circumstances? Where does the problem occur? Why does the problem occur? How does the problem occur?

22

The Problem Statement Asking Why5

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

For example...
1. 2. 3. 4. 5. Why has the machine stopped? A fuse blew because of an overload Why was there an overload? There wasn't enough lubrication for the bearings Why wasn't there enough lubrication? The pump wasn't pumping enough Why wasn't lubricant being pumped? The pump shaft was vibrating due to damaged impeller Why was the impeller damaged? Chips of foreign material entered into the pump

Problem Statement: Foreign material chips are damaging the pump impeller.
23

Problem Definition to Solving the Problem

1) Define the problem
List all requirements and constraints We want this but we cant because of this. We get this because of this.

5) Determine Contradictions
Technical or Physical contradictions

6) Determine Input Parameters

Use 2 of 39 or other parameters

2) Create Ideal Final Result (IFR)

Eliminate the deficiencies Preserve the advantages Not more complicated No new disadvantages

7) Physical or Technical Contradiction

Convert between the two contradictions If Technical then use Contradiction Matrix

8) Determine General Solution

Use 40 Inventive Principles

3) Determine the differences

Compare original system with IFR

9) Examine Solutions
Convert generic solutions to specific Does solution increase Ideality? No go to step 5 Does solution solve the problem? Yes IMPLEMENT
24

4) Create Ideality Equation

List differences as Benefit, Cost, Harmful

Typical Goldfire Project Focus:

Reduce part cost Reduce size Reduce temperature Reduce weight Increase speed Reduce assembly

More efficient
Improve alignment

time Increase strength Reduce vibration Reduce stress/pressure Improve manufacturability

25

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, RCAs, cost savings, liability redesigns, process improvements and product enhancements.
26

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

Which parameter improves and which parameter worsens as a result?

1. Weight of moving object 15. Durability of moving object 29. Accuracy of manufacturing 30. Harmful factors acting on 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

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

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

11. Tension, pressure, stress

12. Shape 13. Stability of object 14. Strength

25. Waste of time

26. Amount of substance 27. Reliability 28. Accuracy of measurement

Select which parameter number is improving, and which is getting worse.

27

TRIZ 40 Principles
Use the Contradiction Matrix to generate ideas using the 40 Principles
1. Segmentation 2. Taking out 3. Local quality 4. Asymmetry 5. Merging 6. Universality 7. "Nested doll" 8. Anti-weight 9. Preliminary anti-action 15. Dynamics 16. Partial or excessive actions 17. Another dimension 18. Mechanical vibration 19. Periodic action 20. Continuity of useful action 21. Skipping 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

22. "Turn Lemons into Lemonade"

23. Feedback 24. 'Intermediary' 25. Self-service 26. Copying 27. Cheap short-living objects

36. Phase transitions

37. Thermal expansion 38. Strong oxidants 39. Inert atmosphere

10. Preliminary action

11. Beforehand cushioning 12. Equipotentiality 13. 'The other way round'

40. Composite materials

14. Spheroidality - Curvature

28 Mechanics substitution 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.
28

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 links relationships 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 and Project 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 daily problem solving?
10-20% of Research analysis and problem solving could = $millions per year

29

Analyze the Problem Functional Analysis

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 and how is it being controlled? Are the actions: Useful? Harmful?
Silicone Bonding Agent Aluminum Skin

Ice Necessary? Adequate? Inadequate? Where are there idle resources?

Space Shuttle Surface Tile

Space Shuttle Tile Functional Diagram

Reentry Air
30

Function Model Goal and Objective

Function Models will become much more important as groups start to focus on cost savings, value analysis, and how to make improvements to existing systems. Function models can also be created for your competitors parts/designs and used to compare as well as understand competitive differences. Functions (components) are listed in flow diagram form (or table form) then both good and bad relationships (action words) are linked between those functions. Once Function Models are created in Goldfire, it can then start to evaluate functions for being most valuable and least valuable. The whole 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.

31

GOLDFIRE INNOVATOR

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 further consideration Identify critical paths Device Analysis Analyze a systems 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
32

Todays RCA Situation without Goldfire

Without a structured software process: The loudest speaking person in the room drives the direction and action of what he perceives to be the important issues. Often times solving the wrong problem or missing the root cause 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 problem solving to occur. True even if you dont use Goldfire.
33

RECOMMENDATIONS

Recommendations
Implement Goldfire innovation software Lunch-n-Learns

Find and use Champions & successes to spread the word

Break problems down to functions and list relationships

between components Conduct more internal specific Function Modeling related training and/or from Invention Machine Create detailed function models & accurate component interactions: 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 problem component
35

APPENDIX

powers Electricity (in) powers add mass moves arm turns on powers signals powers signals drives exposes x-ray generator

X-Ray Machine

Displayed for GE Healthcare signals computer drives bed moves signal signal displays saves digitizes protects protects supports

views

patient

shield Image (out)

37

Advanced Cycle Sink

Temperature Sets

Advanced Cycle Electricity

Advanced Cycle Fuel

Advanced Cycle Air

heats Produces Compress

Gas Turbine
Gets Burned In Flows Through InFlows Generator 2

Burns Produces

Directs

Heats

Contains Produces Limits Contains

Spins

Mix

Spins HRSG Heats Gas Turbine 2 Generator 1 Produces Spins Generator 3 Spins drains

Heats

Directs

Burns

Mix Spins

Heats

Steam Spins

Spins Steam Turbine

Compress

Drains

Control

Control Stabilizes Gas Turbine 1 Add Flexibility Accessories

solder

protects polarizes light (in)

welded decreases oxidizes drains produces voltage output (out)

glass

filters transmission

holds

protects

difficult to attach wire welded silicon chip

does not stick holds

Solar Cell
adhesive

reduces speed held by drill bit wears slips centers vibrates loads chuck loads supports increases speed reduces speed

Harmful Action

vibrates

heats gear pack vibrates creates torque spins encloses dc motor supposrts handle

heats powers

supports drains weights down

Battery Power Tool

battery pack

Inventive Principle # 14 SpheroidalityCurvature 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 rotating movement; utilize a centrifugal force

41

Inventive Principle #35 Parameter Change Transformation of the physical or chemical states of an object
Change an object's aggregate state, density distribution, degree of flexibility, temperature

42

Invention Machine Customers

Page 43

Invention Machine Customers

With Goldfire we did 6 months worth of data analysis in 5 hours with - Technology Provider better results. Used Goldfire to develop a - Oil & Gas Enterprise new tooth whitening solution Reduced research and captured 70% of a $400Mtime by over 60%. Reduced analysis - Medical Device Maker market. time by 75%
- Auto Parts Maker
- Health & Beauty Company

Reduced component costs by 38%, which translated into $77M in savings over 3 years.

Received a patent for a new transistor design expected to generate $8M annually
- Electronics Manufacturer

Using Goldfire developed a new foam with over 40 product applications generating $21.5M.
- Chemical Producer

Page 44

REGISTER NOW: PowerToInnovate.com

Questions?

Contact Information
Web: InventionMachine.com Email Allison at: ALewis@InventionMachine.com Phone: +1.617.305.9250