THE TRIZ PROBLEM SOLVING PROCESS AND ITS APPLICATION TO HUMAN FACTORS AND USABILITY DESIGN AND...

THE TRIZ PROBLEM SOLVING PROCESS AND ITS APPLICATION TO HUMAN

FACTORS AND USABILITY DESIGN AND PROBLEM SOLVING

HFES

BALTIMORE, MDSEPTEMBER 30, 2002

INNOVATION-TRIZ,INC.

®2002 JWH Consulting and Innovation-TRIZ, Inc.

YOUR WORKSHOP LEADERS

Jack HippleInnovation-TRIZ, Inc.

Tampa, FL813-994-9999

[email protected]

Stan CaplanUsability Associates

Rochester, NY585-442-0499

[email protected]

INTRODUCTIONS, PERCEPTIONS, AND EXPECTATIONS

Experience and knowledge in human factors/ergonomics/design

as well as in the areas of innovation, creativity, and TRIZ

OBJECTIVES

Familiarize you with the concepts of TRIZ Ideality, resources, contradictions, patterns

of invention and technological evolutionChange the way you think about problemsIntroduce you to new ways to think about

contradictions in ergonomics and human factors

AGENDA

Morning (9:00-12:00) The basis, history, basics, and technical underpinnings

of TRIZ The basic concepts of operators, ideality, and resources Contradictions, contradiction table, and separation

principles Application to product and workplace design problems

Afternoon (1:00-4:30) Breakout sessions for TRIZ applications to design

problems Patterns of invention and “reverse” TRIZ for failure

prediction

An Six Hats and Lateral Thinking are trademarks of the Edward DeBono organization

BASICS OF OTHER TOOLS

Psychology more than technology DeBono, Lateral Thinking/Six Hats™, CPS Can discuss integration if interested

Randomness Brainstorming, picture, etc. stimulation Can review how to integrate if interested

Highly dependent upon facilitation skills Fine for simple problems Can be easily learned Limited by knowledge in the room--TRIZ is the only

innovation tool which uses the patterns of invention OUTSIDE the room as well

WHAT TO USE TRIZ FOR

Level 2-4 problems 1--straightforward engineering design 2--simple contradictions 3--difficult design and manufacturing

contradictions 4--extremely difficult system design

problems (“intestine problems”) 5--invention of new science

Level 4 can require looking at hundreds of thousands of potential solutions and take many years of effort within an organization

THE OUTPUT OF THE PROCESS

Generates solution paths and concepts of solution, NOT engineering drawings and detail

A better, more clearly defined problem and project

New and nearly exhaustive set of solution concepts

LET’S BENCHMARK….

The New Machine

BENCHMARK--THE NEW MACHINE

MACHINE REPLACES MANWHAT IS IDEALITY?

A robot was brought to a plant to operate a machine. After it wasrigged up and switched on, the elderly worker who had operated themachine for years was amazed at seeing the nimble “iron man”performing all the necessary steps.

A half an hour later, however, the robot came to a standstill, to thebewilderment of the service team of electronic engineers. Whathappened? As it turned out, some chips had fallen from theworkpiece into the moving elements of the machine. This situationwhere a human worker would simply flip the chips away with abroom and continue working brought the robot to a deadlock. Theengineers cleaned the machine with a broom, switched on therobot…only to see the robot stop again. How could this problem besolved? Source: TRIZ: The Right Solution at the Right Time, p3, Used by permission

WHAT IS “TRIZ” ?

A Russian acronym:Theoria Resheneyva Isobretatelskehuh

Zadach

(Theory of Solving Problems Inventively)

WHAT IS “TRIZ” ?

A way of thinkingA family of tools, tool kits, and

software

The “way of thinking” can ALWAYS be used, but the tools in the tool kit can be selected depending the nature of the problem, time available, etc.

THE HISTORY OF TRIZ A discovery of a talented patent examiner for the Russian

navy, Genrich Altshuller, 1950’s Originated from the study of several hundred thousand of

the world’s most inventive patents--now in the millions He recognized that the development of technological

systems follows predictable patterns that cut across ALL areas of technology--the speed of technical evolution can be accelerated

Also recognized that problem solving principles are also predictable and repeatable--anyone can invent!

Established schools to teach after a Stalin 7 yr. prison term--deceased in 1999 at age 71

BASIC CONCEPTS

Systems evolve toward IDEALITY irreversibly

Using RESOURCES within the system or easily convertible

Resolving CONTRADICTIONS as they evolve

PATTERNS OF INVENTIONS/OPERATORS are constantly recognized and used

THINKING OUTSIDE YOUR PARADIGM

SPACE

TIME

POSSIBLE

IMPOSSIBLE

EVENTS AND EXPERIENCES SHAPE OUR BELIEF SYSTEM!!!

MechanicalEffects &

Technology

Electrical &Magnetic Effects

& Technology

Chemical Effects& Technology

Thermo-Dynamics

P roblem

S olution

THE SOLUTION SPACETHE SOLUTION SPACE

®Ideation International, used by permission

TAPPING OUR KNOWLEDGE

All Science

INDUSTRY

COMPANY

PERSONAL

1

2

3

4

5

All That

Is Knowable

NOTE: BRAINSTORMING, ETC. FOCUS ONLY ON USING THE INNER AREA MORE EFFECTIVELY

THE CHEMICAL ENGINEER’S VIEW...

How does a centrifuge work?

THE BAKER’S VIEW

The Waissenberg Effect

When the motion of certain liquids is altered, the liquid achieves a highly plastic state. This state is caused by stress which is normal to the plane of the altered motion. For example, if a rotating shaft emerges from a pool of liquid, the liquid will rise along the shaft. This effect is observed in solutions, in molten polymers, and in gels of low molecular weight. The effect is used to develop extruders that do not use spiral impellers. A characteristic of this effect is that, as the speed of motion increases, the stability of the flow decreases


PARALLEL UNIVERSES

Many other industries or technologies face the same type of problems in a generic sense

It’s almost impossible to follow all areas of technology, read all literature, go to all meetings

Accidents or alerts sometimes change this, but it is normally not proactive in most organizations

In the most efficient problem solving, it is helpful to be aware of problem solving principles used by everyone

WHY IS THIS IMPORTANT?

Let’s take a look at two examples…..


AN OPERATOR

Operator Example

Specific problem Specialized solution 3x2+5x+2 = 0 x = ????

ALGEBRA DOES NOT EXIST!!

AN OPERATOR

Operator Example

Specific problem Specialized solution 3x2+5x+2 = 0 x= -1, -2/3

Trial and Error!!

AN OPERATOR--THE BASIC PRINCIPLE OF TRIZ

Operator ExampleAbstract problem Abstract solutionax2+bx+c = 0 x=(-b+/-b2-4ac )/2a

Specific problem Specialized solution3x2+5x+2 = 0 x= -1, -2/3

TRIZ DOES FOR PROBLEM SOLVING AND FORECASTING WHAT ALGEBRA DOES FOR

EQUATION PROBLEM SOLVING

I HAVE TO REMOVE CORES FROM A MILLION

GREEN PEPPERS….

How would I do this?


Processing Sweet PeppersProcessing Sweet Peppers

PATTERNS OF INVENTIONPATTERNS OF INVENTION


WHAT IS THE OPERATOR?

“Slowly raise pressure and suddenly reduce it” OR “accumulate energy and release it”

A path to a solutionAn approach to solving a problemA direction towards an answer

• Removing stems from bell peppersRemoving stems from bell peppers

• Removing shells form sunflower Removing shells form sunflower seedsseeds

• Cleaning filtersCleaning filters

• Unpacking parts wrapped in Unpacking parts wrapped in protective paperprotective paper

• Splitting diamonds along micro-Splitting diamonds along micro-crackscracks

• Producing sugar powder from sugar Producing sugar powder from sugar crystalscrystals

• Explosive depulpingExplosive depulping


• Removing stems from bell peppersRemoving stems from bell peppers

• Removing shells form sunflower seedsRemoving shells form sunflower seeds

• Cleaning filtersCleaning filters

• Unpacking parts wrapped in protective Unpacking parts wrapped in protective paperpaper

• Splitting diamonds along micro-cracksSplitting diamonds along micro-cracks

(+27 years after pepper patent)(+27 years after pepper patent)

• Producing sugar powder from sugar crystalsProducing sugar powder from sugar crystals

• Explosive depulpingExplosive depulping


123

56789

n

4

123456789

n

ToCorresponding

Solutions

ManyTypical

Problems

Many TypicalRecommendations

forSolutions

(Knowledge base)

A large number of typical problems are available for considerationTRIZ help to marrow the search to a manageable range of typical problemsFor each typical problem, there are one or more potential solutions

Prismof TRIZ -Analytical

tools


WHAT WOULD YOU HAVE TO RECOGNIZE TO BE ABLE TO

TRANSFER THE PEPPER TECHNOLOLGY TO

INDUSTRIAL GRINDING DIAMONDS?


“DEFALCATION”

Does anyone know what this word means?

“The purpose is to reduce/eliminate defalcation

when criminals use false ID to impersonate real customers”

GENERICIZING OUR LANGUAGE

Defalcation•Fraud

–Substitution of one thing for another

Useful in internal communication, but a barrier to problem solving!

HUMAN FACTORS AND ERGONOMICS JARGON

Dialogue boxModalUser-centricTouch pointsFunctional obviousnessGUIMental model

AdductionAbductionRSIPopulation stereotypesPoplitealScotopicClo unitSagittal plane

THE BOTTOM LINE...

MOST PROBLEMS THAT WE SOLVE AND MOST PATHS OF EVOLUTION OF TECHNICAL SYSTEMS ARE

ALREADY KNOWN----THIS IS A MAJOR PSYCHOLOGICAL BARRIER

WHAT WE HAVE TO DO IS TO RECOGNIZE OTHERS’ PROBLEMS AND TECHNOLIGIES IN GENERIC FORM

(IN DISGUISE?)

SOME PEOPLE MAKE A CAREER OUT OF MAKING THEIR PROBLEM SEEM TRULY UNIQE

TRIZ IS BOTH A MENTAL PROCESS AND A SCIENCE, AS WELL AS A SELECTION OF TOOLS IN A TOOL KIT

THE PROBLEM SOLVING PROCESS (ALGORITHM)

Envision and state ideality or the ideal final result

What are the barriers and contradictions?

What are the resources that can be used?

Develop a model of achieving ideality

THE TOOLS IN THE TOOL KIT

Ideal Final Result/Ideality (IFR)ResourcesContradictions, contradiction table, and

separation principlesLines and patterns of evolutionReverse TRIZARIZSoftware

IDEALITY AND RESOURCES

THE BASIC TRIZ PRINCIPLES THAT UNDERLIE SYSTEM EVOLUTION AND

PATTERNS OF PROBLEM SOLVING


The ideal system performs a required function without actually existing. The function is often performed using existing resources. ALL systems evolve in this direction over time by resolving contradictions.

Ideality

= All Useful FunctionsAll Harmful Functions

WHAT IS IDEALITY?WHAT IS IDEALITY?

®Ideation International--used by permission

CHAMBER DESTRUCTION PROBLEM

Container

Acid

Specimen

DRAW A PICTURE OF IDEALITY--DON’T SOLVE

THE PROBLEM (YET)!

HANDOUT


Acid

Specimen


RESOURCES

Another fundamental TRIZ concept--it’s how we get a system

to ideality

What resources did you use in the corrosion problem?

HANDOUT


Acid

Specimen/Container


LET’S LOOK AT WHAT WE DID

Eliminated what was not functional (the chamber was not really necessary)

Used the resources of the system at hand (more later on this topic)

Used geometric effects as resources Used physical effects

fluidity of acid gravity

EXAMPLES OF ERGONOMIC AND HUMAN FACTOR IDEALITY

The machine recognizes the user and instructs and/or orients automatically

The pedal adjusts automatically to the user

HOW DO WE GET TO IDEALITY?

TRIZ provides two general approaches for achieving close-to-ideal solutions (that is, solutions which do not increase system complexity): Use of resources Use of physical, chemical, geometrical

and other effects (remember the Waissenberg effect?)

-

WHAT’S A RESOURCE FROM A TRIZ PERSPECTIVE?

A resource: is any substance (including waste)

available in the system or its environment

has the functional and technological ability to jointly perform additional functions

is an energy reserve, free time, unoccupied space, information, etc.

RESOURCES -- WIRE EXAMPLE

Problem Zone

Copper Wire

AirVoltage

& Current


HANDOUT

IMMEDIATELY AVAILABLE RESOURCES

WireCurrentVoltageAir

CopperContaminates Type AmountDiameterLengthShape of wireAmountForm of excitation signal (A/C)FrequencyAmountForm of excitation signal (A/C)FrequencyHydrogenOxygenNitrogenCarbonTemperature, Pressure, Velocity, Speed

®Ideation International-used by permission

DERIVATIVE RESOURCES -- WIRE EXAMPLE

WireCurrentVoltageAir

CopperContaminates Type AmountDiameterLengthShape of wireAmountForm of excitation signal (A/C)FrequencyAmountForm of excitation signal (A/C)FrequencyHydrogenOxygenNitrogenCarbonTemperaturePressure, Velocity, Speed

Resistance

Magnetic Field

Oxidation

Moisture

CO/CO2

Cooling/Heat Dissipation


RESOURCE CHECKLIST

SubstancesFieldsSpaceTimeInformationFunctional

SYSTEM RESOURCES

When a system’s resources are depleted, it will probably be replaced

Tracking system resources is a good way to predict when a system may be replaced, challenged, or significantly modified

Sometimes it’s a matter of just seeing the resource, other times it’s a matter of figuring out how to use it (ex: field and information generation, Navy example)

SOLVING A CONTACT LENS PROBLEM

Space resources

from the perspective of a contact lens manufacturer

from the standpoint of a semi-conductor manufacturer

IDEALITY AND RESOURCES

LET’S REVISIT THE NEW MACHINE PROBLEM

A SYSTEM EVOLVES….

ANOTHER REAL CASE STUDY…..


PILL MANUFACTURING

Situation: A pill manufacturer is faced with a need for cost reduction. A labor reduction is required to stay competitive. Engineering has evaluated the manufacturing process and determined that by eliminating three inspectors at the end of the production line they can justify an investment of $150,000 for a video inspection system. These inspectors are checking for chip damage at on the circumference of the pills (see attached sketch). Efforts to correct the damage to the pills during production has been going on for years. There are 15 stages of manufacturing and each has been optimized to less than 1% of scrap which exceeds industry standards. The video inspection system will provide a 33% return on investment which meets management’s financial criteria. Unfortunately, money is tight and management has hired your company to find a lower cost solution. (See attached layout of inspection area)

Objective: Find a nearly ideal solution -- the function is performed without the system.

Strategy: Apply TRIZ to solve the problem using the concept of ideality, existing resources and physical, chemical and geometric effects.

Actions: Define the function and the system. Define the problem in terms of ideality, i.e., what should happen? What are the resources and physical, chemical and geometric effects that are readily available? Find a solution to the problem.

® Ideation International--used by permission

Vibratory feed move pills around an internal spiral to top of vibratory bowl where the pills are discharge and slide down an incline plane onto a conveyor. As the pills go by, the inspectors identify and remove the damaged pills.

Damaged Pills

Conveyor

Trash Can

PILL INSPECTION WORKSTATION


SYSTEM PROPOSAL AND CHALLENGE

Replace inspectors with a $200K video inspection system

High return project, but capital is not available

Boss says, that’s a great idea, but “Find another way!!”

GOOD PILLS/BAD PILLS

What is IDEALITY?

What are the RESOURCES we have?

Vibratory feed move pills around an internal spiral to top of vibratory bowl where the pills are discharge and slide down an incline plane onto a conveyor. As the pills go by, the inspectors identify and remove the damaged pills.

Damaged Pills

Conveyor

Trash Can

PILL INSPECTION WORKSTATION


An Elegant Solution: The Pill Inspects Itself

Trash Can

Change the escapement for the vibratory bowl so that the pills are ejected standing on their edge. Move the conveyor 3 inches. Pills that are round will roll at a velocity that allows them to jump to the conveyor. The pills that are chipped will slide or will roll at a lower velocity and fall into the trash.

Resource: Velocity of the sliding or rolling pills

Function (inspection of pills) is performed without the system (human inspectors or video

inspection system).


LET’S THINK ABOUT OTHER SYSTEMS….

Grocery checkoutCar washesSelf-collecting toll boothsYogurt containersCoffee holders in cars

HF/E impact of these changes?

ONE MORE PROBLEM….

THE REPACKAGING PROBLEM AND ITS ERGONOMIC ISSUES

THE REPACKAGING CHALLENGE

A repackaging operation is being carried out in the US. A pack of 10 bags, which will expand easily, comes wrapped in a rubber band. The rubber band is removed and then an operator grabs the bags and stuffs them into a final container for sale. Very labor intensive and prone to hand injury--what can be done?

PAUSE…..

Q/A on Concepts so far…Ideality, Resources, and Operators

.

Contradictions/SeparationPrinciples-

One of the Most Powerful Parts of the

TRIZ Methodology

SECONDARY PROBLEMS--ONE OF THE KEYS TO BREAKTHROUGH INVENTIONS

“That’s a good idea, but………

“The ideal solution would be….., but I can’t achieve it because….

“I improve the system, but then this happens….

SECONDARY PROBLEMS

May be the key to an invention Quickest route to stop a new idea, BUT secondary

problems may be easier to solve than the primary problem--we stop too early

May be key to adoption of new technology or the use of a new process or piece of equipment

The way we normally deal with secondary problems and contradictions: Live with it, design around it (“intestine problems”) Abandon the idea Eliminate (resolve) it (takes a change in attitude as

well as techniques)

EXAMPLES OF CONTRADICTIONS

Weight vs. strength Speed and weight vs. fuel economy Vision accuracy vs. distance Organizational structure vs. entrepreneurial

climate Food that tastes good vs. good for you Open office space vs. quiet Accessibility vs. security and safety “Voice of the customer” vs. radical innovation Security vs. easy access

EXAMPLE

Example: Aircraft cabin design--legroom vs.

number of seats

HOW DO WE RESOLVE AND HANDLE CONTRADICTIONS?

(GROUP INPUT)

THE CONTRADICTION TABLE

The first organized form of TRIZA little bulky and unwieldy without

computerization, but still useful in quick and dirty screening for solutions

Computerized in software products, available on line at various web sites, in many publications

Applies to technical contradictions

Productivity

Level ofAutomation

Weight ofMoving Object

Weight ofNonmoving Object

1

2

39

38

Undesired Result (Degraded Feature)

Featureto Improve

• Possible contradictions Possible contradictions represented in 39 x 39 represented in 39 x 39 tabletable

• Intersections of Intersections of contradicting rows and contradicting rows and columns are references to columns are references to 40 inventive principles for 40 inventive principles for contradiction eliminationcontradiction elimination

28 Replace a mechanical system with a non mechanical system27 An inexpensive short-life object instead of an expensive durable one18 Mechanical vibration40 Composite materials

28 Replace a mechanical system with a non mechanical system27 An inexpensive short-life object instead of an expensive durable one18 Mechanical vibration40 Composite materials

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Proposed Solution Pathways:

CONTRADICTION TABLECONTRADICTION TABLE


SEPARATION PRINCIPLES FOR PHYSICAL CONTRADICTIONS

(PARAMETERS OF A SYSTEM IN CONFLICT)


TechnicalContradiction

Control Parameter, C

PhysicalContradiction

C should be high, andC should be low

So:

A B

CONTRADICTIONSCONTRADICTIONS

®Ideation International

• A characteristic must be higher A characteristic must be higher andand lower lower (self-opposing)(self-opposing)

• Example: An airplane wing should have large Example: An airplane wing should have large area for easy takeoff but small area for higher area for easy takeoff but small area for higher speedspeed

• Example: A pen tip should be sharp to draw Example: A pen tip should be sharp to draw fine lines, but blunt to avoid tearing the paperfine lines, but blunt to avoid tearing the paper

• A characteristic must be present A characteristic must be present andand absent absent

• Example: For sandblasting the abrasive must Example: For sandblasting the abrasive must be present (to abrade) but is not wanted on (or be present (to abrade) but is not wanted on (or in) the productin) the product

• Example: Aircraft landing gear are needed for Example: Aircraft landing gear are needed for landing but undesired in flightlanding but undesired in flight

PHYSICAL CONTRADICTIONPHYSICAL CONTRADICTION


PLATING METAL PARTSPLATING METAL PARTS

• To plate metal parts with nickel To plate metal parts with nickel they were placed in a bath of they were placed in a bath of nickel salt. The bath was heated nickel salt. The bath was heated to increase the productivity of to increase the productivity of the process. However, heating the process. However, heating reduced the stability of the salt reduced the stability of the salt solution and it started to solution and it started to decompose.decompose.


CONTRADICTIONS...

Functional?

Physical?

• Technical ContradictionTechnical Contradiction

• Heating increases productivity (A), but wastes Heating increases productivity (A), but wastes material (B)material (B)

• Control parameter is temperatureControl parameter is temperature• Physical ContradictionPhysical Contradiction

• Temperature (C) should be high to increase Temperature (C) should be high to increase productivity and low to avoid wasteproductivity and low to avoid waste

A B

Control Parameter, C

CONVERTING TECHNICAL CONVERTING TECHNICAL CONTRADICTIONS TO CONTRADICTIONS TO PHYSICAL CONTRADICTIONSPHYSICAL CONTRADICTIONS


• TRIZ seeks to eliminate the TRIZ seeks to eliminate the physical contradiction by physical contradiction by separating the two separating the two contradictory requirementscontradictory requirements

•Separation in spaceSeparation in space•Separation in timeSeparation in time•Separation between the parts Separation between the parts

and the wholeand the whole•Separation upon conditionSeparation upon condition

PRINCIPLES OF SEPARATIONPRINCIPLES OF SEPARATION

• A characteristic is made larger at one time and A characteristic is made larger at one time and smaller at anothersmaller at another

• A characteristic is present at one time and absent A characteristic is present at one time and absent at anotherat another

• Example: Concrete piles must be pointed for easy Example: Concrete piles must be pointed for easy driving but not pointed to support a load. The piles driving but not pointed to support a load. The piles are made with pointed tips which are destroyed are made with pointed tips which are destroyed after driving, via an embedded explosive.after driving, via an embedded explosive.

• Example: Aircraft wings are longer for takeoff, and Example: Aircraft wings are longer for takeoff, and then pivot back for high speed flight.then pivot back for high speed flight.

• Example: Consider the problem of sand Example: Consider the problem of sand accumulation with abrasive sandblasting. An accumulation with abrasive sandblasting. An effective solution is to use dry ice chips as the effective solution is to use dry ice chips as the abrasive. After abrading, the chips will simply abrasive. After abrading, the chips will simply disappear by sublimation.disappear by sublimation.

SEPARATION IN TIMESEPARATION IN TIME


• A characteristic is made larger in A characteristic is made larger in one place and smaller in anotherone place and smaller in another

• A characteristic is present in one A characteristic is present in one place and absent in anotherplace and absent in another

• Example: Submarines which pull Example: Submarines which pull sonar detectors drag the detectors sonar detectors drag the detectors at the end of several thousand feet at the end of several thousand feet of cable to separate the detector of cable to separate the detector from the noise of the submarinefrom the noise of the submarine

• Example: Bifocal glassesExample: Bifocal glasses

SEPARATION IN SPACESEPARATION IN SPACE


• A characteristic has one value at the A characteristic has one value at the system level and the opposite value system level and the opposite value at the component levelat the component level

• A characteristic exists at the system A characteristic exists at the system level but not at the component level level but not at the component level (or vice versa)(or vice versa)

• Example: A bicycle chain is rigid at the Example: A bicycle chain is rigid at the micro-level for strength, and flexible at micro-level for strength, and flexible at the macro-level.the macro-level.

• Example: Epoxy resin and hardener are Example: Epoxy resin and hardener are liquid until mixed, then they solidify.liquid until mixed, then they solidify.

SEPARATION BETWEEN PARTS SEPARATION BETWEEN PARTS AND THE WHOLEAND THE WHOLE


• Example: A business should Example: A business should be large and smallbe large and small

•Large for profits and resourcesLarge for profits and resources•Small for flexibilitySmall for flexibility

• Solution: Formation of a Solution: Formation of a conglomerate of small conglomerate of small independent organizations independent organizations under one umbrellaunder one umbrella

A “SOFT” EXAMPLEA “SOFT” EXAMPLE


• A characteristic is high under one condition A characteristic is high under one condition and low under anotherand low under another

• A characteristic is present under one A characteristic is present under one condition and absent under anothercondition and absent under another

• Example: A kitchen sieve is porous with Example: A kitchen sieve is porous with regard to water and solid with regard to regard to water and solid with regard to food.food.

• Example: Water is “soft if entered at a low Example: Water is “soft if entered at a low speed. However, it one jumps into the speed. However, it one jumps into the same water from a height of 10 meters, same water from a height of 10 meters, the water feels considerably harder. the water feels considerably harder. Thus, the speed of the body’s interaction Thus, the speed of the body’s interaction with the water is the condition to be with the water is the condition to be considered when applying this principleconsidered when applying this principle..

SEPARATION UPON CONDITION


Which separation principle was used to solve the plating

solution problem and what was the design concept?

PLATING METAL PARTSPLATING METAL PARTS

• To plate metal parts with nickel To plate metal parts with nickel they were placed in a bath of they were placed in a bath of nickel salt. The bath was heated nickel salt. The bath was heated to increase the productivity of to increase the productivity of the process. However, heating the process. However, heating reduced the stability of the salt reduced the stability of the salt solution and it started to solution and it started to decompose.decompose.


• In the nickel plating of parts, In the nickel plating of parts, increased temperature is increased temperature is necessary only in proximity to necessary only in proximity to the parts. To accomplish this, the parts. To accomplish this, the parts themselves may be the parts themselves may be heated, rather than the solution.heated, rather than the solution.

®Ideation International-

SEPARATION IN SPACESEPARATION IN SPACE

Intersecting Highways

Two major highways are proposed to intersect. Traffic cannot flow on both highways without conflict.

State the technical contradiction:

State as a physical contradiction:

?


Separation in space:

Separation in time:

Over/under pass

Stoplight or rush hour directional control


Separation by Parts:

Rotary or highways merge and crossover


Separation upon Condition:

Drawbridge or access control such as gates, or possibly stoplights.

OTHER EXAMPLES

I want my children to be able to color, but I don’t want them to color on the walls…….I want shorts in summer and jeans in winter--in the same piece of clothingMattress design to accommodate different firmness preferencesWater filled weight lifting bars which can be packaged and then filled with water later

HANDOUT OF CONTRADICTION TABLE AND DEMONSTRATION OF

USE

OTHER EXAMPLES

Energy spent vs.---- weight, length, and area of non-moving

object force, tension/pressure harmful factors complexity of device complexity of automation

APPLICATION OF SEPARATION PRINCIPLES TO ERGONOMIC

AND HUMAN FACTORS ISSUES

CASE STUDY 1

Car Seat Legroom What is ideality? What are the resources we have? Application of separation principles to

generate ideas Application of 40 inventive principles

Review of recent TRIZ Journal Publication on airplane seat design options

CASE STUDY 2

The Pill Bottle What is ideality?

From whose perspective?

What are the resources availableAre they different for adults and children?

Application of separation principles and 40 inventive principles

CASE STUDY 3

Clock RadioWhat is ideality

• From whose perspective?

What resources are usable?Use of 40 inventive principles and

separation principles

CASE STUDY 4

Control Panel Design What is ideality? From whose

perspective? What resources are available? When?

From who? Application of separation principles and

40 inventive principles

CASE STUDY 5

On-off switches vs. country and voltage What is ideality? Vs. where? What are the usable resources? What are the contradictions? From

whose perspective?

CASE STUDY 6

Fuser toner thermal burnsWhat is ideality?What are the resources we have?What are the machine and human

contradictions?

REVERSE TRIZ FOR FAILURE ANALYSIS AND PREDICTION

CLASS EXAMPLE

Checklist for this workshop

• What failures may occur?What failures may occur?

• Why failures did occur?Why failures did occur?

SystemSystemPotentialFailures

PotentialCause

FailuresFailures

REVERSE TRIZREVERSE TRIZ

REVERSE TRIZ

Formulate original problemInvert the original problemAmplify the inverted problemSearch for information and resourcesHypothesis, tests, and correction

The Russian navy, in the early years of the cold war, developed sophisticated combustion technology which allowed a ship to sail under power without a significantly visible smoke trail, making observation by airplanes or satellites very difficult. On its first trial, the ship sailed out and no visible smoke trail could be seen. As a backup precaution, a picture was taken from an airplane, the picture developed, and a smoke trail was seen in the photo. After rechecking all logistics and procedures, the trial was repeated and exactly the same smoke trail in the photo was observed.

What is your checklist for avoiding this result?

Real view Photo

SMOKE-FREE TEST SHIP

Bulk storage Received by rail car and truck, unloaded by N2

pressure or pump Distribution to process Scrubber for containment Unloading with pressure transfer (T/C) and

pump (T/T) Foam control in storage area

HAZARDOUS CHEMICAL HANDLING SYSTEM

N2

Unload

To Process

Vent

Scrubber

THE REVERSE TRIZ APPROACH

The problem: I want to prevent a leak Invert the problem: I WANT to have a leakExaggerate/amplify the inverted problem: I

WANT to have a CATASTROPHIC leak, causing MAJOR damage and public affairs impact

What RESOURCES do I need to have/cause a leak?

If I was a saboteur, how would I cause this system to leak? Hurt someone? Cause the town to be evacuated? Make our company famous in the national press?

™afd is a trademark of Ideation International

VS. OTHER PROCESSES

Compared to the HAZOP or FEMA checklist process, generates far more real possibilities, puts people in an aggressive mind set, and finds possibilities not otherwise found

Software supported Larger knowledge base Use inventive skills and thinking from traditional

TRIZ problem-solving

USES

Failure prediction for projectsFailure prediction and/or analysis for

technology developmentsFailure prediction for technology

adoptionFailure analysis for product

design/system failuresFailure analysis for product use and

application

IF I WANTED TO SABOTAGE THE TRIZ SEMINAR, I WOULD………..

GROUP EXAMPLES OF FAILURE PROBLEMS

APPLYING TRIZ AT DIFFERENT LEVELS

The principles of TRIZ can be applied at different system levels from a competitive standpoint

Need to understand what those levels are and how they might affect us

What are potential solutions at DIFFERENT levels?

Different definitions of ideality Different resources

SupersystemSupersystem

SystemSystem

SubsystemSubsystem

PastPast

PastPast

PastPast

Future

Future

Future

Present

LEVEL OF PROBLEM ATTACKLEVEL OF PROBLEM ATTACK

(NINE BOX LOOK)(NINE BOX LOOK)

FRONT LOAD THE PROCESS

“The worst sin of all is to do an excellent job at that which should not have been done at all”

NY Times, anonymous

“We never have time to do it right, but we always have time (and money!) to do it over”

Anonymous

FRONT LOADING

TRIZ problem definition will ADD to what is already defined with QFD or with other tools

Graphical representation in software packages can be a real plus

Our experience is that few people have truly thought through the problem they are trying to or were told to solve

IN CONCLUSION…...

TRIZ is both a powerful problem definition and solution tool

It changes the way we think about problems

It adds value to many other problem definition and solution tools, including QFD and Six Sigma

FINAL INSIGHTS

CHALLENGES IN USING

A disciplined process The effort is up front in defining the problem An exhaustive solution set--are you prepared

to handle and analyze? Makes everyone an innovator, not just a few Potentially seen as a threat by a few Analogic thinking training?

INSTANT TAKEAWAYS

Think in terms of ideality for ALL problems you have Use the resource checklist to assist any ideation you

are doing, regardless of its type Try the contradiction table on ergonomic contradictions Use the separation principles for ergonomic

contradictions that have a physical basis of contradiction

Try the AFD (“how” vs. “what”) for some product or system failure problem you currently have

Understand the ergonomic contradictions inherent in progressing along lines of evolution

An Introduction to:An Introduction to:

Patterns of EvolutionPatterns of EvolutionLines of EvolutionLines of Evolution

1. 1. Stages of EvolutionStages of Evolution

2. Evolution Toward Increased Ideality2. Evolution Toward Increased Ideality

3. Non-Uniform Development of Systems Elements3. Non-Uniform Development of Systems Elements

4. Evolution Toward Increased Dynamism and 4. Evolution Toward Increased Dynamism and ControllabilityControllability

5. Increased Complexity then Simplification 5. Increased Complexity then Simplification (Reduction)(Reduction)

6. Evolution with Matching and Mismatching 6. Evolution with Matching and Mismatching ComponentsComponents

7. Evolution Toward Micro-level and Increased Use of 7. Evolution Toward Micro-level and Increased Use of FieldsFields

8. Evolution Toward Decreased Human Involvement8. Evolution Toward Decreased Human Involvement

PATTERNS OF EVOLUTION OF PATTERNS OF EVOLUTION OF TECHNICAL SYSTEMSTECHNICAL SYSTEMS

INVENTIONS DRIVE NEW IDEAS--AS THEY RESOLVE CONTRADICTIONS AND

ALLOW A SYSTEM TO EVOLVE TO SOLVE THE “NEXT”

CONTRADICTION


WHEN WERE THESE TECHNOLOGIES DEVELOPED?

Aircraft with 12 wingsHelicopterCombustion engineJet enginePropellersGyroscopic auto-pilot

CASE STUDY: THE NEXT LINE

The evolution of “pointers”

Non-DynamicSystem

Non-DynamicSystem

System withChangeable

Elements

System withChangeable

Elements

System withVariable

Components

System withVariable

Components

System Changeableat the Mechanical

Level: with a Hinge,Hinge Mechanism,

Flexible Materials, etc.

System Changeableat the Mechanical

Level: with a Hinge,Hinge Mechanism,

Flexible Materials, etc.

System Changeableat the Micro-Level:

Phase Transformations,Chemical

Transformations, etc.

System Changeableat the Micro-Level:

Phase Transformations,Chemical

Transformations, etc.

Non-DynamicSystem

Non-DynamicSystem

Increasing Degrees of Freedom

Transition to Multifunctional Performance Increasing system dynamism allows functions to be performed with greater flexibility or variety

4. EVOLUTION TOWARD 4. EVOLUTION TOWARD INCREASED DYNAMICS AND INCREASED DYNAMICS AND CONTROLCONTROL


THE LINE OF SEGMENTATION

Monolith

Set of PlatesLoose Body

Paste, gel

Liquid, foam

Gas, aerosol

Plasma

Vacuum

Field

To Increase Dynamicity Consider

Provide more than one stable state Bi-stable membrane Over center clamp

Make a fixed component movable Make parts movable relative to each other

Hinge Flexible materials as links

Introduce a mobile object NOTE: All of these have different ergonomic

implications

CASE STUDY

Examples of SegmentationRigid, flexible, wave

Exercise equipment

What human factors issues arise when a system becomes more dynamic?

CLASS PROBLEM

PRELUDE TO NEXT LINE OF EVOLUTION---TRACE THE

EVOLUTION OF SUNGLASS TECHNOLOGY

• Technological systems tend to develop first Technological systems tend to develop first toward increased complexity (i.e., increased toward increased complexity (i.e., increased quantity and quality of systems functions), quantity and quality of systems functions), and then toward simplification (where the and then toward simplification (where the same or better performance is provided by same or better performance is provided by a less complex system). This may be a less complex system). This may be accomplished by transforming the system accomplished by transforming the system into a bi- or poly-system, as shown here in into a bi- or poly-system, as shown here in two of the lines of evolution related to this two of the lines of evolution related to this pattern.pattern.

Mono-systemMono-system Bi-system Improved (Simplified) Mono-system

Mono-systemMono-system Bi-system Improved (Simplified) Mono-system

Mono-systemMono-system Poly-system Improved (Simplified) Mono-system

5. INCREASED COMPLEXITY 5. INCREASED COMPLEXITY AND THEN SIMPLIFICATIONAND THEN SIMPLIFICATION


Remember the New Machine?

CASE STUDY: THE NEXT LINE

The evolution of photographyQUESTION: What about the

different skills required with each new evolution?

QUESTION: What are the differences in ergonomic implications?

• Technological systems tend to transition Technological systems tend to transition from macro systems to micro systems. from macro systems to micro systems. During this transition, different types of During this transition, different types of energy fields are used to achieve better energy fields are used to achieve better performance or controlperformance or control

• Example: Cooking oven developmentExample: Cooking oven development

• Large cast iron wood stoveLarge cast iron wood stove• Smaller stove fired by natural gasSmaller stove fired by natural gas• Electrically-heated ovenElectrically-heated oven• Microwave ovenMicrowave oven

Macro-Level

Macro-Level

Poly-system fromsmall particles(powder, etc.)

Poly-system fromsmall particles(powder, etc.)

Use ofMaterialStructure

Use ofMaterialStructure

Use of AtomicLevel

Use of AtomicLevel

Use ofEnergyFields

Use ofEnergyFields

Use ofChemicalProcesses

Use ofChemicalProcesses

Poly-system fromparts with simple

shapes (balls, rods,sheets, etc.)

Poly-system fromparts with simple

shapes (balls, rods,sheets, etc.)

7. EVOLUTION TOWARD THE 7. EVOLUTION TOWARD THE MICROLEVEL AND INCREASED USE OF MICROLEVEL AND INCREASED USE OF

FIELDSFIELDS


THE TRANSITION

MeThChEM(Mechanical, Thermal, Chemical, Electronic,

Magnetic, Electromagnetic)

Ex: Polymer Processing, Photography

EXAMPLES

Toothbrushes Adhesives Pointers House construction Telephone Automobile steering, other

systems Functional connections Writing instruments Software development Polymer processing

Tools Flow of electricity Control systems (on/off,

regulates, regulates vs. needs) Hydraulic pressure, synchronicity,

matched frequency, away from resonant frequencies

Sunglasses, compensating bysystems

A/C systems Computer interfaces

EXAMPLE:Clamping or Holding Methods

Macro level

Poly - simple shapes

Poly - small particles

Material structure

Chemical process

Field Magnetic clamping

Powder for 3 dimensional shapes

Contain material in a foam

Freeze material to permit clamping

By hand or flat vise

Cylinders between plates to grip irregular cylinders

WHAT WOULD THE “NEXT” FIELD BE IN YOUR SYSTEM? COULD YOU USE IT? DO YOU UNDERSTAND IT? WHAT

ARE THE ERGONOMIC CONSEQUENCES?

• Systems develop to perform tedious Systems develop to perform tedious functions that free people to do more functions that free people to do more intellectual workintellectual work

• Example: Clothes washingExample: Clothes washing

• Tub and washboardTub and washboard• Ringer washing machineRinger washing machine• Automatic washing machineAutomatic washing machine• Automatic washing machine with Automatic washing machine with

automatic dispensing of bleach and automatic dispensing of bleach and fabric softenerfabric softener

• REMEMBER THE NEW MACHINE AND REMEMBER THE NEW MACHINE AND PILL???PILL???

8. EVOLUTION TOWARD 8. EVOLUTION TOWARD DECREASED HUMAN DECREASED HUMAN

INVOLVEMENTINVOLVEMENT

WHAT IS THE NEXT STEP IN AUTOMATION? WHAT TECHNOLOGY

IS REQUIRED? WHAT ARE THE ERGONOMIC CONSEQUENCES? IN OPERATION? IN MAINTENANCE?

HOW AND WHEN TO USELINES OF EVOLUTION

Next generation product development What are the ergonomic implications?

Consumer researchForecasting--ergonomic impacts

RESOURCES Annual Altshuller conference, Philadelphia, spring,

2003 Introductory workshops, TRIZ in non-technical areas, how

to implement, Altshuller Institute, www.aitriz.org

www.innovation-triz.com web site, newsletter TRIZ Journal, on line at www.triz-journal.com Books

“And Suddenly the Inventor Appeared”, Altshuller “TRIZ: The Right Solution at the Right Time”, Salamatov “The Engineering of Creativity”, Savransky, CRC Press “Simplified TRIZ”, Rantanen and Domb, CRC Press “Hands on Systematic Innovation”, Mann, CREAX Press

THE TRIZ PROBLEM SOLVING PROCESS AND ITS APPLICATION TO HUMAN FACTORS AND USABILITY DESIGN AND...

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