Engineering Contradiction Research Articles

Conceptual Design of a Sustainable Bionanocomposite Bracket for a Transmission Tower’s Cross Arm Using a Hybrid Concurrent Engineering Approach

This research article elaborates on the conceptual design development of a sustainable bionanocomposite bracket for bracing installation in composite cross arm structures. The product design development employed the hybrid techniques of the theory of inventive problem solving (TRIZ), morphological chart, and analytic network process (ANP) methods. The current bracket design in the braced composite cross arm is composed of heavy and easy-to-rust steel material. Therefore, this research aims to develop a new bionanocomposite bracket design to replace the heavy and easy-to-rust steel bracket. This research also aims to implement a concurrent engineering approach for the conceptual design of bionanocomposite bracket installation to enhance the overall insulation performance. A preliminary process was implemented, which covered the relationship between the current problem of the design and design planning to build a proper direction to create a new design product using TRIZ. Later, the TRIZ inventive solution was selected based on the engineering contradiction matrix with specific design strategies. From the design strategies, the results were refined in a morphological chart to form several conceptual designs to select the ANP technique to systematically develop the final conceptual design of the bionanocomposite bracket for the cross arm component. The outcomes showed that Concept Design 1 scored the highest and ranked first among the four proposed designs. The challenges of the bionanocomposite bracket design for cross arm structures and the improvement criteria in concurrent engineering are also presented.

A TRIZ-Supported Concept and Protocol Development for Roof Tile Transportation and Inspection Systems

Currently, the use of manual labour in the transportation and inspection systems of leading roof tile manufacturing companies in Indonesia is still prevalent. Manual labour is usually labour-intensive, has higher risks of musculoskeletal disorders, and produces frequent occurrences of errors and losses. Furthermore, the current studies of suitable concepts and test protocols for roof tile transportation at the manufacturing stage as well as their inspection systems are not practicable in Indonesia. There is also no study that has used the theory of inventive problem-solving (TRIZ) in the development of concepts and protocols for roof tile transportation and inspection systems. Using TRIZ as a supporting tool, this study investigated the development of a transportation system to be employed during the manufacturing of the roof tile and a test protocol for their usability in Indonesian companies to overcome this concern. The study included screening and scoring concepts and usability test protocols identified from the existing literature, with the support of TRIZ tools such as the engineering contradiction, contradiction matrix, and inventive principles. Thus, the finalised concept comprised a belt conveyor system (Inventive Principle 20: Continuity of Useful Action) with a flipping mechanism for transportation and a vision-based camera for inspection. Results of the study showed that the concept excelled in cost, durability, reliability, versatility, low risk to the product, efficiency, and safety. The t-test protocol (Inventive Principle 23: Feedback) was selected based on the results due to its versatility in testing efficiency, reliability, and productivity. It was concluded that this concept has the potential to alleviate roof tile workers of physical work and reduce the prevalence of musculoskeletal disorders.

A TRIZ-Inspired Conceptual Development of a Roof Tile Transportation and Inspection System

The Indonesian roof tile manufacturing industry relies heavily on manual operations, specifically in transportation and inspection processes, which creates multiple issues, such as fatigue, injuries, human error, and reduced productivity. Various industries in the Indonesian industrial landscape have begun embracing a problem-solving approach known as the theory of inventive problem-solving (TRIZ) to mine solutions for industrial issues. Nevertheless, its application in the Indonesian roof tile manufacturing industry remains unaddressed. The study aims to solve manual handling issues in the roof tile manufacturing industry using TRIZ. Three observations were outlined from manual roof tile transportation and inspection, followed by the formulation of engineering contradictions (ECs). The ECs were linked with system parameters, which were used as indicators within the contradiction matrix to extract inventive principles as solution models for conceptual development. The concept included an automated system with a conveyor belt (#15: dynamics) for effective transportation, automated image capture (#28: mechanics substitution) for effective inspection, and a flipping conveyor (#25: self-service) to eliminate manual contact. Although the study addressed several issues stemming from manual operations, mechanical analysis, prototyping, and usability testing still require improvements.

Driving-induced lower back pain: Investigation of causes and recommendations with TRIZ

Background: Driving-induced lower back pain (DLBP) is associated with long driving times and awkward postures. Nonetheless, its actual causes and solutions remain unclear due to intervening causes from activities of daily living and traumatic injuries. This study investigated the causes and recommendations for DLBP using the theory of inventive problem solving (TRIZ). Methods: A cause-and-effect chain analysis (CECA) was conducted based on discussions with 19 ergonomics experts from Malaysia. Engineering contradictions were formulated according to the causes and associated with the parameters of the TRIZ system. These parameters were then intersected in the contradiction matrix to extract the inventive principles. Finally, recommendations were made based on these principles. Results: CECA uncovered the design- and posture-related causes of DLBP. It was implied that missing seat adjustment controls might cause drivers to sit with their knees positioned higher than their hips. This issue causes an excessive posterior pelvic tilt, resulting in DLBP. To address this issue, an inert atmosphere involving the addition of inflatable bubble wraps to elevate the posterior position was recommended. Conclusion: While there have been studies on DLBP, the present study demonstrated originality by using TRIZ to preliminarily but systematically investigate and resolve DLBP. Further triangulations, prototyping, experimentations, and verifications were not possible due to time and budgetary constraints. Nevertheless, this research uncovered the TRIZ-integrated perspectives on ergonomic solutions to DLBP that are more cost-effective than medical treatments or design overhauls.

Driving-induced lower back pain: Investigation of causes and recommendations with TRIZ

Background: Driving-induced lower back pain (DLBP) is associated with long driving times and awkward postures. Nonetheless, its actual causes and solutions remain unclear due to intervening causes from activities of daily living and traumatic injuries. This study investigated the causes and recommendations for DLBP using the theory of inventive problem solving (TRIZ). Methods: A cause-and-effect chain analysis (CECA) was conducted based on discussions with 19 ergonomics experts from Malaysia. Engineering contradictions were formulated according to the causes and associated with the parameters of the TRIZ system. These parameters were then intersected in the contradiction matrix to extract the inventive principles. Finally, recommendations were made based on these principles. Results: CECA uncovered the design- and posture-related causes of DLBP. It was implied that missing seat adjustment controls might cause drivers to sit with their knees positioned higher than their hips. This issue causes an excessive posterior pelvic tilt, resulting in DLBP. To address this issue, an inert atmosphere involving the addition of inflatable bubble wraps to elevate the posterior position was recommended. Conclusion: While there have been studies on DLBP, the present study demonstrated originality by using TRIZ to preliminarily but systematically investigate and resolve DLBP. Further triangulations, prototyping, experimentations, and verifications were not possible due to time and budgetary constraints. Nevertheless, this research uncovered the TRIZ-integrated perspectives on ergonomic solutions to DLBP that are more cost-effective than medical treatments or design overhauls.

Application of TRIZ in Inventive Product Design: A Case Study on Baking Tray Rack

Innovation is an important weapon for enterprises to achieve sustainable development in the market. In the large number of product markets featuring dramatic changes today, the products that attract consumers and win their heart must be manufactured to create business opportunities. Therefore, it is more vital to create opportunities of product innovation than to determine consumer needs. Taking the baking tray racks produced by an enterprise for an example, this study innovated the product with the skills and knowledge of TRIZ, a systematic innovation tool, according to consumer needs. In this study, function analysis was adopted to analyze the components and interaction of baking tray racks, and create a function model graph. The causal contradiction chain was analyzed to explore diverse consumer needs for baking tray racks, all the problems were analyzed one by one, and then, interlinked to determine the roots of the problems and identify contradictions. After analysis, 39 engineering parameters were introduced regarding all factors, and the engineering contradiction matrix was employed to seek the invention principles for innovative ideas. Moreover, the design of the baking tray racks was simplified according to the concept of simplistic design. Eventually, the assumed improved baking tray rack was endowed with three innovative functions: (1) it could be stored away ; (2) baking trays of various sizes could be placed on it at the same time; (3) it enabled enterprises to meet consumer needs and be innovative .

Design and Development of an Ergonomic Milling Machine Control Knob using TRIZ Principles

TRIZ, a Russian abbreviation known as the Theory of Inventive Problem Solving, refers to a methodology for problem-solving rooted in logic and data rather than intuition. It promotes the ability to solve problems creatively. Using TRIZ tools for problem-solving such as the cause-effect-chain analysis and engineering contradiction, a new ergonomic milling machine control knob was developed for improved musculoskeletal comfort. The major improvisations from the original milling machine knob included its spherical shape design, the indentations to accommodate a lateral pinch and the addition of a rubbery material for increased sensation. In the validation test, it was found that this new and improved ergonomic milling machine control knob was able to reduce the amount of pinch force by about 72% for males and 55% for females compared to the original knob, hence potentially eliminating risks of overexertion in pinch grips. This solution potentially reduces occupational injuries and cumulative trauma disorders. An implicit benefit is that the quality of machined parts using the milling machine can be potentially enhanced due to better control of the machine knobs that could eventually lead to the reduction of rejects and reworks, which also translates to improved productivity.

Inventive problem-solving puzzle game design and development

This paper depicts the production of a game for learning theory of inventive problem solving or TRIZ. The theory is meant for resolving engineering contradiction and forecasting trends and evolution of technologies. Despite being an effective invention tool, TRIZ has been criticised for its steep learning curve by people who have no engineering background. Beginning learners commonly face difficulties to comprehend TRIZ principles, not to mention using them to solve problems. To resolve this issue, a ten-level puzzle game was designed and developed. A key challenge was confronted by the production team as the game designers were trying to ensure transfer of knowledge, from solving in-game puzzles to understanding of the usage of each principle. This paper illustrates how the challenge was overcome in the gamification process. The insight might benefit content experts in other fields of study who intend to design and develop games for teaching and learning purposes.

Verifying Innovative Solutions of TRIZ Engineering Contradiction Matrix Using Substance-Field Analysis in Manufacturing

TRIZ has been well-established and is widely applied in multi-national enterprises to enhance design innovation and problem solving for design and manufacturing problems. Most applications of TRIZ utilise the engineering contradiction tools to solve design and manufacturing problems. This paper initially applied the engineering contradiction matrix to solve a semi-processed material transfer misalignment problem while passing through a furnace via a long mesh metal conveyor belt in the productions of automotive parts. Then, using another TRIZ tool, substance-field analysis to verify the solutions obtained earlier. This verification is to reduce the possible of errors in solving problems using the engineering contradiction matrix.

Developing a Rework Process for Underfilled Electronics Components via Integration of TRIZ and Cluster Analysis

This paper integrates the theory of inventive problem solving and cluster analysis to develop effective rework processes for underfilled electronic components. First, the function analysis is used to clarify the functional disadvantages such as underfill material attaching to the component, the printed circuit board (PCB), and the solder joints during the rework process. The cause–effect contradiction chain analysis then helps to identify engineering contradictions. Second, this research proposes clustered contradiction matrix. The optimal number of clusters for the inventive principles is determined by Ward’s method of hierarchical approach. The $K$ -means method is then used to allocate the engineering parameters to the appropriate cluster to achieve superior clustering performance. The priority of inventive principles considered as solution triggers is based on their corresponding frequency of appearances. Three solutions focused laser beam to remove electronics component, dispensable component bracket, and interchangeable PCB are proposed to rework the underfilled electronics components. Finally, the idealities of solutions are assessed and the most ideal solution interchangeable PCB is nominated for the U.S. patent.