Chapter 5: GEARS Design Framework

1. Goals (G)

Focus: Define what success looks like for the project.

• Deliverables: Clearly outline what the team will deliver (e.g., a prototype, a design report, or a working model).
• Functionality Requirements: Identify what the system, device, or product must accomplish.
• Design Specifications: Establish precise requirements like dimensions, material properties, and operational conditions.
• Key Performance Indicators (KPIs): Specify measurable criteria (e.g., load capacity, efficiency, speed) that will be used to evaluate the project.

Implementation Steps:

1. Work with clients or stakeholders to clarify the desired outcomes.
2. Document these goals in a project charter or design brief.
3. Ensure all team members have a shared understanding of the objectives.

2. Engineering Specifications (E)

Focus: Translate project goals into precise technical requirements.

• Define critical dimensions, material tolerances, and environmental considerations.
• Ensure all specifications meet industry standards, regulatory requirements, and safety margins.

Implementation Steps:

1. Use tools like CAD software to develop detailed schematics.
2. Identify tolerance limits for key components (e.g., ±0.05 mm for a shaft diameter).
3. Conduct a preliminary review to ensure specifications are realistic and achievable within the project constraints.

3. Analysis (A)

Focus: Evaluate the design to ensure reliability and safety.

• Assess the system against tolerance limits, KPIs, and safety margins.
• Identify risks, such as potential failure modes, and address them early.

Implementation Steps:

1. Perform engineering calculations, simulations, or finite element analysis (FEA) to evaluate stresses, deformations, and safety factors.
2. Use risk assessment tools (e.g., Failure Mode and Effects Analysis - FMEA) to identify and mitigate risks.
3. Document the analysis and align it with project goals and specifications.

4. Refinement (R)

Focus: Improve the design through prototyping, testing, and iteration.

• Develop and test physical or virtual prototypes to validate performance.
• Adjust the design as needed to meet goals, specifications, and KPIs.

Implementation Steps:

1. Fabricate a prototype or conduct simulations for testing.
2. Compare test results to KPIs and specifications.
3. Iterate the design based on testing feedback, focusing on improvements in safety, performance, and manufacturability.
4. Ensure proper documentation of changes for future reference.

5. Success Metrics (S)

Focus: Validate that the final product meets or exceeds expectations.

• Compare the performance of the final design against KPIs and client goals.
• Ensure compliance with all specifications and safety requirements.

Implementation Steps:

1. Conduct final testing and evaluations to verify the device’s performance.
2. Compile results into a final project report or presentation for stakeholders.
3. Use feedback from clients and advisors to confirm project success.

Applying GEARS in a Capstone Team

• Teamwork: Assign team members to specific stages of GEARS based on their expertise (e.g., someone skilled in CAD for "Engineering Specifications" and another with simulation expertise for "Analysis").
• Tools: Use project management tools (e.g., Gantt charts, Trello) to track progress through the GEARS phases.
• Documentation: Maintain thorough records of decisions, designs, and test results throughout the process.

By following the GEARS framework, capstone students can systematically tackle complex engineering challenges, ensuring their designs are functional, safe, and aligned with client expectations.