Patent Publication Number: US-6220743-B1

Title: Processes and materials selection knowledge-based system

Description:
This application claims priority benefit of copending U.S. Provisional Patent application No. 60/014,941, filed on Apr. 5, 1996. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to an apparatus and methods for the design and economic analysis of new durable goods based on knowledge of the durable good of interest, the plastics materials and processes to be used, and cost, market, and market share information. 
     More particularly, the present invention relates to apparatus, systems and methods for computer-aided design of new durable good from knowledge of the durable good of interest, the durable good&#39;s shape and size, using a shape selection protocol, the materials and/or processes for a particular durable goods application, and information related to determining the economics thereof. In even another particular, the present invention relates to a computer software system for the selection of materials and/or processes for a particular durable goods application, and for determining the economics thereof. 
     2. Description of the Related Art 
     The identification of business opportunities and the selection of the appropriate materials and fabrication processes for a “durable goods” application require knowledge which spans various domains of expertise. Business opportunity identification requires understanding of multiple industries, various market conditions, general business environment, and technical dimensions of various applications. 
     Selection of suitable materials and fabrication processes involve knowledge about strengths and weaknesses of fabrication processes, materials properties, mechanical design, and the shape and size of the durable good to interest. Selection of a suitable durable goods using a selected material, manufactured by a suitable fabrication processes also requires an economic analysis to determine whether the newly developed durable good has the necessary economics to make a viable new product for the markets place. 
     A person possessing the knowledge and skill to accurately and quickly identify business opportunities and select the appropriate materials and fabrication processes for a “durable goods” application would indeed be an expert. While such a person may exist, it is desirable to provide an apparatus incorporating a memory, a central processing unit, a display device and an user interface incorporating a computer based intelligent system to accurately and quickly identify business opportunities and select the appropriate materials and fabrication processes for a “durable goods” application. 
     U.S. Pat. No. 3,626,377, issued Dec. 7, 1971 to Markley, discloses a matrix generator for use in solving feed formulation problems. As disclosed, a matrix is developed in a matrix register, which is a logic array of component storage locations or registers for holding an organization of data relating to nutrients and ingredients. The specification of nutrients and ingredients for a desired feed is registered as two columns in the matrix register, from which the system operates to complete the entire matrix with information from an ingredient storage means which contains nutrient information on various specific ingredients. 
     U.S. Pat. No. 3,560,725, issued Feb. 2, 1971 and U.S. Pat. No. 3,628,004, issued Dec. 14, 1971, both to Claxton et al., both disclose a special purpose analogue computer designed for optimization of the ingredient levels of a rubber compound. The physical characteristics of a particular rubber compound may be closely approximated by a general empirical model equation expressed in terms of the ingredients. By analysis of raw experimental data relating to the physical characteristics of interest, a different set of influence coefficients for the general equation terms may be determined for each physical characteristic, whereby a number of special model equations are obtained. U.S. Pat. No. 5,260,882, issued Nov. 9, 1993 to Blanco et al., discloses a process a computer driven process for the estimation of physical and chemical properties of a proposed polymeric or copolymeric substance or material. The process for estimating generally involves defining the molecular chemical composition, estimating properties of the molecular chemical composition when 3-d folded, and forming the composition into a polymeric cluster, and the estimating the physical properties of the polymeric cluster. 
     U.S. Pat. No. 5,424,954, issued Jun. 13, 1995 to Makishima, discloses a computer-aided glass composition design apparatus and method. The disclosed algorithm includes a memory device having stored therein glass component compound data and glass physical property data, and includes a display device for initially displaying a plurality of glass component compounds from among the glass component data. Using an input device, a glass composition is selected from among the displayed glass components. The glass physical property data is processed to approximate at least one physical property of the selected glass composition. Alternately, the glass physical properties themselves are displayed and values assigned thereto, and the component processed to obtain a glass composition having approximated physical property values in accordance with the selected physical property values. 
     U.S. Pat. No. 5,463,564, issued Oct. 31, 1995 to Agrafiotis et al., discloses a system and method of automatically generating chemical compounds with desired properties. The system is a computer based, iterative process for generating chemical entities with defined physical, chemical and/or bioactive properties. During each iteration of the process, (1) a directed diversity chemical library is robotically generated in accordance with robotic synthesis instructions; (2) the compounds in the directed diversity chemical library are analyzed to identify compounds with the desired properties; (3) structure-property data are used to select compounds to be synthesized in the next iteration; and (4) new robotic synthesis instructions are automatically generated to control the synthesis of the directed diversity chemical library for the next iteration. 
     Jovanovic et al., “ESR—A Large Knowledge-Based System Project of European Generation Industry”, Expert Systems With Applications, Vol. 5, pp. 465, 477 (1993), discloses a knowledge-based system with three generic Windows applications that communicate between each other dynamically using dynamic linked library or dynamic data exchange. 
     However, in spite of these advancements in the prior art, none of these prior art references disclose or suggest a system for the design and economic analysis of new durable goods concepts using a computer based knowledge system that will utilizes selected processes and materials for a durable goods application, its size and shape or design and a economic set of selected economic factors. Thus, these is still a need for a system for the selection of processes and materials for a durable goods application, and that will also provide an economic analysis. 
     SUMMARY OF THE INVENTION 
     It is an object of the present invention to provide for a system for the selection of processes and materials for a durable goods application, and that will also provide an economic analysis. 
     The present invention further provides an apparatus including a processing unit, a memory containing types of durable goods, durable goods manufacturing materials, material properties information, processes and processing information, economic information and other relevant information, an user interface, and a set of memory based instructions for durable goods size and shape and type selection so that new durable goods can be designed and analyzed economically. 
     This and other objects of the present invention will become apparent to those of skill in the art upon review of this specification, including its drawings and claims. 
     The Processes And Materials Selection (PAMS) system of the present invention is a hybrid knowledge-based system composite requiring three main functions: (1) an expert system function; (2) a user interface function; and (3) a model and database function. It is to be understood that these three functions can be implemented utilizing any combination of one or more programs. 
     In a first embodiment of the invention, referred to herein as “SYS 1 ”, these three functions are implemented utilizing three software programs, Assymetrix ToolBook for the graphical user interface (“GUI”), Microsoft Excel for the model and database function, and Neuron Data Nexpert Object for the expert system function. 
     In a second embodiment of the present invention, referred to herein as “SYS 2 ”, the expert system function, a user interface function, and a model and database function are implemented utilizing two software programs. Again, Microsoft Excel is utilized to implement the model and database function, and ART*Enterprise is utilized to implement both the graphical user interface function and the expert system function. 
     The present invention also provides a method, stored in a computer memory and implemented in a computer central processing unit, for determining the shape and size criteria for a durable good so that material and processing information can be utilized with economic data to predict commercial and economic feasibility. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a schematic showing an overview of the communication system  10  used within the both the SYS 1  SYS 2  embodiments of the present invention, showing the relationship between the user  11 , a graphics user interface  13 , an expert system shell  15 , a spreadsheet  16 , a knowledge engineer (KE) and a domain expert (DE)  18 . 
     FIG. 2 is a schematic map of information flow for both the SYS 1  and the SYS 2  embodiment during a consultation, showing that user  11  may access the four major functions of the SYS 2  embodiment  100 , the selection function  40 , the mechanical analysis function  50 , the economic analysis function  60 , or the shape selection function  70  (SYS 2  only), in any order, or in any type of combination, to obtain information regarding processes or materials  41 , dimensions  51 , cost  61 , or shapes and features  71 . 
     FIG. 3 represents a conceptual map of the structure and information flow for the book level of the SYS 1  embodiment using the GUI  13 . 
     FIG. 4 provides the legend for FIG.  3 . 
     FIGS. 5 and 6 represent the opportunity identification (e.g., an expert perspective for doing opportunity identification) and picture hierarchies of concepts, which include semantic and inheritance of characteristics of behaviors, and provide the “what” and the “how” for the program. 
     FIG. 7 represents the selection of processes and materials and pictures a hierarchy of concepts. 
     FIG. 8 shows a representation of part of the program for the selection of processes and materials. 
     FIG. 9 shows a small decision tree, with each packet of this tree represents a rule. 
     FIGS. 10, and  12 - 18 , show high level representations of the inference chains and prototypes for the Processes and Materials Selection Module, with the legend for those figures provided in FIG.  11 . 
     FIGS. 19-38 provided a high level illustration of inference chains, events and prototypes for the Opportunity Identification Module. 
     FIG. 39 provides a legend for FIGS. 19-38. 
     FIG. 40 shows an example of a material specific entry screen for the economic models of the present invention. 
     FIG. 41 shows an example of a process specific information screen. 
     FIGS. 42 and 43 show the input screens for inputting technical constraints and requirements for data relating to aesthetics, durability, ergonomics, environmental, mechanical, reliability and weight. 
     FIG. 44 shows the input screen for data relating to comparing existing versus new products, with existing product data including material used and process types, and new solution data including the users material and application type. 
     FIG. 45 shows the input screen for data relating to technical capacity, which data includes material, process and design analysis data, for both the customer and the user. 
     FIG. 46 shows the input screen for data relating to the business customer&#39;s major goals, with data including percentage of cost reduction value, importance of cost reduction, percent gain of market share, importance of market share gain, and performance improvement. 
     FIG. 47 shows the input screen for data relating to customer interest and business, with input variables including application growth, profitability, sales, market share, potential for product differentiation, capacity utilization, selling/marketing cost, price variation, and ability to brand. 
     FIG. 48 shows the input screen for data relating to customer direct competition and pressure, with input variables including: top  2  and  5  share of market for competitor concentration analysis; market growth for market maturity analysis; and top  3  customers, cost to switch, backward integrate, alternative suppliers; and differentiation position for the customer bargaining leverage analysis. 
     FIG. 49 shows the input screen for data relating to customer pressure and soft issues, with input data including customer price sensitivity of customer profitability, plastic cost, discount cost, real price growth, and also including “soft issues” such as credibility of customer, history of customer to develop products, innovation history of customer, and any personal issues. 
     FIG. 50 shows the input screen relating to customer support and commitment, including input variables relating to internal agreement, organization functions and levels, partnership, and resources and investments. 
     FIG. 51 shows the input screen relating to the user&#39;s revenue, with input variables relating to volume of units, plastic per unit, expansion potential, and options to maximize revenue. 
     FIG. 52 shows the input screen for data relating to the user&#39;s assets/strategies, with input variables relating to the user&#39;s competitive advantage and whether the project fits with the user&#39;s strategy. 
     FIG. 53 shows the input screen for data relating to the user&#39;s differentiation, with input variables relating to account penetration, design assistance, global supply, historical industry presence, technical assistance, unique delivery options, and unique product performance. 
     FIG. 54 shows the input screen data relating to the user&#39;s cost position, with input variables including conversion costs, raw materials, capacity utilization, plant age, process technology, and cost of capital. 
     FIG. 55 shows input screens data relating to the user&#39;s development project, with input variables including activities, person-time forecast, resources, and time frame. 
     FIG. 56 shows an output screen with information relating to opportunity analysis (OA) results for understanding the customer. Output variables include market attractiveness, project importance, customer commitment, and technical feasibility. 
     FIG. 57 shows an output screen with information relating to opportunity analysis (OA) results for the user&#39;s (illustrated as Dow in the figure) business. 
     FIG. 58 shows an output screen with information relating to the overall opportunity analysis (OA) results. 
     FIG. 59 shows an input screen for selecting the type of application, with selection to be made according to various levels “ 35 ”, “ 45 ”, “ 55 ” and “ 65 ”, with the specificity of the levels increasing with the designation number. 
     FIG. 60 shows an the input screen for the part specification environment, with input data including chemical exposure, chemical types, hydrolytic stability, HDT, and ignition resistance. 
     FIG. 61 shows an input screen for part specifications surface and electrical, with input data including surface finish, color and texture. 
     FIG. 62 shows an input screen for mechanical and environmental and legal, with input data including ambient toughness, creep resistance, fatigue resistance, part toughness, part stiffness, emissions, environmental impact, recyclability. Input data is as shown on the screen. 
     FIG. 63 shows an input screen for part specifications shape, with input data including additions, complexity, constraints/dimensionality, degrees of draft, inside tolerances control, and shape control accuracy. 
     FIG. 64 shows an input screen for shape (continued) and production volume, with input data including size, undercuts and volume. 
     FIG. 65 shows the Pre-Selection Dialog Box in which the system informs the user that it will take some time to process the information that has been provided. 
     FIG. 66 shows the Cold Temperature Toughness Dialog Box in which the system requests more information from the user. 
     FIG. 67 shows the Wear/Abrasion Dialog Box in which the system requests more information from the user. 
     FIG. 68 shows the Legal Constraints Dialog Box in which the system requests more information from the user. 
     FIGS. 69,  70 ,  71 ,  72  and  73 , show dialog screens for Recyclability, Sheet Molding Compound (SMC), Reaction Injection Molding (RIM), Structural Reaction Injection Molding (SRIM) and Resin Transfer Molding (RTM), respectively. 
     FIGS. 74 and 75 show the results from the processes and materials selection expressed in terms of lists of appropriate or rejected processes and materials, and explanations on how the conclusions were reached. 
     FIGS. 76 and 81 illustrate the screen triggered from menu item “overall shape”. 
     FIG. 77 illustrates the screen triggered from menu item “additions”. 
     FIG. 78 shows GUI input dynamics logic. 
     FIG. 79 shows the shape selection/decomposition screen output, with legend provided in FIG.  80 . 
     FIGS. 82 to  109  show the screen outputs for the SYS 2  embodiment of the present invention. 
     FIG. 82 shows a screen related to applications. 
     FIG. 83 shows a screen related to surface, application functional requirements. 
     FIG. 84 shows a screen related to shape, application functional requirements. 
     FIG. 85 shows a screen related to miscellaneous, application functional requirements. 
     FIG. 86 shows a screen related to mechanical, application functional requirements. 
     FIG. 87 shows a screen related to environmental legal, application functional requirements. 
     FIG. 88 shows a screen related to environment, application functional requirements. 
     FIG. 89 shows a screen related to processes and materials selection, results. 
     FIG. 90 shows a screen to override the processes and materials selection. 
     FIG. 91 shows a screen related to candidate material with a compatible, candidate process manually rejected. 
     FIG. 92 shows a screen related to manually selected, rejected materials with no compatible, candidate processes. 
     FIG. 93 shows a screen related to processes and materials selection. 
     FIG. 94 shows a screen related to economics. 
     FIG. 95 shows a screen related to economics, general user input. 
     FIG. 96 shows a screen related to grade families compatible with a process. 
     FIG. 97 shows a screen related to compatible grades families for SRIM. 
     FIG. 98 shows a screen related to compatible grades families for TIM and SRIM. 
     FIG. 99 shows a screen related to process specific, user input request. 
     FIG. 100 shows a screen related to family specific, user input request. 
     FIG. 101 shows a screen related to processes economic analyses results. 
     FIG. 102 shows a screen related to processes economic models. 
     FIG. 103 shows a screen related to mechanical analyses, overall stiffness. 
     FIG. 104 shows a screen related to overall stiffness calculation. 
     FIG. 105 shows a screen related to standard shape and shell plate models. 
     FIG. 106 shows a screen related to GUI for the rectangular plate with edges simply supported. 
     FIG. 107 shows a screen related to families dimensions results. 
     FIG. 108 shows a screen related to overview of windowing environment for mechanical analyses. 
     FIG. 109 shows a screen related to mechanical models. 
     FIG. 110 is a flowchart of the macro view of the operation of the present invention. 
     FIGS. 111A-111G are a flowchart of the operation of the PAMS system of the present invention showing more detail than FIG.  110 . 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     I. Overview 
     In a durable goods application, the knowledge required to understand technical and business needs, identify business opportunities, and select the best materials and fabrication processes for a “durable goods” application, spans multiple product lines and various technologies. The different forms of knowledge include symbolic reasoning, numerical computing, and data storage and retrieval. Different programming tools are needed for modeling these various forms of knowledge and providing adequate system functions. 
     As a result, the Processes And Materials Selection (PAMS) system of the present invention is a hybrid knowledge-based system composite requiring three functions: (1) a user interface function (discussed in detail in section III below); (2) an expert system function (discussed in detail in section IV below); and (3) a model and database function (discussed in detail in section V below). It is to be understood that the functions of the present invention may be implemented by any combination of one or more programs, including non-commercial and commercially available programs. 
     In a first embodiment of the invention, referred to herein as “SYS 1 ”, these three functions are implemented utilizing three commercially available software programs, ToolBook for the graphical user interface (“GUI”), Microsoft Excel for the model and database function, and Nexpert Object for the expert system function. 
     Within the framework described above, the PAMS SYS 1  of the present invention features: a graphical user interface; an opportunity identification sub-system; a selection procedure for selecting appropriate processes based on application requirements with an explanation of how conclusions were reached; a selection procedure for choosing adequate classes of materials based on application requirements, functional values, and application domains with an explanation of the selection process; a procedure for running several mechanical models (standard shapes) for common grades of materials; a procedure for providing IBIS Associates economic models for limited processes; and an integrated database of engineering properties of various materials. 
     In a second embodiment of the present invention, referred to herein as “SYS 2 ”, the expert system function, a user interface function, and a model and database function are implemented utilizing two commercially available software programs. Basically, with SYS 2 , the functions of SYS 1  have been further refined. The opportunity analysis was not implemented in SYS 2 , but SYS 2  provides a more robust shape selection protocol, whereas in SYS 1  the user must select the shape from a limited number of predefined shapes. Again, Microsoft Excel is utilized to implement the model and database function, and ART*Enterprise is utilized to implement both the graphics user interface function and the expert system function. 
     PAMS-SYS 2  is a later version of the SYS 1  embodiment and adds: a shape selection/decomposition module to help determine the shape and the features (e.g., holes, ribs) required for an application, as well as, providing the possible decomposition of the application shape into simpler shapes; a completed and refined knowledge base related to application requirements, processes characteristics and materials functional values; shell/plates mechanical models; a completed and integrated engineering properties database with the mechanical and economic models; more IBIS Associates economic models for more processes where the models are normalized to allow for meaningful comparisons between scenarios; and an enhanced and more flexible procedure for accessing the various functions of the system; and the ability to play “what if” scenarios. 
     Broadly, for both embodiments, spreadsheets perform numerical computing, and store and retrieve data. The expert system shell captures the decision making process and performs symbolic computing on the indicated information; while hypertext/graphical software implements a graphical user interface. 
     It is preferred that the system utilized be highly modular. For example, mechanical and economic models are contained in or correspond to different spreadsheets, macro sheets, or workbooks; materials functional values and processes characteristics are stored in separate databases; the opportunity identification procedure, the selection of processes procedure and the selection of materials procedure correspond to distinct knowledge bases; and the graphical user interface is divided into meaningful sections, windows or window groups. For both embodiments, these various applications communicate between each other using dynamic data exchange (DDE) or dynamic linked libraries (DLL) or a combination thereof FIG. 1 is a schematic showing an overview of the communication system  10  used within the both the SYS 1  and SYS 2  embodiments of the present invention. This figure shows the relationship between the user  11 , interface  13 , expert system shell  15 , spreadsheet  16  and the knowledge engineer and the domain expert  18 . Graphic user interface  13  communicates with the expert system shell  15  utilizing dynamic linked libraries (DLL), and the with spreadsheet  16  utilizing dynamic data exchange (DDE). Communication between the expert system shell  15  and the spreadsheet  16  requires both dynamic linked libraries and dynamic data exchange. 
     FIG. 2 is a schematic map showing information flow for both the SYS 1  and the SYS 2  embodiment of the present invention during a consultation. As shown in FIG. 2, user  11  may access the four major functions of the PAMS system  100 , the selection function  40 , the mechanical analysis function  50 , the economic analysis function  60 , or the shape selection function  70 , in any order, or in any combination, to obtain information regarding processes or materials  41 , dimensions  51 , costs  61 , or shapes and features  71 . 
     During a consultation session, the system state changes to take into account user input via the user interface  13  and previous conclusions or states. Conveniently, what has been done previously affects what will happen next. Of course, although graphics user interfaces are more conducive to window based applications, other type of interfaces can be used as well which do not utilize graphics. 
     II. System Hardware &amp; Software 
     It is to be understood that the present invention may be implemented utilizing any suitable computer or computing environments, including mainframes, minicomputers, workstations, networked computers, and desktop and notebook computers of both the PC and Macintosh type, or the present invention can be implemented on a networked client server. Presently, both the SYS 1  and the SYS 2  embodiments developed by the inventors are implemented on a PC type desktop computer. 
     In the practice of the present invention, the minimum system requirements for implementation of SYS 1  on a PC type computer, besides the software providing the graphical user interface function and the expert system functions, are as follows: 
     
       
         
           
               
               
               
             
               
                   
                   
               
             
            
               
                   
                 Hardware 
                   
               
               
                   
                 Processor 
                 486 or equivalent computer 
               
               
                   
                 RAM: 
                 4 Mb 
               
               
                   
                 Disk Space: 
                 7.1 Mb (for PAMS) 
               
               
                   
                 Monitor 
                 VGA or Super VGA (with 256-color display) 
               
               
                   
                 Software 
               
               
                   
                 Operating System: 
                 DOS 5.0 or later 
               
               
                   
                 Windowing System: 
                 Microsoft Windows 3.1 
               
               
                   
                   
               
            
           
         
       
     
     SYS 2  is a later version of SYS 1 , and has slightly different minimum system requirements as follows: 
     
       
         
           
               
               
             
               
                   
               
             
            
               
                 Hardware 
                   
               
               
                 Processor 
                 486 or equivalent computer 
               
               
                 RAM: 
                 16 Mb 
               
               
                 Disk Space: 
                 40 Mb (for PAMS) 
               
               
                 Monitor 
                 VGA or Super VGA (with 256-color display) 
               
               
                 Software 
               
               
                 Operating System: 
                 DOS 5.0 or later 
               
               
                 Windowing System: 
                 Microsoft Windows 3.1 in enhanced mode with 40 
               
               
                   
                 Mb permanent swap space. 
               
               
                 WIN32 
                 (allows 32 bit applications to run under Windows 
               
               
                   
                 3.1) 
               
               
                   
               
            
           
         
       
     
     Table 1 provides the functions, sizes, and software for the principal files of the PAMS-SYS 1  embodiment of the present system. Of course, the SYS 2  system utilizes ART*Enterprise for the graphical user interface and expert systems functions, instead of both ToolBook and Nexpert Object, and some of the file sizes have grown to reflect increases in the database size. 
     
       
         
           
               
             
               
                 TABLE 1 
               
             
            
               
                   
               
               
                 Files for PAMS SYS1 
               
            
           
           
               
               
               
               
               
            
               
                 Topics 
                 Files 
                 Size (b) 
                 Software 
                 Functions 
               
               
                   
               
            
           
           
               
               
               
               
               
            
               
                 GUI 
                 SYS1.tbk 
                 2428943 
                 ToolBook 
                 GUI 
               
               
                 Reasoning 
                 OA.ckb 
                 627078 
                 Nexpert Object 
                 Opportiinity Analyses 
               
               
                   
                 Selector.ckb 
                 492550 
                   
                 Selection of Processes and Materials 
               
               
                   
                 Models.ckb 
                 39025 
                   
                 Analyses for Grades of Materials 
               
               
                 Models 
                 Inject1.xlu 
                 130031 
                 Microsoft Excel for 
                 IBIS Associates Technical Cost 
               
               
                   
                   
                   
                 Windows 
                 Models 
               
               
                   
                 Diecast1.xlu 
                 139441 
                   
                 IBIS Associates Technical Cost 
               
               
                   
                   
                   
                   
                 Models 
               
               
                   
                 Econom1.xls 
                 49480 
                   
                 In-house Economic Models 
               
               
                   
                 MechSYS1.xlw 
                 109515 
                   
                 Mechanical Models 
               
               
                 Databases 
                 ProcSYS1.slk 
                 23909 
                 Microsoft Excel for 
                 Processes Characteristics 
               
               
                   
                 MatSYS1.slk 
                 57651 
                 Windows 
                 Materials Functional Values 
               
               
                   
                 EngSYS1.slk 
                 25962 
                   
                 Engineering Properties 
               
               
                   
               
            
           
         
       
     
     III. Graphical User Interface (GUI) 
     It is desired that the user interface be user friendly, relatively easy to operate, and be suitable to accommodate the large amount of human-computer interactions expected. Thus, it is preferred to utilize a graphical user interface with pull-down menus, that is driven by, for example, a mouse or other such pointer device, such as a roll ball, track ball, finger pad, finger stick, and the like. 
     Referring again to FIG. 1, the SYS 1  GUI module  13  communicates with the other modules  15  and  16  through dynamic link libraries (DLL) and dynamic link exchange (DDE). It is generally desired that GUI  13  provides: (1) dynamic link libraries to bridge the expert system shell and allow for call back from the inference engine through the GUI  13 ; (2) a friendly and flexible, English like, object-flavored script language which includes message handlers; (3) a wide variety of graphical objects (also referred to herein as “widgets”); and (4) a mouse with control options for performing selecting and positioning tasks. 
     Commercial GUI programs exist, and any suitable program may be utilized. Examples of suitable GUI programs include ToolBook, Plus, Hypercard (for MAC), Supercard, and MS Visual Basic. 
     In the SYS 1  embodiment of the present invention developed by the inventors, the GUI is implemented with a graphical, hypertext software (ToolBook  1 . 53 ) which runs under Microsoft Windows 3.1 or higher. SYS 2  utilizes the expert system software ART*Enterprise having an incorporated GUI module. While SYS 1  and SYS 2  utilize different programs for the GUI, the screens faced by the user appear essentially identical. The GUI of the present invention will generally be explained by reference to SYS 1 , with important SYS 2  exceptions noted where appropriate. 
     The SYS 1  GUI developed by the inventors, is highly modular, being divided in input, output, script, and communication sections. Only the input and output sections are visible to the user. In addition, the preferred SYS 1  GUI developed by the inventors is structured according to the following ToolBook objects events-driven hierarchy: 
     1. The book. 
     2. The backgrounds of the book. 
     3. The widgets of the backgrounds. 
     4. The pages of the background pages. 
     5. The pages of the backgrounds. 
     6. The widgets of background pages. 
     7. The book pages. 
     8. The widgets of the book pages. 
     The book level contains handlers that determine the general behavior of the SYS 1  GUI (e.g., window size, menu bar, or menu items) and the implements communication with the SYS 1  expert system shell Nexpert Object 2.0B, the help routines of the windowing software, Help for Microsoft Windows, and the spreadsheet program Microsoft Excel 4.0 (e.g., launching of applications, Excel Macro executions, Nexpert Object inference engine controls). In particular, it contains generic handlers for the dynamic linked library and the dynamic data exchange with Nexpert Object and Microsoft Excel, respectively. 
     FIG. 3 represents a conceptual map of the structure and information flow for the book level of the SYS 1  embodiment GUI, with FIG. 4 providing the legend for FIG.  3 . User defined handlers and functions are attached to the various objects and message-sending through the hierarchy defines the behavior of the SYS 1  GUI. The following Table 2 summarizes the functions for each section of the SYS 1  GUI developed by the inventors. 
     
       
         
           
               
             
               
                 TABLE 2 
               
             
            
               
                   
               
               
                 Modularity 
               
               
                 The GUI itself is highly modular. It is divided in input, output, script, and 
               
               
                 communication sections. Only the input and output section are visible to the 
               
               
                 user. Table summarizes the functions for each section of the GUI. 
               
               
                 GUI Sections 
               
            
           
           
               
               
               
               
            
               
                   
                 Sections (i.e., 
                   
                   
               
               
                 Types 
                 Backgrounds) 
                 Functionality 
                 Pages 
               
               
                   
               
            
           
           
               
               
               
               
            
               
                 Input 
                 PAMS 
                 Welcome 
                 1 
               
               
                   
                 Applications 
                 Select a “durable goods” application. 
                 1 
               
               
                   
                 Part Specifications 
                 Enter part functional requirements. 
                 5 
               
               
                   
                 Design 
                 Select shape, enter mechanical constraints. 
                 17 
               
               
                   
                 Opportunity 
                 Provide opportunity analyses information. 
                 14 
               
               
                 Output 
                 Opportunity 
                 Give recommendations. 
                 3 
               
               
                   
                 Selection 
                 List candidate and rejected, processes and 
                 2 
               
               
                   
                   
                 materials. 
               
               
                   
                 Analyses 
                 List results of mechanical and economic 
                 1 
               
               
                   
                   
                 analyses. 
               
               
                   
                 Advisor 
                 Not functional yet! 
                 1 
               
               
                 Script 
                 Data 
                 Look at the databases. 
                 1 
               
               
                   
                 Models 
                 Look at the mechanical and economic 
                 1 
               
               
                   
                   
                 spreadsheets. 
               
               
                   
                 BookAlternate 
                 Control Nexpert Object (DLL handlers) and 
                 1 
               
               
                   
                   
                 Microsoft Excel (DDE handlers). 
               
               
                   
                   
                 Include functions for the explanation utility. 
               
               
                   
                 ScriptAlternate 
                 Contain general functions and handlers for 
                 1 
               
               
                   
                   
                 pages and widgets. 
               
               
                   
                   
                 Link the I/O backgrounds to the 
               
               
                   
                   
                 Communication backgrounds. 
               
               
                   
                 ApplicationsAlternate 
                 Define levels of market cuts 
                 1 
               
               
                   
                 UtilitiesAlternate 
                 Contain functions and message handlers for 
                 1 
               
               
                   
                   
                 the utilities. 
               
               
                 Communication 
                 OABoard 
                 Map I/O between ToolBook and Nexpert 
                 1 
               
               
                   
                   
                 Object. 
               
               
                   
                 PreSelectionBoard 
                 Map I/O between ToolBook and Nexpert 
                 93 
               
               
                   
                   
                 Object. 
               
               
                   
                   
                 Include functions for the explanation utility. 
               
               
                   
                 DesignBoard 
                 Map I/O between ToolBook, Nexpert Object, 
                 1 
               
               
                   
                   
                 and Microsoft Excel. 
               
               
                   
                   
                 Control Microsoft Excel. 
               
               
                   
                 FundamentalAnalysesBoard 
                 Contain functions for mechanical and 
                 1 
               
               
                   
                   
                 economic results. 
               
               
                   
                 AdvisorBoard 
                 Not functional yet! 
                 7 
               
               
                   
               
            
           
         
       
     
     In the SYS 1  embodiment, in order to address maintenance issues, attention has been paid to balancing modularity and granularity. The SYS 1  GUI is modular, but not to the extent of being granular. The SYS 1  GUI has a multi-board structure where private conversations are allowed. Each background of the communication section as listed in the above Table 2, can be used as a blackboard. Although the SYS 1  GUI implements the scheduler of this multi-board architecture, not all the communication goes through the GUI and private communication between the spreadsheet and the expert system shell takes place. 
     The inventors do note that ToolBook has somewhat limited portability to various platforms, and the serial communication between Nexpert Object and ToolBook through the dynamic linked library is somewhat inefficient. Thus, it would be preferred to port the GUI function to a multimedia tool available on multiple platforms or to move it to a graphical tool kit integrated with the expert system shell. Most preferred is a portable, integrated to the expert system shell, object-oriented graphical tool kit to reduce the implementation effort of the GUI and facilitate portability and maintenance. Many of these concerns are addressed in the SYS 2  embodiment, which utilizes ART*Enterprise. Commercially available multimedia tools suitable for use in the present invention, and which have greater portability than ToolBook include OIT (open interface toolkit) from Neuron Data. 
     Commercial programs also are available which incorporate both an expert system and a GUI. For example, besides ART*Enterprise, Level5 Object 3.0 available from Information Builders, Inc., provides an expert system with rules, forward and backward chaining logic, and very limited object oriented processing, and an integrated graphical tool kit. As another example, ART-IM 4.0, SmartElements from Neuron Data, provides an expert system with rules, forward and backward chaining, pattern matching, non monotonic reasoning, full object oriented capabilities, and an object oriented graphical tool kit, and portable scripting language capabilities. 
     It is desirable to design the system to make the input and output screens as user friendly as possible. Preferably, the following issues are considered in designing the screens: to (1) consistency of color, font, shape, and style; (2) specificity of meaning for widget, font, and color; (3) cleanness and clarity of display; (4) amount of information displayed directly; (5) amount of context sensitive detail; and (6) visual fitness and understanding, preferably top to down and left to right. 
     The following Tables 3-15 describe the important message handlers and scripts for all the sections of the SYS 1  GUI as listed in Table 2, above. 
     
       
         
           
               
             
               
                 TABLE 3 
               
             
            
               
                   
               
               
                 The Book 
               
               
                 Book Handlers 
               
            
           
           
               
               
            
               
                 Handlers 
                 Functionality 
               
               
                   
               
               
                 enterBook 
                 set system variables, clear fields, reset button labels, size window 
               
               
                   
                 link Nexpert Object DLL, user defined DLL to Nexpert Object 
               
               
                   
                 link Window help DLL, ToolBook dialog box DLL 
               
               
                   
                 run Excel and load workbook 
               
               
                 leaveBook 
                 unlink DLL 
               
               
                   
                 quit Excel 
               
               
                 DDEExcelRun theStr, nAtoms, 
                 execute Excel macro 
               
               
                 theAtoms 
                 DDE to Excel: get “[activate(“ &amp; quote &amp; theStr &amp; quote &amp; ”)]” 
               
               
                   
                 executeRemote it application Excel topic system 
               
               
                 DDEExcelPoke theStr, 
                 poke the value VValue of the Nexpert Object slot (theAtoms) to 
               
               
                 nAtoms, theAtoms 
                 Excel cell MyCell using TBK_GetAtomFromList and 
               
               
                   
                 NXP_GetAtomInfo and continue inferencing 
               
               
                   
                 DDE to Excel: setRemote MyCell to VValue application Excel 
               
               
                   
                 topic theTopic 
               
               
                 DDEExcelRequest theStr, 
                 request the value of Excel cell MyCell, volunteer to a Nexpert 
               
               
                 nAtoms, theAtoms 
                 Object slot, and continue inferencing using put 
               
               
                   
                 TBK_GetAtomFromList and get NXP_Volunteer 
               
               
                   
                 DDE to Excel: getRemote MyCell application Excel topic 
               
               
                   
                 theTopic 
               
               
                 author 
                 request a password to switch to developer mode 
               
               
                 enterComments 
                 message handler for the “Enter Comments” menu item 
               
               
                   
                 get showCommentsScreen(the name of this 
               
               
                   
                 page,VKeepComments of this page,GCo,“EnterComments”) of 
               
               
                   
                 page UtilitiesAlternate 
               
               
                 SaveAllComments 
                 message handler for the “Save All Comments” menu item 
               
               
                   
                 get cancelCommentsScreen(the name of this 
               
               
                   
                 page,VKeepComments of this page,GCo) of page 
               
               
                   
                 UtilitiesAlternate 
               
               
                 Questionnaire 
                 message handler for the “Questionnaire” menu item 
               
               
                   
                 DDE to Excel to load, run, save, and close the workbook 
               
               
                   
                 Question.XLW 
               
               
                 Database 
                 DDE to Excel to load, run, save, and close the engineering properties 
               
               
                   
                 database 
               
               
                 TestCases 
                 message handler for the “Test Cases” menu item 
               
               
                   
                 DDE to Excel to load, run, save, and close the worksheet 
               
               
                   
                 Verify.XLS 
               
               
                 PAMS 
                 message handler for the “PAMS” menu item 
               
               
                   
                 get theInformationDisplayed(the name of this page,“”,GAbout, 
               
               
                   
                 “&amp;PAMS”) of page UtilitiesAlternate 
               
               
                 AboutPAMS 
                 message handler for the “About PAMS” menu item 
               
               
                   
                 get theInformationDisplayed(the name of this 
               
               
                   
                 page,“”,GaboutPAMS, “&amp;About PAMS”) of page UtilitiesAlternate 
               
               
                 Team 
                 message handler for the “Team” menu item 
               
               
                   
                 get theInformationDisplayed(the name ot this page,“”,GTeam, 
               
               
                   
                 “&amp;Team”) of page UtilitiesAlternate 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 4 
               
             
            
               
                   
               
               
                 Book Handlers (Continued) 
               
            
           
           
               
               
            
               
                 Handler and Script 
                 Functionality 
               
               
                   
               
               
                 Sponsors 
                 message handler. for the “Sponsors” menu item 
               
               
                   
                 get theInformationDisplayed(the name of this page,“”,GSponsors, 
               
               
                   
                 “&amp;Sponsors” ) of page UtilitiesAlternate 
               
               
                 ReferenceManual 
                 message handler for the “Reference Manual” menu item 
               
               
                   
                 use windows DLL winHelpIndex(sysWindowHandle, 
               
               
                   
                 ReferenceManualFile, 3, 0) and winHelpKey(sysWindowHandle, 
               
               
                   
                 ReferenceManualFile, 257,it) 
               
               
                 UserGuide 
                 message handler for the “User Guide” menu item 
               
               
                   
                 use windows DLL winHelpIndex(sysWindowHandle, 
               
               
                   
                 UserGuideFile,3,0) and winHelpKey(sysWindowHandle, 
               
               
                   
                 UseGuideFile,257,it) 
               
               
                 general 
                 message handler for the “General Help” menu item 
               
               
                   
                 get displayHelp(the name of this page,theText, GHelp, general) 
               
               
                   
                 of page UtilitiesAlternate 
               
               
                 restartPAMSConsultation 
                 go to first page of the book 
               
               
                   
                 restart knowledge base (Nexpert Oblect&#39;s inference engine) 
               
               
                 restartPAMS 
                 go to first page of the book 
               
               
                   
                 get UnLoadKnowledgeBase of background BookAlternate 
               
               
                 ALH code, str 
                 bring different type of dialog boxes for Nexpert Object call-back 
               
               
                   
                 (e.g., information, end of session) 
               
               
                   
                 use message handlers to buttons 
               
               
                   
                 BMessageHandleDiatogBoxOk, 
               
               
                   
                 BMessageHandleDialogBoxEOS, or 
               
               
                   
                 BMessageHandleDialogBoxCONTINUE of background 
               
               
                   
                 UtilitiesAlternate 
               
               
                 QH theAtom, theQuestion 
                 bring different type of dialog boxes for Nexpert Object data 
               
               
                   
                 request call-back, depending of the data type 
               
               
                   
                 use message handlers BMessageHandleDialogBoxMList and 
               
               
                   
                 BMessageHandleDialogBoxList of background UtilitiesAlternate 
               
               
                   
                 utilize ask and request handlers 
               
               
                 Generic theStr, nAtoms, 
                 a user-defined generic handler to transfer information from 
               
               
                 theAtoms 
                 Nexpert Object to ToolBook 
               
               
                   
                 depending on theCode (last word of theStr), get: 
               
               
                   
                 explain(theText,nAtoms,theAtoms) of page BookAlternate, 
               
               
                   
                 results(theText,nAtoms,theAtoms) of page BookAlternate, 
               
               
                   
                 prepare TheLists(theText,nAtoms,theAtoms) of background 
               
               
                   
                 PreSelectionBoard, theLists(theText,nAtoms,theAtoms) of 
               
               
                   
                 background PreSelectionBoard, 
               
               
                   
                 explanationToBoard(theText,nAtoms,theAtoms) of page 
               
               
                   
                 PreSetectionBoard, 
               
               
                   
                 listMechResults(theText,nAtoms,theAtoms,Materials,Analyses) of 
               
               
                   
                 background FundamentalAnalysesBoard, 
               
               
                   
                 listEconResults(theText,nAtoms,theAtoms,Processes,Analyses) 
               
               
                   
                 of background FundamentalAnalysesBoard, 
               
               
                   
                 listTheGrades(theText,nAtoms,theAtoms,Grades,Grades) of 
               
               
                   
                 background DesignBoard 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 5 
               
             
            
               
                   
               
               
                 Book Handlers (Continued) 
               
            
           
           
               
               
            
               
                 Handler and Script 
                 Functionality 
               
               
                   
               
               
                 HourGlass theStr, nAtoms, 
                 modify the mouse cursor shape as appropriate 
               
               
                 theAtoms 
               
               
                 PreSelectionOfProcessesAnd 
                 message handler for the “PreSelection of Processes and 
               
               
                 Materials 
                 Materials” menu item 
               
               
                   
                 clear appropriate fields reset menu and button captions for the 
               
               
                   
                 new consultation 
               
               
                   
                 set system variables and update the bottom status line 
               
               
                 PreSelectionAndAnalyses 
                 message handler for the “PreSelection and Analyses” menu item 
               
               
                   
                 clear appropriate fields, reset menu and button captions for the 
               
               
                   
                 new consultation 
               
               
                   
                 set system variables and update the bottom status line 
               
               
                 OpportunityAnalyses 
                 message handler for the “Opportunity Analyses” menu item 
               
               
                   
                 clear appropriate fields, reset menu and button captions for the 
               
               
                   
                 new consultation 
               
               
                   
                 set system variables and update the bottom status line 
               
               
                 CompleteConsultation 
                 message handler for the “Complete Consultation” menu item 
               
               
                   
                 clear appropriate fields, reset menu and button captions for the 
               
               
                   
                 new consultation 
               
               
                   
                 set system variables and update the bottom status line 
               
               
                 EconomicModels 
                 message handler for the “ . . . Models” menu item 
               
               
                 MechanicalModels 
                 check menu item and go to page Model 
               
               
                 EngineeringProperties 
                 message handler for the “Engineering Properties” menu item 
               
               
                   
                 check menu item and go to page Data 
               
               
                 Design 
                 message handler for the “Design” menu item 
               
               
                   
                 clear appropriate fields, reset menu and button captions for the 
               
               
                   
                 new consulation 
               
               
                   
                 set system variables and upate the bottom status line 
               
               
                 exitPAMS 
                 send leaveBook 
               
               
                 MyInitialMenu 
                 initialize menu bar and menu items 
               
               
                 MyAddMenuItems theExplain 
                 customize menu bar and items 
               
               
                   
                 depend on consultation type and phase 
               
               
                 Browse 
                 message handler for the “Browse” menu item 
               
               
                   
                 send history 
               
               
                 ResetForwardString TheString 
                 volunteer values to the Nexpert Object slot TheString to trigger 
               
               
                   
                 the meta-slot which reset the decision tree related to TheString 
               
               
                 uncheckMenuConsultations 
                 uncheck the menu items of the menu Consultations 
               
               
                 PAMSFinishSolving 
                 DDE execute message handler with Excel Solver for the mechanical 
               
               
                   
                 analyses 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 6 
               
             
            
               
                   
               
               
                 Input/Output Sections 
               
               
                 Handlers and Scripts for the Input/Output Sections 
               
            
           
           
               
               
               
               
            
               
                   
                 Background 
                   
                   
               
               
                 Section 
                 and Pages 
                 Handler and Script 
                 Functionality 
               
               
                   
               
               
                 PAMS 
                 background 
                 handle BContinuePAMS 
                 set menu and progression 
               
               
                   
                   
                   
                 depending on the consultation 
               
               
                   
                 page PAMS 
                 handle enterPage 
                 set system variables 
               
               
                   
                   
                   
                 update bottom status line 
               
               
                   
                   
                 handle teavePage 
                 set system variabtes 
               
               
                   
                   
                 handle idle 
                 move group GMECCircles 
               
               
                 Applications 
                 background 
                 handle BContinueApplications 
                 load knowledge base 
               
               
                   
                   
                 handle BBackApplications 
                 unload knowledge base 
               
               
                   
                 page 
                 handle enterPage, 
                 set bottom status line and highlight 
               
               
                   
                 Applications 
                   
                 selection 
               
               
                   
                   
                 handle leavePage 
                 record selection 
               
               
                 Opportunity 
                 background 
                 handle BContinueOpportunity 
                 unload and load knowledge bases 
               
               
                 Identification 
                   
                   
                 and, depending on the consultation; 
               
               
                   
                   
                   
                 volunteer, suggest, and run Nexpert 
               
               
                   
                   
                   
                 Object 
               
               
                   
                   
                 handle BBackOpportunity 
                 unload and load knowledge bases 
               
               
                   
                   
                   
                 depending on consultation 
               
               
                   
                 pages 
                 handle enterPage 
                 set bottom status line; set the list of 
               
               
                   
                 Opportunity 
                   
                 input variables, and highlight 
               
               
                   
                 to 
                   
                 selection when necessary 
               
               
                   
                 Opportunity12 
               
               
                   
                   
                 handle leavePage 
                 reset some system variables 
               
               
                   
                   
                 handle ButtonUp (Next&gt;&gt;) 
                 set bottom status line and transfer 
               
               
                   
                   
                   
                 input variables values to OABoard 
               
               
                   
                   
                 handle ButtonUp (&lt;&lt;Previous) 
                 in general, go to the previous page 
               
               
                   
                   
                 handle ButtonUp (&lt;&lt;Previous) 
                 in general, go to the previous page 
               
               
                   
                 page 
                 handle enterPage 
                 set bottom status line; set the list of 
               
               
                   
                 Opportunity13 
                   
                 input variables, and highlight 
               
               
                   
                   
                   
                 selection when necessary 
               
               
                   
                   
                 handle leavePage 
                 reset some system variables 
               
               
                   
                   
                 handle ButtonUp (Next&gt;&gt;) 
                 set bottom status line and menus 
               
               
                   
                   
                   
                 transfer input variables values to 
               
               
                   
                   
                   
                 OABoard, prepare the fields for the 
               
               
                   
                   
                   
                 OA results, volunteer, and control 
               
               
                   
                   
                   
                 Nexpert Object inference engine 
               
               
                   
                   
                 handle ButtonUp (&lt;&lt;Previous) 
                 in general, go to the previous page 
               
               
                   
                   
                 handle ButtonUp (&lt;&lt;Previous) 
                 in general, go to the previous page 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 7 
               
             
            
               
                   
               
               
                 Handlers and Scripts for the Input/Output Sections (Continued) 
               
            
           
           
               
               
               
               
            
               
                   
                 Background 
                   
                   
               
               
                 Section 
                 and Pages 
                 Handler and Script 
                 Functionality 
               
               
                   
               
               
                 Opportunity 
                 page 
                 handle leavePage 
                 reset some system variables 
               
               
                 Identification 
                 Opportunity14 
               
               
                   
                   
                 handle ButtonUp (Next&gt;&gt;) 
                 go to the next page 
               
               
                   
                   
                 handTe ButtonUp (&lt;&lt;Previous) 
                 reset knowledge base or choose 
               
               
                   
                   
                   
                 another consultation 
               
               
                   
                 page 
                 handle leavePage 
                 reset some system variables 
               
               
                   
                 Opportunity15 
               
               
                   
                   
                 handle enterPage 
                 set status line 
               
               
                   
                   
                 handle ButtonUp (Next&gt;&gt;) 
                 go to the next page 
               
               
                   
                   
                 handle ButtonUp (&lt;&lt;Previous) 
                 go to the previous page 
               
               
                   
                 page 
                 handle leavePage 
                 reset some system variables 
               
               
                   
                 Opportunity16 
               
               
                   
                   
                 handle enterPage 
                 set status line 
               
               
                   
                   
                 handle ButtonUp (Next&gt;&gt;) 
                 send BContinueOpportunity 
               
               
                   
                   
                 handle ButtonUp (&lt;&lt;Previous) 
                 go to the previous page 
               
               
                 Part 
                 background 
                 handle 
                 volunteer data files names and 
               
               
                 Specifications 
                   
                 BContinuePartSpecifications 
                 suggest Setector.BoolVar (Nexpert) 
               
               
                   
                   
                 handle 
                 go back to main menu or to the 
               
               
                   
                   
                 BBackPartSpecifications 
                 Opportunity identification (unload 
               
               
                   
                   
                   
                 and load knowledge base in 
               
               
                   
                   
                   
                 Nexpert Object) 
               
               
                   
                 page Part 
                 handle enterPage 
                 set bottom status line, set the list of 
               
               
                   
                 Specifications 
                   
                 input variables, display the groups 
               
               
                   
                   
                   
                 on the page (depending on the 
               
               
                   
                   
                   
                 application domain), and highlight 
               
               
                   
                   
                   
                 the selections when necessary 
               
               
                   
                   
                 handle leavepage 
                 reset some system variables 
               
               
                   
                   
                 handle ButtonUp 
                 set bottom status line and transfer 
               
               
                   
                   
                 (Continue&gt;&gt;) 
                 input variables values to the 
               
               
                   
                   
                   
                 PreSelectionBoard 
               
               
                   
                   
                 handle ButtonUp 
                 send BBackPartSpecifications 
               
               
                   
                   
                 (&lt;&lt;Opportunity Identification) 
               
               
                   
                 pages Part 
                 handle enterPage 
                 set bottom status line, set the list of 
               
               
                   
                 Specifications1 
                   
                 input variabies, display the groups 
               
               
                   
                 to 
                   
                 on the page (depending on the 
               
               
                   
                 Part 
                   
                 application domain), and highlight 
               
               
                   
                 Specifications3 
                   
                 the selections when necessary 
               
               
                   
                   
                 handle leavePage 
                 reset some system variables 
               
               
                   
                   
                 handle ButtonUp 
                 transfer input variables values to 
               
               
                   
                   
                 (Continue&gt;&gt;) 
                 PreSelectionBoard 
               
               
                   
                   
                 handle BuffonUp 
                 go to previous page 
               
               
                   
                   
                 (&lt;&lt;Opportunity Identification) 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 8 
               
             
            
               
                   
               
               
                 Handles and Scripts for the Input/Output Sections (Continued) 
               
            
           
           
               
               
               
               
            
               
                   
                 Background 
                   
                   
               
               
                 Section 
                 and Pages 
                 Handler and Script 
                 Functionality 
               
               
                   
               
               
                 Part 
                 page Part 
                 handle enterPage 
                 set bottom status line; set the list of 
               
               
                 Specifications 
                 Specifications4 
                   
                 input variables, display the groups 
               
               
                   
                   
                   
                 on the page (depending on the 
               
               
                   
                   
                   
                 application domain), and highlight 
               
               
                   
                   
                   
                 the selections when necessary 
               
               
                   
                   
                 handle leavePage 
                 reset some system variables 
               
               
                   
                   
                 handle ButtonUp 
                 transfer input variables values to 
               
               
                   
                   
                 (PreSelectionResults&gt;&gt;) 
                 PreSelectionBoard, send 
               
               
                   
                   
                   
                 BBackPartSpecifications, and 
               
               
                   
                   
                   
                 update menu 
               
               
                   
                   
                 handle ButtonUp 
                 go to previous page 
               
               
                   
                   
                 (&lt;&lt;Opportunity Identification) 
               
               
                 Selection 
                 background 
                 handle BContinueSelection 
                 unload, load knowledge bases, 
               
               
                   
                   
                   
                 volunteer, suggest, and control to 
               
               
                   
                   
                   
                 Nexpertg Object&#39;s inference engine 
               
               
                   
                   
                   
                 depending on the consultation. Set 
               
               
                   
                   
                   
                 bottom status line 
               
               
                   
                   
                 handle BBackSelection 
                 send BBackPartSpecifications or 
               
               
                   
                   
                   
                 BContinueOpportunity depending 
               
               
                   
                   
                   
                 on consultation 
               
               
                   
                 page Selection 
                 handle enterPage 
                 set bottom status line, prepare 
               
               
                   
                   
                   
                 display for re-selection results 
               
               
                   
                   
                 handle leavePage 
                 reset some system variables 
               
               
                   
                   
                 handle ButtonUp Rejected&gt;&gt;) 
                 go to Rejected 
               
               
                   
                   
                 handle ButtonUp (&lt;&lt;Part 
                 send BBackSelection 
               
               
                   
                   
                 Specifications) 
               
               
                   
                 page Rejected 
                 handle enterPage 
                 set bottom status line, prepare 
               
               
                   
                   
                   
                 display for re-selection results 
               
               
                   
                   
                 handle leavePage 
                 reset some system variables 
               
               
                   
                   
                 handle ButtonUp (Design&gt;&gt;) 
                 send BContinueSelection 
               
               
                   
                   
                 handle ButtonUp (&lt;&lt;Selected) 
                 go to Selection 
               
               
                 Design 
                 background 
                 handle BContinueDesign 
                 set some system variables and 
               
               
                   
                   
                   
                 place data onto the DesignBoard; 
               
               
                   
                   
                   
                 volunteer, suggest, and control the 
               
               
                   
                   
                   
                 Nexpert Object inference engine 
               
               
                   
                   
                   
                 set the bottom status line 
               
               
                   
                   
                 handle BBackDesign 
                 unload, load, or restart knowledge 
               
               
                   
                   
                   
                 base depending on the consultation 
               
               
                   
                 page Design 
                 handle enterPage 
                 set the list of variables, highlight 
               
               
                   
                   
                   
                 selection 
               
               
                   
                   
                 handle leavePage 
                 set some system variables and 
               
               
                   
                   
                   
                 keep record of highlights 
               
               
                   
                   
                 handle ButtonUp (Mech &amp; 
                 set bottom status line, place data on 
               
               
                   
                   
                 Econ Analyses&gt;&gt;) 
                 the DesignBoard 
               
               
                   
                   
                 handle ButtonUp (&lt;&lt;Grades) 
                 set bottom status line; prepare, 
               
               
                   
                   
                   
                 reset some decision trees, and 
               
               
                   
                   
                   
                 restart Nexpert Object inference 
               
               
                   
                   
                   
                 engine 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 9 
               
             
            
               
                   
               
               
                 Handlers and Scripts for the Input/Output Sections (Continued) 
               
            
           
           
               
               
               
               
            
               
                   
                 Background 
                   
                   
               
               
                 Section 
                 and Pages 
                 Handler and Script 
                 Functionality 
               
               
                   
               
               
                 Design 
                 page Grades 
                 handle enterPage 
                 set bottom status line, highlight 
               
               
                   
                   
                   
                 grades selection 
               
               
                   
                   
                 handle leavePage 
                 keep record of highlights 
               
               
                   
                   
                 handle ButtonUp (Continue&gt;&gt;) 
                 reset some decision trees, suggest 
               
               
                   
                   
                   
                 and control Nexpert Object&#39;s 
               
               
                   
                   
                   
                 inference engine 
               
               
                   
                   
                 handle ButtonUp 
                 send BBackDesign 
               
               
                   
                   
                 (&lt;&lt;PreSelection) 
               
               
                   
                 pages 
                 handle enterPage 
                 set bottom status line, highlight 
               
               
                   
                 EqualLeggedAngle 
                   
                 selection, set the list ot input 
               
               
                   
                 to 
                   
                 variables 
               
               
                   
                 UProfileChannel 
               
               
                   
                   
                 handle leavePage 
                 keep record og highlights and set 
               
               
                   
                   
                   
                 some system variables 
               
               
                   
                   
                 handle ButtonUp (Mech &amp; 
                 set bottom status line, prepare 
               
               
                   
                   
                 Econ Results&gt;&gt;) 
                 display for the mechanical results, 
               
               
                   
                   
                   
                 place data on the DesignBoard, and 
               
               
                   
                   
                   
                 send BContinueDesign 
               
               
                   
                   
                 handle ButtonUp (&lt;&lt;Back) 
                 set bottom status line, go to page 
               
               
                   
                   
                   
                 Design 
               
               
                 Analyses 
                 background 
                 handle BContinueAnalyses 
                 unload, load knowledge base 
               
               
                   
                   
                   
                 (Nexpert Object) 
               
               
                   
                   
                 handle BBackAnalyses 
                 depending on the analyses to run, 
               
               
                   
                   
                   
                 reset specific decision trees in 
               
               
                   
                   
                   
                 Nexpert Object 
               
               
                   
                 page Analyses 
                 handle enterPage 
                 prepare display of the mechanical 
               
               
                   
                   
                   
                 and economic analyses 
               
               
                   
                   
                 handle leavePage 
                 set some system variables 
               
               
                   
                   
                 handle ButtonUp (Advisor&gt;&gt;) 
                 send BContinueAnalyses 
               
               
                   
                   
                 handle ButtonUp (&lt;&lt;Fund. 
                 send BBackAnalyses 
               
               
                   
                   
                 Analyses) 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 10 
               
             
            
               
                   
               
               
                 Scripts Sections 
               
               
                 Handlers and Scripts for tha Script Sections 
               
            
           
           
               
               
               
               
            
               
                   
                 Background 
                   
                   
               
               
                 Section 
                 and Pages 
                 Handler and Script 
                 Functionality 
               
               
                   
               
               
                 BookAlternate 
                 background 
                 get LoadKnowledgeBase 
                 call UnloadKnowledgeBase and 
               
               
                   
                   
                 theKB,theHypo 
                 load the knowledge base theKB 
               
               
                   
                   
                   
                 (Nexpert Object) 
               
               
                   
                   
                 get UnloadKnowledgeBase 
                 unload the (KBid) knowledge base 
               
               
                   
                   
                   
                 (Nexpert Object) 
               
               
                   
                   
                 get VolunteerIntoToSoftware 
                 volunteer or poke value theValue 
               
               
                   
                   
                 theVariable,theValue,theBoard, 
                 to variable theVariable placed on 
               
               
                   
                   
                 theSoftware 
                 board theBoard into sotfware 
               
               
                   
                   
                   
                 theSoftware (Nexpert Object or 
               
               
                   
                   
                   
                 Excel) 
               
               
                   
                   
                 get startBackwardChaining 
                 suggest hypothesis theHypo and 
               
               
                   
                   
                 theHypo 
                 run the inference engine (Nexpert 
               
               
                   
                   
                   
                 Object) 
               
               
                   
                 page 
                 get Explain 
                 prepare the various explanation 
               
               
                   
                 BookAlternate 
                 theTag,nAtoms,theAtoms 
                 (the topic is indicated by theTag) of 
               
               
                   
                   
                   
                 the reasoning for the Opportunity 
               
               
                   
                   
                   
                 Identification and the Selection, 
               
               
                   
                   
                   
                 and store them as properties of the 
               
               
                   
                   
                   
                 background UtilitiesAlternate 
               
               
                   
                   
                 get Results 
                 display the results (the topic is 
               
               
                   
                   
                 theTag,nAtoms,theAtoms 
                 indicated by theTag) of the 
               
               
                   
                   
                   
                 Opportunity Identification 
               
               
                 ScriptAlternate 
                 background 
                 get clearFields 
                 clear fields of the list theList and on 
               
               
                   
                   
                 theList,thePage 
                 the page thePage 
               
               
                   
                   
                 get formatNumber theNumber 
                 format number theNumber 
               
               
                   
                   
                 get StripCRLF myVar 
                 remove carriage return and line 
               
               
                   
                   
                   
                 feed from the string myVar 
               
               
                   
                   
                 get AddUnitToNumber 
                 add unit to number theNumber 
               
               
                   
                   
                 TheNumber 
               
               
                   
                   
                 get StripCRLF myVar 
                 remove carriage return and line 
               
               
                   
                   
                   
                 feed from the string myVar 
               
               
                   
                   
                 get hightLight 
                 highlight or record the selections of 
               
               
                   
                   
                 thePage,theList,theCode 
                 the items of the list theList when 
               
               
                   
                   
                   
                 entering (theCode) or leaving the 
               
               
                   
                   
                   
                 page thePage 
               
               
                   
                   
                 get 
                 change colors for the cell theCell of 
               
               
                   
                   
                 HChangeTableYesNoColors 
                 horizontal mutli or single-select list 
               
               
                   
                   
                 theCell 
                 boxes 
               
               
                   
                   
                 get FieldFormat 
                 format the field theField 
               
               
                   
                   
                 theField,theFillColor, theFont, 
               
               
                   
                   
                 theStroke, 
               
               
                   
                   
                 theSize,theFontType 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 11 
               
             
            
               
                   
               
               
                 Handlers and Scripts for the Script Sections (Continued) 
               
            
           
           
               
               
               
               
            
               
                   
                 Background 
                   
                   
               
               
                 Section 
                 and Pages 
                 Handler and Script 
                 Functionality 
               
               
                   
               
               
                 SciptAlternate 
                 Background 
                 get populateListBox 
                 populate a vertical list box with the 
               
               
                   
                   
                 theList,theLine,theField,theFill 
                 appropriate items and format 
               
               
                   
                   
                 Color, theFont, theStroke, 
               
               
                   
                   
                 theSize,theFontType 
               
               
                   
                   
                 get ChangeNumber theField, 
                 increment or decrement by Delta 
               
               
                   
                   
                 UpperLimit, LowerLimit, 
                 the integer value contained in field 
               
               
                   
                   
                 Direction, Delta 
                 theField according to UpperLimit 
               
               
                   
                   
                   
                 LowerLimit, and Direction 
               
               
                   
                   
                 get stripPercentageXY 
                 remove special characters such as 
               
               
                   
                   
                 theValue 
                 %, x, y from theValue 
               
               
                   
                   
                 get scanColors 
                 highlight selection tor horizontal 
               
               
                   
                   
                 RowNumber,NumberOfColumns, 
                 multi-select list box 
               
               
                   
                   
                 thePresentPage 
               
               
                   
                   
                 get synchScrolling 
                 synchronize scrolling between 
               
               
                   
                   
                 thepage,theField,theOtherField 
                 fields theField and theOtherField 
               
               
                   
                   
                   
                 of the page thePage 
               
               
                   
                   
                 get MyParseSpace TheStr 
                 substitute “ ” or “&amp;” by “_” in the 
               
               
                   
                   
                   
                 string TheStr 
               
               
                   
                   
                 get 
                 remove “ ”, “&amp;” or “/” from the 
               
               
                   
                   
                 getRidOfSpecialCharacters 
                 string TheStr 
               
               
                   
                   
                 TheStr 
               
               
                   
                   
                 get 
                 replace “_” by “ ” in string TheStr 
               
               
                   
                   
                 MyParseUnderscoreToSpace 
               
               
                   
                   
                 TheStr 
               
               
                   
                   
                 get 
                 replace “_” by “&amp;” in string TheStr 
               
               
                   
                   
                 MyParseUnderscoreToAmpersand 
               
               
                   
                   
                 TheStr 
               
               
                   
                   
                 get extractNameFromSlot 
                 return object name from Nexpert 
               
               
                   
                   
                 MyName 
                 Object slot 
               
               
                   
                   
                 get substituteSpaceForComa 
                 substitute space for coma in string 
               
               
                   
                   
                 theString 
                 theString 
               
               
                   
                 page 
                 get 
                 place information of the page 
               
               
                   
                 ScriptAlternate 
                 PutInformationIntoTheBoard 
                 thePresentPage onto the board 
               
               
                   
                   
                 theBoard, 
                 TheBoard, and call 
               
               
                   
                   
                 thePresentPage,theSoftware 
                 VolunteerIntoToSoftware to 
               
               
                   
                   
                   
                 transfer it to theSoftware (Nexpert 
               
               
                   
                   
                   
                 Object or Excel) 
               
               
                 Applications 
                 background 
                 get theApplication 
                 return the application selected by 
               
               
                 Alternate 
                   
                   
                 the user 
               
               
                   
                   
                 get makeTheList thisField 
                 display the lists ot applications to 
               
               
                   
                   
                   
                 choose trom (levels 35 to 55) 
               
               
                   
                 page 
                 get displayLevel65 
                 display level 65 of market cut 
               
               
                   
                 Applications 
               
               
                   
                 Alternate 
               
               
                 Data 
                 page Data 
                 handle enterPage 
                 set bottom status line 
               
               
                   
                   
                 handle leavePage 
                 set some system variables 
               
               
                 Models 
                 page Models 
                 handle enterPage 
                 set bottom status line 
               
               
                   
                   
                 handle leavePage 
                 set some system variables 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 12 
               
             
            
               
                   
               
               
                 Handlers and Scripts for the Script Sections (Continued) 
               
            
           
           
               
               
               
               
            
               
                   
                 Background 
                   
                   
               
               
                 Section 
                 and Pages 
                 Handler and Script 
                 Functionality 
               
               
                   
               
               
                 Utilities 
                 background 
                 handle buttonUp theText 
                 bring a dialog box with an “OK” button 
               
               
                 Alternate 
                   
                 (MessageHandlerDialogBoxOK) 
                 and display a text thelext 
               
               
                   
                   
                 handle buttonUp theText 
                 bring a dialog box with a “Continue” 
               
               
                   
                   
                 (MessageHandlerDialogBoxContinue) 
                 button and display a text theText; 
               
               
                   
                   
                   
                 “Continue” reruns the Nexpert Object 
               
               
                   
                   
                   
                 inference engine 
               
               
                   
                   
                 handle buttonUp 
                 bring a dialog box with a “Continue” 
               
               
                   
                   
                 (MessageHandlerDialogBoxList) 
                 button, display a question, and a single- 
               
               
                   
                   
                   
                 select list box; “Continue” volunteers the 
               
               
                   
                   
                   
                 selection to Nexpert Object and reruns 
               
               
                   
                   
                   
                 the inference engine 
               
               
                   
                   
                 handle buttonUp 
                 bring a dialog box with a “Continue” 
               
               
                   
                   
                 (MessageHandlerDialogBoxMList) 
                 button display a question, and a multi- 
               
               
                   
                   
                   
                 select list box; “Continue” volunteers the 
               
               
                   
                   
                   
                 selection to Nexpert Object and reruns 
               
               
                   
                   
                   
                 the interence engine 
               
               
                   
                   
                 handle buttonUp theText 
                 bring a dialog box with an “OK” button 
               
               
                   
                   
                 (MessageHanderDialogBoxEOS 
                 and display a text theText “OK” 
               
               
                   
                   
                   
                 displays the end of consultation screen 
               
               
                   
                   
                 handle buttonUp theText 
                 bring a dialog box with “OK” and “Print” 
               
               
                   
                   
                 (HelpExplain) 
                 buttons and display an explanation text 
               
               
                   
                   
                   
                 theText; “OK” calls cancelHelp() 
               
               
                   
                   
                   
                 and “Print” calls get cancelHelp() and 
               
               
                   
                   
                   
                 get printExplain(theText,the name of this 
               
               
                   
                   
                   
                 background) of page UtilitiesAlternate 
               
               
                   
                   
                 handle buttonUp theText 
                 bring a dialog box with “OK”, “Save”, 
               
               
                   
                   
                 (Comments) 
                 “Save All”, and “Print” buttons. The 
               
               
                   
                   
                   
                 buttons call different script of page 
               
               
                   
                   
                   
                 UtilitiesAlternate 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 13 
               
             
            
               
                   
               
               
                 Handlers and Scripts for the Script Sections (Continued) 
               
            
           
           
               
               
               
               
            
               
                   
                 Background 
                   
                   
               
               
                 Section 
                 and Pages 
                 Handler and Script 
                 Functionality 
               
               
                   
               
               
                 Utilities 
                 page Utilities 
                 get theInformationDisplayed 
                 display information and check menu item 
               
               
                 Alternate 
                 Alternate 
                 thePreviousPage, theText, 
               
               
                   
                   
                 theObject, theMenuItem 
               
               
                   
                   
                 get theInformationGone 
                 remove information and uncheck menu 
               
               
                   
                   
                 thePreviousPage, theText, 
                 item 
               
               
                   
                   
                 theObject, theMenuItem 
               
               
                   
                   
                 get displayHelp 
                 display general help for each page 
               
               
                   
                   
                 thePreviousPage, theText, 
                 thePreviousPage of the book 
               
               
                   
                   
                 theObject,theIndex 
               
               
                   
                   
                 get cancelHelp 
                 cancel general help for each page of the 
               
               
                   
                   
                 thePreviousPage, theText, 
                 book 
               
               
                   
                   
                 theObject 
               
               
                   
                   
                 get showCommentsScreen 
                 show the dialog box for entering 
               
               
                   
                   
                 thePreviousPage,theText,the 
                 comments and check menu 
               
               
                   
                   
                 Object,theMenuItem 
               
               
                   
                   
                 get saveCommentsScreen 
                 save comments for the page 
               
               
                   
                   
                 thePreviousPage,theText,the 
                 thePreviousPage 
               
               
                   
                   
                 Object 
               
               
                   
                   
                 get saveAllCommentsScreen 
                 save comments for all the pages of the 
               
               
                   
                   
                   
                 book 
               
               
                   
                   
                 get DisplayEndOfSession 
                 display the end of consultation screen 
               
               
                   
                   
                 get displayExplain 
                 bring the dialog box for displaying the 
               
               
                   
                   
                 thePreviousPage,theText,the 
                 explanation for the major elements of 
               
               
                   
                   
                 Object,theIndex,theMenuItem 
                 opportunity identitication and Selection, 
               
               
                   
                   
                   
                 and check menu 
               
               
                   
                   
                 get cancelExplain 
                 uncheck menu items when cancelling 
               
               
                   
                   
                 thePreviousPage, theText, 
                 explain 
               
               
                   
                   
                 theObject 
               
               
                   
                   
                 get 
                 uncheck all the menu items 
               
               
                   
                   
                 uncheckMenuItemsForUtilities 
               
               
                   
                   
                 get printExplain 
                 print explanation 
               
               
                   
                   
                 theText,theBackground 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 14 
               
             
            
               
                   
               
               
                 Communication Sections 
               
               
                 Handlers and Scripts for the Board Sections 
               
            
           
           
               
               
               
               
            
               
                   
                 Background 
                   
                   
               
               
                 Section 
                 and Pages 
                 Handler and Script 
                 Functionality 
               
               
                   
               
               
                 OABoard 
                 background 
                 get MatrixToNXP 
                 map input variables (theVariable) for 
               
               
                   
                   
                 theVariable,theValue 
                 the Opportunity Identification to Nexpert 
               
               
                   
                   
                 Object slots 
               
               
                 PreSelection 
                 background 
                 get MatrixToNXP 
                 map input variables (theVariable) for 
               
               
                 Board 
                   
                 theVariable,theValue 
                 the Selection to Nexpert Object slots 
               
               
                   
                   
                 get prepareTheLists 
                 set the lists of groups to display for the 
               
               
                   
                   
                 theText,nAtoms,theAtoms 
                 Part Specifications pages depending on 
               
               
                   
                   
                   
                 the application domains 
               
               
                   
                   
                 get MapApplicationToGroup 
                 set the position of the different groups 
               
               
                   
                   
                 thePage 
                 on the page thePage 
               
               
                   
                   
                 get groupHeights theGroup 
                 determine the group theGroup heights 
               
               
                   
                   
                 get theLists theTag, nAtoms, 
                 list and sort candidate and rejected 
               
               
                   
                   
                 theAtoms 
                 materials and processes 
               
               
                   
                 Page 
                 get explanationToBoard 
                 store expianation for each rejected or 
               
               
                   
                 PreSelection 
                 theTag,nAtoms,theAtoms 
                 accepted process and material in 
               
               
                   
                 Board 
                   
                 properties of pages 
               
               
                   
                   
                 get modifyLists 
                 keep track ot the appropriate lists of 
               
               
                   
                   
                 theText,theLines,theLine, 
                 processes and materials for further 
               
               
                   
                   
                 thePage,theField 
                 analyses aner user interaction 
               
               
                   
                   
                 get 
                 map long materials names to short 
               
               
                   
                   
                 correspondanceMaterialsToObjects 
                 names 
               
               
                   
                   
                 theMaterial 
               
               
                   
                   
                 get 
                 map long processes names to short 
               
               
                   
                   
                 correspondanceProcessesTo 
                 names 
               
               
                   
                   
                 Objects theProcess 
               
               
                 DesignBoard 
                 background 
                 get MatrixToExcel 
                 map input variables to Excel 
               
               
                   
                   
                 theVariable,theValue 
                 worksheets cells 
               
               
                   
                   
                 get MatrixToNXP 
                 map variables to Nexpert Object slots 
               
               
                   
                   
                 theVariable,theValue 
               
               
                   
                   
                 get listTheGrades 
                 list the grades of materials (theAtoms) 
               
               
                   
                   
                 theText,nAtoms,theAtoms,the 
                 in field theField on page thePage 
               
               
                   
                   
                 Field,thePage 
               
               
                   
                 page 
                 get runModel thePage 
                 run the Excel Solver for a particular 
               
               
                   
                 DesignBoard 
                   
                 shape, specific constraints, and a given 
               
               
                   
                   
                   
                 grade 
               
               
                   
                   
                 get LengthToDepth 
                 set message for length to depth test 
               
               
                   
                   
                 Shape,thePage 
               
               
                   
                   
                 get modifyLists 
                 keep track of the appropriate grades list 
               
               
                   
                   
                 theText,theLines,theLine, 
                 for further analyses after user 
               
               
                   
                   
                 thePage,theField 
                 interaction 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 15 
               
             
            
               
                   
               
               
                 Table 15 Handlers and Scripts for the Board Sections (Continued) 
               
            
           
           
               
               
               
               
            
               
                   
                 Background 
                   
                   
               
               
                 Section 
                 and Pages 
                 Handler and Script 
                 Functionality 
               
               
                   
               
               
                 Fundamental 
                 background 
                 get listMechResults 
                 list the results of the mechanical 
               
               
                 Analyses 
                   
                 theText,nAtoms,theAtoms,the 
                 anaiyses for all considered grades 
               
               
                 Board 
                   
                 Field,thePage 
                 (theAtoms) in field theField on page 
               
               
                   
                   
                   
                 thePage 
               
               
                   
                   
                 get listEconResults 
                 list the results ot the mechanical 
               
               
                   
                   
                 theText,nAtoms,theAtoms,the 
                 analyses for all considered grades and 
               
               
                   
                   
                 Field,thePage 
                 their associated processes in field 
               
               
                   
                   
                   
                 theField on page thePage 
               
               
                   
               
            
           
         
       
     
     IV. Expert System Shell 
     A. Overview 
     Several criteria were developed to select the expert system shell. The expert system shell must accommodate the integration of various forms of knowledge, the portability to several platforms, and the link to a graphical user interface (GUI) tool. 
     Any suitable commercial expert system shell may be utilized in the present invention. Examples of suitable commercially available programs include Art*Interprise, ART-IM,, Level5 Object, Nexpert Object of the Smart Elements. Level5 Object 3.0 available from Information Builders, Inc., provides an expert system with rules, forward and backward chaining logic, and very limited object oriented processing, and an integrated graphical tool kit. 
     As another example, Art*Enterprise available from Inference Corporation, provides an expert system with rules, forward and backward chaining, pattern matching, non monotonic reasoning, full object oriented case-based reasoning, and an object oriented graphical tool kit. 
     Finally, Nexpert objects of the Smart Elements Suite available from Neuron Data, provides an expert system with rules, mainly backward and forward chaining, and object oriented reasoning, and GUI scripting language. 
     Although ART-IM 4.0 paradigms for representing knowledge were more sophisticated than Nexpert Object 2.0b, and Level5 Object had a rudimentary integrated graphical tool kit, Nexpert Object 2.0b was selected for implementation of the SYS 1  embodiment because it had a better integration to databases. ART*Enterprise was selected for use with SYS 2 . 
     In the SYS 1  embodiment of the present invention developed by the inventors, the Reasoning/Strategy/Problem Solving module of the expert shell system comprises: (1) a Processes and Materials Selection Module; and (2) an Opportunity Identification Module. SYS 2  extends problem solving strategies to include shape selection module. Implementation of these modules in SYS 1  and SYS 2  is organized according to the View of the World (VOW) concept explained below. 
     Classes, objects, and methods implement the declarative and procedural knowledge, and rules capture the search strategies. The rules, correspond to “rules of thumb” elicited from experts during the knowledge acquisition process. 
     B. View of a World (VOW) 
     Declarative knowledge and search strategies are two corner stones of problem solving. The declarative knowledge and the search strategies which solve a specific problem about a world, represent a particular commitment, perspective, or view of this world. The set of ontological commitments which focus on a particular perspective of a world for solving a specific problem can be called a “View Of a World” (VOW). 
     The different forms of knowledge in the present invention include symbolic reasoning, numerical computing, and data storage and retrieval. In general, events happen which involve objects of a particular universe. Reasoning strategies and plans determine why and when events (e.g., decision, actions) occur. 
     In order for a computer system to solve a problem about a particular universe (world), the declarative knowledge as well as the intelligent search strategies need to be represented and implemented. Such a description in terms of objects and events for a particular world also constitutes a VOW. 
     The understanding and the descriptions of these objects, events, and their relationships are necessary to simulate or emulate, to a given level of complexity and intelligence, these situations or worlds. 
     In the practice of the present invention, the reasoning strategies are encapsulated in units of knowledge called rules. A network of rules corresponds to intelligent search paths, decision trees, and lines of reasoning (inference chains). This View Of the World concept is further illustrated in the following FIGs. 
     Referring now to FIGS. 5 and 6 there is shown a representation of part of the SYS 1  VOW for the opportunity identification module (e.g., an expert perspective for doing opportunity identification) picturing hierarchies of concepts. The hierarchies, which include semantic and inheritance of characteristics and behaviors, provide the “What” and the “How” (the “Who”) for the VOW. 
     Referring now to FIG. 7 there is shown a representation of part of the VOW for the selection of processes and materials picturing a hierarchy of concepts for both SYS 1  and SYS 2 . This hierarchy provides context and inheritance of characteristics in terms of attributes and behaviors. 
     Referring now to FIG. 8, there is shown a representation of part of the VOW for the selection of processes and materials. Some of the main concepts (i.e., Mechanical, and Surface characteristics) are expanded to include more concepts (e.g., Stiffness). The leaf nodes of such hierarchies can represent facts, physical objects, and variables (e.g., Ambient Toughness). 
     Referring now to FIG. 9 there is shown a small decision tree. Each packet of this tree represents a rule (such as the one inside the dotted line rectangle). A rule is a unit of knowledge that captures some of the strategies to minimize search effort and optimize solutions: a rule corresponds to a “whenever some facts are true about the world then take some actions and/or assert other facts”. 
     C. Processes and Materials Selection Module 
     1. Overview 
     This module of the SYS 1  and SYS 2  embodiments contains knowledge that helps in selecting the most appropriate classes of materials and fabrication processes for a particular “durable goods” application. The selection process is based on material functional values and on process characteristics which is sometimes referred to as an application domain. 
     Materials and fabrication processes can rapidly be selected or rejected for a particular “durable goods” application based on materials functional values and processes characteristics. The application must meet certain criteria and perform definite functions, and, therefore, materials and fabrication processes are selected that meet the criteria and functional limitations of the particular “durable goods” application of interest. Shape complexity, part toughness, and transparency are instances of such criteria. Such criteria and functions are used in the section process. 
     Examples of the materials and fabrication processes selection process are as follows: 
     1. An application that requires a high shape complexity (e.g., a housing for a camcorder) cannot be fabricated using, for instance, Filament Winding, Pultrusion, In Line Thermoforming, or Drape Forming. 
     2. High part toughness is required in applications such as bumper beams. 
     3. Part toughness depends on both material toughness and part shape. 
     4. Average toughness materials can be retained when high shape complexity processes are selected and are economically feasible. In this case, the selection depends on materials properties, processes characteristics, part design, and fabrication economics. 
     The criteria for both SYS 1  and SYS 2  are grouped in terms of the major elements of the analysis: Environment, Surface, Electrical, Mechanical, Environmental &amp; Legal, Shape, and Production Volume. Tables 16, 17, 18, 19 and 20, presented and described in more detail below, reflect these groups and list all the functional values, including possible values, definitions, and contexts. 
     Experts&#39; knowledge is used to match application requirements with materials properties and fabrication characteristics. The output is expressed in terms of candidate or rejected processes and materials along with an explanation of how each of the conclusions are reached. 
     The number of discrete values for the output variables is finite because of the limited number of classes of materials and fabrication processes. For example, Table 21 lists these output variables, including possible values, definitions, and contexts, for SYS 1 . Similar variables were utilized in SYS 2  with some deletions and additions to reflect changes in the program. 
     
       
         
           
               
             
               
                 TABLE 21 
               
             
            
               
                   
               
               
                 Processes and Materials 
               
            
           
           
               
               
               
            
               
                 Elements of 
                 Output 
                   
               
               
                 Analyses 
                 Variables 
                 Values 
               
               
                   
               
               
                 Candidate 
                 Processes 
                 Resin Transfer Molding, Structural Reacticn Injection Molding, Reaction 
               
               
                   
                   
                 Injection Molding, Hand LayUp, SprayUp, Filament Winding, Purtrusion, 
               
               
                   
                   
                 Thermoplastic Injection Molding, In Line Thermoforming, Single Station 
               
               
                   
                   
                 Thermoforming, Vacuum Thermoforming, Drape Forming, Vacuum Plug 
               
               
                   
                   
                 Assisted Thermoforming, Pressure Forming, Pressure Vacuum Forming, 
               
               
                   
                   
                 Matched Mold Forming, Twin Sheet Forming, Extrusion Blow Molding, 
               
               
                   
                   
                 Low Pressure Structural Foam, Gas Counter Pressure Structural Foam, 
               
               
                   
                   
                 High Pressure Structural Foam, Injection Blow Molding, Gas Assisted 
               
               
                   
                   
                 Injection Molding, Rotational Molding, Sheet Molding Compound, Bulk 
               
               
                   
                   
                 Molding Compound, Compression Molding, Die Casting 
               
               
                   
                 Materials 
                 ULDPE, LDPE, LLDPE, HDPE, PC, GPPS, HIPS, ISOPLAST Opaque, 
               
               
                   
                   
                 ISCPLAST Clear, ISOPLAST Long Glass Reinforced, SAN, Mass ABS, 
               
               
                   
                   
                 Emulsion ABS, Hybrid ABS, PC ABS, PP CoPolymers, PP 
               
               
                   
                   
                 HomoPolymers, Epoxy Novolacs, Epoxy Resins, Electronic Grade Resins, 
               
               
                   
                   
                 Advanced Electronic Resins, VinylEster, RIM PolyUrethane, PolyUrea, 
               
               
                   
                   
                 SRIM PolyUrethane, PolyCyanate, PolyEster, PET, PBT, PCT, PETG, 
               
               
                   
                   
                 PolyCaprolactone PolyTetraMethyleneGlycolEther Resin, PolyAdipate, 
               
               
                   
                   
                 Automotive Resin, Health Care Resin, Specialty Resin, PC PolyEster, 
               
               
                   
                   
                 PMP, PVC, Acrylics SMA, ASA, PolyArylate, LCP, Nylon6, Nylon66, 
               
               
                   
                   
                 Amorphous Nylon, PPA, PPS, Acetals CoPolymer, Acetals HomoPolymer, 
               
               
                   
                   
                 PEEK, PSO, PAS, PEI, PAI, PVDF, ABS TPU, mPPO, Aluminium, Zinc, 
               
               
                   
                   
                 Magnesium 
               
               
                 Rejected 
                 Processes 
                 Same as above 
               
               
                   
                 Materials 
               
               
                   
               
            
           
         
       
     
     2. Algorithm of Processes and Materials 
     The reasoning implemented in the PAMS embodiments for the selection of processes and materials can be represented by the following scheme: 
     1. Choose the application domain which determines the selection criteria and their respective importance. 
     2. Consider processes or materials classes as long as they meet the application functional requirements and keep track of why they are selected. 
     3. Reject a material or material class or a process as soon as it does not meet one of the application functional criterion and record the reason why it is eliminated. 
     4. At any time, check if there are processes left to process each candidate material. If not, then eliminate the material. 
     5. At any time, check if there are materials left to be processed by each candidate process. If not, then eliminate the process. 
     Event  1  happens first whereas events  2  and  3  happen sequentially according to the search determined by the application domain. Events  4  and  5  are asynchronous and can occur at regular intervals or at any time during the selection process. 
     The search sequence for SYS 1  for a particular application domain corresponds to a subset of the following sequence of criteria, with criteria for SYS 2  being essentially the same with some minor modifications: 
     chemical types, chemical resistance, hydrolytic stability, heat deflection temperature, cold temperature toughness, radiation sterilizability, weatherability, color, surface finish, texture, transparency, dielectric, ambient toughness, creep resistance, fatigue resistance, wear and abrasion resistance, additions, complexity, constraints, draft, inside tolerances control, shape control accuracy, size, undercuts, production volume, impact resistance, stiffness, ignition resistance, environmental impact, legal, recyclability, emissions. 
     For each solution meeting the material functional values and on process characteristics of a chosen application domain, the user is provided with an explanation of how the system reaches its conclusions or selected that particular solution to the material functional values and on process characteristics. The explanation is delivered in terms of the major groups of functional values and characteristics including explanations as to individual processes, materials and classes of materials. 
     Referring now to FIGS. 10, and  12 - 18 , there are shown high level representations of the inference chains and prototypes for the Processes and Materials Selection Module, with the legend for those figures provided in FIG.  11 . Specifically, FIG. 10 shows inference chains for the Processes and Materials Selection Module as implemented in SYS 1 . 
     In this FIG. 10, three groups of inference chains have been represented with dotted lines suggesting multiple links to other chains: (1) the Application Domains inference chain; (2) the Matcher inference chain; and (3) the Specifier inference chains. 
     The Specifier has performs the task of focusing attention on features unique to a particular process or given class of materials during selection processing. The function of the Matcher is to compare the application functional requirements with various materials functional values and processes characteristics. 
     FIGS. 12-18 illustrate prototypes for the Matcher. Specifically, FIG. 12 shows root prototypes for the basic logical functioning of the Matcher; FIG. 13 shows data and cleaning processes and materials prototypes (i.e., reviewing the retrieved data to determine whether process can be eliminated because no materials match the process or whether a material can be eliminated because no process is left to process the material); FIG. 14 shows recyclability, legal considerations, environmental impact, ignition resistance, stiffness and impact resistance prototypes; FIG. 15 shows production volume, undercuts, size, shape control accuracy, inside tolerances control, and draft prototypes; FIG. 16 shows constraints dimensionality, shape complexity, additions, wear/abrasion resistance, fatigue resistance, and creep resistance prototypes; FIG. 17 shows ambient toughness, dielectric, transparency, texture, surface finish and color prototypes; and FIG. 18 shows weatherability, radiation sterilizability, cold temperature toughness, heat deflection temperature, hydrolytic stability, and chemical resistance prototypes. 
     Both PAMS embodiments developed by the inventors include a dynamic explanation of reasoning for each selection made and for each solution finally suggested. The module explains how it reaches its conclusions and provides information about the inference chains if used to derive the conclusions. The module has the capability to explain why a particular material or process is eliminated or selected for further analyses. Also, it details what happens to materials and processes during inferencing for each group of functional requirements. 
     The module contains two separate, similar, structures to implement these two modes of explanation. Each of these two structures features: (1) the encapsulation of meaning and context within rules; (2) the use of necessary containers (attributes, objects, and classes); and (3) the tracking of the firing of rules. 
     The following Table 22A illustrates the control for the Selection Module of the PAMS system of the present invention. The topics of the Matcher and their order depend on the application domain. The Proc I and Mat I of the Specifier, and their order depend on the results of the Matcher and on the inference engine. 
     
       
         
           
               
             
               
                 TABLE 22A 
               
             
            
               
                   
               
               
                 Control Agenda for the Selection Module 
               
            
           
           
               
               
            
               
                 Hypotheses 
                 Control 
               
               
                   
               
               
                 1. Customer Application 
                 Suggested by the user from the GUI 
               
               
                 2. Selection 
               
               
                  3. Matcher 
                 Left to Inference Engine 
               
               
                   3.1 Topic I 
               
               
                   3.2 . . . 
               
               
                  4. Specifier 
               
               
                   4.1 Specific Processes 
               
               
                   4.11 Proc I 
               
               
                   4.12 . . . 
               
               
                   4.2 Specific Materials 
               
               
                    4.21 Mat I 
               
               
                    4.21 . . . 
               
               
                   
               
            
           
         
       
     
     3. Input Data for Processes and Materials 
     Tables 16-20, describe the input data needed for the processes and materials modules. Tables 16 shows the input data relating to the parts specifications environment. For instance, the application might be required to retain most of its properties when exposed to chemicals in a manufacturing environment, to heat in an automotive environment, to water and sunlight in outdoor environment, or to cold as part of a refrigeration system. 
     Some functional values can take several of the values listed, e.g., the value for “Chemical Types” can be “Alcohols, Gasoline, Brake Fluid”. Other values correspond to exclusive choices, e.g., the value for “Ignition Resistance” is “High” or “Low” (exclusive). Other inputs are numeric, e.g., the value for “HDT” is a number between 40 to 500. Input variables include chemical exposure, chemical types, hydrolytic stability, heat deflection temperature (HDT), cold temperature toughness, ignition resistance, radiation sterilizability and weatherability. 
     
       
         
           
               
             
               
                 TABLE 16 
               
             
            
               
                   
               
               
                 Parts Specifications Environment 
               
            
           
           
               
               
               
               
            
               
                 Elements of 
                 Input Variables 
                   
                   
               
               
                 Analyses 
                 (Functional Values) 
                 Values 
                 Contexts 
               
               
                   
               
               
                 Environment 
                 Chemical Exposure 
                 Continuous Exposure 
                   
               
               
                   
                   
                 Required 
               
               
                   
                   
                 Intermittent Exposure Required 
               
               
                   
                   
                 No Exposure Expected 
               
               
                   
                 Chemical Types 
                 Adds Inorganic Weak 
                 If the exposure mode is No Exposure Expected then 
               
               
                   
                   
                 Acids Inorganic Strong 
                 NO materials will be eliminated even if several 
               
               
                   
                   
                 Acids Organic Weak 
                 chemicals are selected. 
               
               
                   
                   
                 Acids Organic Strong 
               
               
                   
                   
                 Alcohols 
               
               
                   
                   
                 Amines Aliphatic 
               
               
                   
                   
                 Amines Aromatic 
               
               
                   
                   
                 Bases Concentrated 
               
               
                   
                   
                 Bases Diluted 
               
               
                   
                   
                 Brake Fluid 
               
               
                   
                   
                 Esters 
               
               
                   
                   
                 Fats Oils Waxes 
               
               
                   
                   
                 Gasoline 
               
               
                   
                   
                 Glycols 
               
               
                   
                   
                 Hydrocarbons Aliphatic 
               
               
                   
                   
                 Hydrocarbons Aromatic 
               
               
                   
                   
                 Hydrocarbons Halogenated 
               
               
                   
                   
                 Ketones 
               
               
                   
                   
                 Motor Oil 
               
               
                   
                   
                 Ozone 
               
               
                   
                   
                 Phenols 
               
               
                   
                   
                 Salt Solutions 
               
               
                   
                 Hydrolytic Stability 
                 Not Important (low) 
                 Hydrolytic stability describes the resistance of the 
               
               
                   
                   
                 Important (medium) 
                 material to water. 
               
               
                   
                   
                 Determining Factor (high) 
                 A HIGH hydrotytic stability is such that the material 
               
               
                   
                   
                   
                 does NOT loss more than 5% of its properties when 
               
               
                   
                   
                   
                 exposed to water for 28 days at room temperature. 
               
               
                   
                   
                   
                 A MEDIUM hydroiytic stability is such that the 
               
               
                   
                   
                   
                 material does NOT lose more than 20% of its 
               
               
                   
                   
                   
                 properties when exposed to water for 28 days at 
               
               
                   
                   
                   
                 room temperature. 
               
               
                   
                   
                   
                 A LOW hydrolytic stability is such that the material 
               
               
                   
                   
                   
                 does lose mare than 20% of its properties when 
               
               
                   
                   
                   
                 exposed to water for 28 days at room temperature. 
               
               
                   
                 HDT 
                 40 to 500 F. 
                 The part deflection must be less than a given 
               
               
                   
                   
                   
                 (maximum) amount when the material is heated at 
               
               
                   
                   
                   
                 the HDT at 264 psi. Intuitively: The part must keep 
               
               
                   
                   
                   
                 good mechanical performance up to 360 F. (oven), or 
               
               
                   
                   
                   
                 it needs to perform well on the dash board of a car in 
               
               
                   
                   
                   
                 full sun (180 F.). 
               
               
                   
                 Cold Temperature 
                 Low, 
                 HIGH: The material sustains 200 in-lb of total energy 
               
               
                   
                 Toughness 
                 High 
                 at −20 C. (Instrumented Dart Impact test). 
               
               
                   
                   
                   
                 MEDIUM: The material sustains between 50 to 200 
               
               
                   
                   
                   
                 in-lb of total energy at −20 C. 
               
               
                   
                   
                   
                 LOW: The material sustains less than 50 in-lb of 
               
               
                   
                   
                   
                 total energy at −20 C. 
               
               
                   
                 Ignition Resistance 
                   
                 HIGH: material inherently meets UL 94 V-O 
               
               
                   
                   
                   
                 flammability rating. 
               
               
                   
                   
                   
                 LOW: material inherently meets UL 94 HB 
               
               
                   
                   
                   
                 (horizontal burn test) flammability rating. 
               
               
                   
                   
                   
                 Materials with low inherent ignition resistance often 
               
               
                   
                   
                   
                 can be modified with additives to have a high ignition 
               
               
                   
                   
                   
                 resistance 
               
               
                   
                 Radiation 
                 Not Important 
                 HIGH: The material does NOT lose 10% of its 
               
               
                   
                 Sterilizability 
                 Average 
                 properties (tensile, impact) when exposed to a 10 
               
               
                   
                   
                 High 
                 MRad radiation. 
               
               
                   
                   
                   
                 MEDIUM: The matarial loses more tham 10% of its 
               
               
                   
                   
                   
                 properties when exposed to a 10 MRad radiation and 
               
               
                   
                   
                   
                 less than 10% of its properties when exposed to a 
               
               
                   
                   
                   
                 2.5 MRad or less radiation. 
               
               
                   
                   
                   
                 LOW: The material loses more than 50% of its 
               
               
                   
                   
                   
                 properties when exposed to a 2.5 MRad or less 
               
               
                   
                   
                   
                 radiation. 
               
               
                   
                 Weatherability 
                   
                 HIGH: The material does NOT lose more than 10% 
               
               
                   
                   
                   
                 its properties (tensile, impact) under a xenon arc 
               
               
                   
                   
                   
                 (65 C. black panel temperature) for a 1000 hours. 
               
               
                   
                   
                   
                 LOW: The matarial loses more than 50% of its 
               
               
                   
                   
                   
                 properties under the same conditions. 
               
               
                   
               
            
           
         
       
     
     Table 17 shows the part specification input data relating to surface and electrical properties showing the elements of analysis for the surface and electrical properties. Input data for the surface aspect of the input module includes surface finish, color, texture, and transparency; while input data for electrical properties comprise the dielectric property desired. 
     
       
         
           
               
             
               
                 TABLE 17 
               
             
            
               
                   
               
               
                 Part Specifications Surface &amp; Electrical 
               
            
           
           
               
               
               
               
            
               
                 Elements of 
                 Input Variables 
                   
                   
               
               
                 Analyses 
                 (Functional Values) 
                 Values 
                 Contexts 
               
               
                   
               
               
                 Surface 
                 Surface Finish 
                 Class A Required 
                 Class A is an automotive definition. A part has 
               
               
                   
                   
                 Class A Not 
                 a class A surface when the low incidence tight 
               
               
                   
                   
                 Necessary 
                 reflected by its surface does not show 
               
               
                   
                   
                   
                 undulations from sink marks, gates, and others. 
               
               
                   
                 Color 
                 IMC 
                 The color can be obtained directly from the 
               
               
                   
                   
                 Paint 
                 process or in a second operation. The choices 
               
               
                   
                   
                 None 
                 are: 
               
               
                   
                   
                   
                 1) IMC (In Mold Coating), or 
               
               
                   
                   
                   
                 2) Painting. 
               
               
                   
                 Texture 
                 Not Important 
                 High pressure processes can deliver fine 
               
               
                   
                   
                 Average 
                 texture parts depending on the material; fine 
               
               
                   
                   
                 Fine 
                 texture means that the process replicates well 
               
               
                   
                   
                   
                 the tool texture in the part. 
               
               
                   
                   
                   
                 FINE: Fine and delicate prints and patterns are 
               
               
                   
                   
                   
                 desired (e.g., computer monitor). 
               
               
                   
                   
                   
                 AVERAGE: Fairly smooth surface (e.g., ‘non 
               
               
                   
                   
                   
                 show’ part like a load floor). 
               
               
                   
                 Transparency 
                 0% to 100% 
                 Transparency can be obtained with amorphous 
               
               
                   
                   
                   
                 materials. In general, amorphous 
               
               
                   
                   
                   
                 thermoplastics are transparent. The 
               
               
                   
                   
                   
                 transparency is expressed in terms of % of light 
               
               
                   
                   
                   
                 transmitted through a sample of given 
               
               
                   
                   
                   
                 thickness. As such, 100% corresponds to a 
               
               
                   
                   
                   
                 totally transparent material. 
               
               
                 Electrical 
                 Dielectric 
                 Not Important 
                 HIGH: The material relative dielectric constant 
               
               
                   
                 Properties 
                 Important 
                 is &gt;=5. 
               
               
                   
                   
                   
                 LOW: The material relative dielectric constant 
               
               
                   
                   
                   
                 is &lt;3. 
               
               
                   
               
            
           
         
       
     
     Table 18 shows part specifications input data relating to mechanical and environment and legal criteria showing elements of analysis for the two criteria. The input data for mechanical include ambient toughness, creep resistance, fatigue resistance, part toughness, part stiffness, and wear/abrasion resistance. The input data for environmental and legal include emissions, environmental impact, legal and recyclability. 
     Note that processes and materials are not selected or eliminated based on their Environmental and Legal criteria, but rather, the system informs the user (if desired to be informed) about the processes emissions and recyclability characteristics, and the materials environmental and legal issues in the form of appropriated warnings or warning messages. 
     
       
         
           
               
             
               
                 TABLE 18 
               
             
            
               
                   
               
               
                 Part Specifications Mechanical, Environmental &amp; Legal 
               
            
           
           
               
               
               
               
            
               
                 Elements of 
                 Input Variables 
                   
                   
               
               
                 Analyses 
                 (Functional Values) 
                 Values 
                 Contexts 
               
               
                   
               
               
                 Mechanical 
                 Ambient 
                 Low 
                 HIGH: The material sustains &gt;= 300 in-lb of total energy at 
               
               
                   
                 Toughness 
                 Medium 
                 23 C. (Instrumented Dart Impact test). 
               
               
                   
                   
                 High 
                 MEDIUM: The material sustains between 300 to 50 in-lb of 
               
               
                   
                   
                   
                 total energy. 
               
               
                   
                   
                   
                 LOW: The material sustains less than 50 in-lb of total energy. 
               
               
                   
                 Creep Resistance 
                 Low 
                 HIGH: The material does not deform more than 0.5% at 50% 
               
               
                   
                   
                 High 
                 of yield strength (1000 hours and 23 C.). 
               
               
                   
                 Fatigue 
                 Low 
                 HIGH: The endurance limit of the material is at least 
               
               
                   
                 Resistance 
                 Medium 
                 1000000 cycles (30 Hz) at 3000 psi. 
               
               
                   
                   
                 High 
                 MEDIUM: The endurance limit of the material is between 
               
               
                   
                   
                   
                 10000 and 1000000 cycles (30 Hz) at 3000 psi. 
               
               
                   
                   
                   
                 LOW: The endurance limit or the material is less than 10000 
               
               
                   
                   
                   
                 cycles (30 Hz) at 3000 psi. 
               
               
                   
                 Part Toughness 
                   
                 High Part Toughness 5 requirod for parts such as bumper 
               
               
                   
                   
                   
                 beams. The Part Toughness depends both on materials and 
               
               
                   
                   
                   
                 shape (e.g., a process that allows for a more complex shape 
               
               
                   
                   
                   
                 can give the same Part Toughness with a material with a 
               
               
                   
                   
                   
                 lower toughness). 
               
               
                   
                   
                   
                 High Part Toughness: e.g., Automobile knee bolster 
               
               
                   
                   
                   
                 Medum Part Toughness: e.g., Vacuum cleaner housing. 
               
               
                   
                   
                   
                 Low Part Toughness: e.g., Printer cover. 
               
               
                   
                 Part Stiffness 
                   
                 The stiffness of the part is related to the tensile strength (or 
               
               
                   
                   
                   
                 tensile modulus) or the material as well as to its moment of 
               
               
                   
                   
                   
                 Inertia. The stiffness depends both on materials and shape. 
               
               
                   
                   
                   
                 A process that allows for a more complex shape can give the 
               
               
                   
                   
                   
                 same stiffness with a material with a lower tensile modulus. 
               
               
                   
                   
                   
                 High Part Stiffness: e.g., Automobile cross member or riding 
               
               
                   
                   
                   
                 lawnmower chassis (High material stiffness: Tensile Modulus 
               
               
                   
                   
                   
                 &gt;1 Msi (1 Msi = 10 6 psi). 
               
               
                   
                   
                   
                 Medium Part Stiffness: e.g., Room air conditioner housing or 
               
               
                   
                   
                   
                 can opener housing (Medium material stiffness: Tensile 
               
               
                   
                   
                   
                 Modulus &lt;= 1 Msi and &gt;0.3 Msi). 
               
               
                   
                   
                   
                 Low Part Stiffness: e.g., Computer montior bezel (Low 
               
               
                   
                   
                   
                 material stiffness: Tensile Modulus 0.3 Msi). 
               
               
                   
                 Wear/Abrasion 
                 Low 
                 HIGH: The weight loss of a sample is less than 10 mf after 
               
               
                   
                 Resistance 
                 High 
                 1000 cycles. 
               
               
                 Environmental 
                 Emissions 
                 No Warning 
                 Warning: to be informed when prooesses involve handling 
               
               
                 &amp; Legal 
                   
                 Warning 
                 harmful emissions or hazardous chemicals 
               
               
                   
                 Environmental 
                   
                 Warning: to be informed when materials have environmental 
               
               
                   
                 Impact 
                   
                 problems potential. 
               
               
                   
                 Legal 
                   
                 Warning: to be informed when materials require FDA 
               
               
                   
                   
                   
                 compliance. 
               
               
                   
                 Recyclability 
                   
                 Warning: to be informed about processes recyclability. 
               
               
                   
               
            
           
         
       
     
     Table 19 shows part specifications input data relating to shape and production volume. Input variables for shape include structural additions needed to part such as attachments, inserts or holes, complexity of shape, constraints and dimensionality, degrees of draft, inside tolerances control, shape control accuracy, size and undercuts and for production volume comprises the production volume. 
     
       
         
           
               
             
               
                 TABLE 19 
               
             
            
               
                   
               
               
                 Part Specifications Shape 
               
            
           
           
               
               
               
               
            
               
                 Elements of 
                 Input Variables 
                   
                   
               
               
                 Analyses 
                 (Functional Values) 
                 Values 
                 Contexts 
               
               
                   
               
               
                 Shape 
                 Additions 
                 Attachments, Inserts 
                 Depending on the appliation the 
               
               
                   
                   
                 Holes 
                 part might incorporate holes, 
               
               
                   
                   
                 None 
                 inserts, and other features. 
               
               
                   
                 Complexity 
                 Low 
                 Some processes such as extrusion 
               
               
                   
                   
                 Medium 
                 blow molding cannot handle 
               
               
                   
                   
                 High 
                 complex shapes whereas others 
               
               
                   
                   
                   
                 such as thermoplastic injection 
               
               
                   
                   
                   
                 molding can make complex parts. 
               
               
                   
                   
                   
                 High Complexity: 
               
               
                   
                   
                   
                 housing for Camcorder. 
               
               
                   
                   
                   
                 Medium Complexity: 
               
               
                   
                   
                   
                 computer monitor. 
               
               
                   
                   
                   
                 Low Complexity: bottle. 
               
               
                   
                 Constraints 
                 Cut of Cylinder 
                 2-D is equivalent to: 2-D NO Ribs 
               
               
                   
                 Dimensionality 
                 2 D 
                 3-D not closed means the same as: 
               
               
                   
                   
                 3 D Not Closed 
                 2-D + Ribs or no box 
               
               
                   
                   
                 3 D Closed 
                 3-D closed means that the object 
               
               
                   
                   
                 None 
                 has a closed shape (like a bottle for 
               
               
                   
                   
                 Straight Constant Cross Section 
                 instance) or is equivalent to box. 
               
               
                   
                 Draft 
                 0 to 8 degrees 
                 Some processes can be eliminated 
               
               
                   
                   
                   
                 because they cannot make part 
               
               
                   
                   
                   
                 with a small draft. 
               
               
                   
                 Inside 
                 Not Important 
                 How important is it to have a good 
               
               
                   
                 Tolerances 
                 Important 
                 control of the part inside 
               
               
                   
                 Control 
                   
                 tolerances? 
               
               
                   
                 Shape Control 
                   
                 How important is it to have a good 
               
               
                   
                 Accuracy 
                   
                 control of the outside shape? 
               
               
                 Shape 
                 Size 
                 Small 
                 Large: part weight &gt; or = to 100 lb 
               
               
                   
                   
                 Medium 
                 Medium: 10 lb &lt; part weight &lt; 100 lb 
               
               
                   
                   
                 Large 
                 Small: part weight &lt; or = to 10 lb 
               
               
                   
                 Undercuts 
                 Not Necessary 
                 Does the part require undercuts? 
               
               
                   
                   
                 Required 
               
               
                 Production 
                 Volume 
                 number of units/year 
                 Estimated number of parts produced or to 
               
               
                 Volume 
                   
                   
                 be produced per year. How big is the 
               
               
                   
                   
                   
                 market; how many parts per year does 
               
               
                   
                   
                   
                 the customer want to produce? 
               
               
                   
               
            
           
         
       
     
     D. Opportunity Identification Module 
     1. Overview 
     Opportunity identification is available only in the SYS 1  embodiment, and is based on the evaluation of a large number of variables and their interdependencies. Experts&#39; knowledge is used to process the information, explore alternatives, weigh importance, make judgments, and reach conclusions. The outcome takes the form of detailed sets of recommendations and explanation of the customer&#39;s technical and business needs, and of users&#39;s business potential. Like the Processes and Materials Selection Module, the Opportunity Identification module is also organized based upon the VOW concept discussed above. 
     2. Algorithm of Opportunity Module 
     Referring now to FIGS. 19-38 there are provided a high level description of inference chains, events and prototypes for the Opportunity Identification Module, while FIG. 39 provides a legend for FIGS. 19-38. FIGS. 19-38 depict expanded views of the topics (nodes) of the inference chains of the Opportunity Identification Module. Each topic is represented by a prototype which corresponds to a series of deductions or abductions (i.e., rules). 
     Specifically, FIG. 19 shows the Opportunity Identification root prototypes; FIGS. 20 and 21 show the market attractiveness prototypes including prototypes for market attractiveness, pressure, bargaining leverage, price sensitivity, direct competition, product standardization, and competitor concentration; FIG. 22 shows project importance and major goals prototypes including prototypes for project importance, cost reduction and interest and business; FIG. 23 shows customer commitment prototypes including prototypes for customer commitment, organization levels, organization functions and organization levels; FIG. 24 shows technical capability feasibility prototypes including prototypes for technical capability feasibility, probability technical success, technical feasibility Dow and customer, material technical feasibility, and process and design technical feasibility; FIG. 25 shows development project prototypes including prototypes for development project; FIG. 26 shows revenue potential prototypes including prototypes for Dow revenue potential; FIG. 27 shows assets and strategies prototypes including prototypes for assets and strategies; and FIG. 28 shows competitive advantage prototypes including prototypes for Dow competitive advantage, Dow cost position competition vs. competition, manufacturing costs, production capability, Dow differentiation vs. competition, and differentiation vs. competition sum. 
     Additionally, FIG. 29 shows lines of reasoning for understanding the customer and user business; FIG. 30 shows lines of reasoning for market attractiveness; FIG. 31 shows line of reasoning for project importance; FIG. 32 shows lines of reasoning for customer commitment; FIG. 33 shows lines of reasoning for customer major goals; FIG. 34 shows lines of reasoning for technical capability feasibility; FIG. 35 shows lines of reasoning for development project; FIG. 36 shows lines of reasoning for revenue; FIG. 37 shows lines of reasoning for assets and strategies; and FIG. 38 shows lines of reasoning for competitive advantage. 
     As with the Processes and Materials Selection Module, the Opportunity Identification knowledge base module includes a dynamic explanation of reasoning. The system explains how it reaches conclusions and provides information on the inference chains used to arrive at any particular conclusion. In order to supply the user with such explanatory information, the module has been designed so that: (1) relevant context and meaning have been encapsulated in rules; (2) the necessary containers (classes, objects, and attributes) have been defined; and (3) a record of rules firing has been kept. 
     In the SYS 1  embodiment of the present invention developed by the inventors, system control is essentially left to the Nexpert Object inference engine as follows: (1) the inference engine is stopped while all the input variable values are volunteered by the user through the GUI; (2) the Opportunity Identification hypothesis is suggested by the GUI; and (3) the inference engine processes the information until the end of session is reached. 
     3. Input Data for Opportunity Module 
     The Opportunity Identification Module of the PAMS system contains a body of knowledge that helps in understanding customers&#39; needs and identifying business opportunities for “durable goods” applications. This opportunity identification function in the realm of “durable goods” applications is based on the evaluation of over 100 variables, each of them with several possible soft or hard values, and their interdependencies. Soft values refers to linguistic values such as “high”, “medium” or “low”, whereas hard values refer to numeric or quantitative values. 
     The input variables are grouped in terms of the major elements of the analysis: Technical; Customer Business; and User Business. The following Tables 22B-37 reflect these groups and list all the input variables, including possible values, definitions, and contexts for each group of elements used by the Opportunity Identification module to analyze a give durable goods scenario. The contexts form part of the explanation of the solutions derived by the inference engines for the input data selection made the user. 
     Tables 22B and 23 below show data relating to technical restraints and requirements, including aesthetics, durability, ergonomics, environmental, mechanical, reliability and weight. For aesthetics, the user determines importance of the finish, color, shape and texture, rating them from 1 to 5 for both an existing product and new solution. For environmental, the user determines the importance of chemical resistance, corrosion resistance, temperature resistance, and radiation resistance, for both the existing product and the new solution. For mechanical, the user determines the importance of cycles, duration, impact load and magnitude, rating them from 1 to 5 for both the existing product and the new solution. 
     
       
         
           
               
             
               
                 TABLE 22B 
               
             
            
               
                   
               
               
                 Technical Constraints &amp; Requirments 
               
            
           
           
               
               
               
               
            
               
                 Elements of 
                   
                   
                   
               
               
                 Analyses 
                 Input Variables 
                 Values 
                 Contexts 
               
               
                   
               
               
                 Aesthetics 
                 Class A Finish 
                 1 to 5 
                 What is the importance of the feature in the 
               
               
                   
                   
                   
                 existing product? How important is it to keep, 
               
               
                   
                   
                   
                 improve, or change that feature in the new or 
               
               
                   
                   
                   
                 improved product? 
               
               
                   
                 Color 
               
               
                   
                 Shape 
               
               
                   
                 Texture 
               
               
                 Durability 
                   
                 same as 
                 same as above 
               
               
                   
                   
                 above 
               
               
                 Ergonomics 
                   
                 same as 
                 same as above 
               
               
                   
                   
                 above 
               
               
                 Environmental 
                 Chemical Resistance 
                 same as 
                 same as above 
               
               
                   
                 Resistance 
               
               
                   
                 Radiation Resistance 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 23 
               
             
            
               
                   
               
               
                 Technical Constraints &amp; Requirments (Continued) 
               
            
           
           
               
               
               
               
            
               
                 Elements of 
                   
                   
                   
               
               
                 Analyses 
                 Input Variables 
                 Values 
                 Contexts 
               
               
                   
               
               
                 Mechanical 
                 Cycles (Fatigue) 
                 1 to 5 
                 What is lhe importance of the feature in the 
               
               
                   
                   
                   
                 existing product? How important is it to 
               
               
                   
                   
                   
                 keep, improve, or change that feature in 
               
               
                   
                   
                   
                 the new or improved product? 
               
               
                   
                 Duration 
               
               
                   
                 Impact Load 
               
               
                   
                 Magnitude 
               
               
                 Reliability 
                   
                 same as 
                 same as above 
               
               
                   
                   
                 above 
               
               
                 Weight 
                   
                 same as 
                 same as above 
               
               
                   
                   
                 above 
               
               
                   
               
            
           
         
       
     
     Table 24 below shows the input data relating to the analysis for comparing an existing product versus a new product where the elements of analysis are the existing product and new solution(s). The input data for these elements of analysis include material used and process types for the existing product element and user&#39;s material (Dow material in the table) and application type for the new solution(s) element. 
     
       
         
           
               
             
               
                 TABLE 24 
               
             
            
               
                   
               
               
                 Technical Existing vs. New Products 
               
            
           
           
               
               
               
               
            
               
                 Elements of 
                 Input 
                   
                   
               
               
                 Analyses 
                 Variables 
                 Values 
                 Contexts 
               
               
                   
               
               
                 Existing 
                 Material 
                 Plastic 
                 The application is completely or partially in 
               
               
                 Product 
                 Used 
                 Traditional 
                 plastic. 
               
               
                   
                   
                   
                 The application is completely in traditional 
               
               
                   
                   
                   
                 materials (such as wood, metal, or glass . . . ); it may 
               
               
                   
                   
                   
                 be possible to consolidate parts and substitute the 
               
               
                   
                   
                   
                 traditional material with plastic materials. 
               
               
                   
                 Process 
                 Reform + 
                 Processes which produce standard shapes that 
               
               
                   
                 Type 
                 Assembly 
                 are assembled, soldered, welded, or bolted 
               
               
                   
                   
                   
                 together. 
               
               
                   
                   
                 Near Net 
                 Prccesses which give: 
               
               
                   
                   
                 Shape 
                 either all the shapes that are needed on 
               
               
                   
                   
                   
                 one side (inside or outside) of the part (e.g., blow 
               
               
                   
                   
                   
                 molding, thermoforming, glass blowing); 
               
               
                   
                   
                   
                 or, dimensions that can be held inside 
               
               
                   
                   
                   
                 and outside but with a Iot of flash or poor surtace 
               
               
                   
                   
                   
                 finish (e.g., die casting, sand casting) so that there 
               
               
                   
                   
                   
                 is a need for primihg and painting or machining. 
               
               
                   
                   
                 Net Shape 
                 Processes for which the desired shapes come 
               
               
                   
                   
                   
                 directly out of the mold (e.q., injection molding). 
               
               
                 New 
                 Dow 
                 Current 
                 A current Dow material will be used in the new or 
               
               
                 Solution(s) 
                 Material 
                   
                 improved application. 
               
               
                   
                   
                 Modified 
                 A modified Dow material will be used in the new 
               
               
                   
                   
                   
                 or improved application. 
               
               
                   
                   
                 New 
                 A new Dow material will be used in the new or 
               
               
                   
                   
                   
                 improved application. 
               
               
                   
                 Application 
                 Current 
                 The application is currently in production. 
               
               
                   
                 Type 
                 Minor 
                 The new product involves minimal redesign of the 
               
               
                   
                   
                 Modification 
                 existing application and will still use in-place 
               
               
                   
                   
                   
                 manufacturing. 
               
               
                   
                   
                 Major 
                 The new product includes major new model 
               
               
                   
                   
                 Modification 
                 introduction, new platform, new production 
               
               
                   
                   
                   
                 protocol, and new design approach. 
               
               
                   
                   
                 New-to-the- 
                 The application is truly new-on-scene product. 
               
               
                   
                   
                 World 
               
               
                   
               
            
           
         
       
     
     Table 25 below shows the input data relating to technical capacity including the analysis elements material, process and design. Input data for each element are customer and user (Dow in the table). 
     
       
         
           
               
             
               
                 TABLE 25 
               
             
            
               
                   
               
               
                 Technical Capability 
               
            
           
           
               
               
               
               
            
               
                 Elements of 
                 Input 
                   
                   
               
               
                 Analyses 
                 Variables 
                 Values 
                 Contexts 
               
               
                   
               
               
                 Material 
                 Customer 
                 Strong, 
                 What is the strength of the customer&#39;s expertise in 
               
               
                   
                   
                 Weak 
                 materials? 
               
               
                   
                 Dow 
                   
                 What is the strength of Dow&#39;s expertise in materials? 
               
               
                 Process 
                 Customer 
                 Strong, 
                 What is the strength of the customer&#39;s understanding 
               
               
                   
                   
                 Weak 
                 in fabrication processes? 
               
               
                   
                 Dow 
                   
                 What is the strength of Dow&#39;s understanding in 
               
               
                   
                   
                   
                 fabrication processes? 
               
               
                 Design 
                 Customer 
                 Strong, 
                 What is the strength of the customer in design? 
               
               
                   
                   
                 Weak 
               
               
                   
                 Dow 
                   
                 What is the strength of Dow in design? 
               
               
                   
               
            
           
         
       
     
     Table 26 shows the input data relating to the business customer&#39;s major goals element of analysis. Major goal element input data includes cost reduction value (%), importance of cost reduction, market share (%), importance of market share gain, and performance improvement. 
     
       
         
           
               
             
               
                 TABLE 26 
               
             
            
               
                   
               
               
                 Business Customers Major Goals 
               
            
           
           
               
               
               
               
            
               
                 Elements of 
                   
                   
                   
               
               
                 Analyses 
                 Input Variables 
                 Values 
                 Contexts 
               
               
                   
               
               
                 Customer 
                 Cost Reduction 
                 0% to 
                 How much does the customer want to reduce the cost of the 
               
               
                 Major Goals 
                   
                 80% 
                 application in % of the existing cost (for the application or a 
               
               
                   
                   
                   
                 similar competitor&#39;s application)? The target cost is usually 
               
               
                   
                   
                   
                 provided by the client: i.e. 10% reduction of the current cost. 
               
               
                   
                 Cost Reduction 
                 1 to 5 
               
               
                   
                 Importance 
               
               
                   
                 Gain of Market 
                 0% to 
                 How much of the market share does the customer want to 
               
               
                   
                 Shares 
                 100% 
                 gain? In other words enter the additional market share that 
               
               
                   
                   
                   
                 the customer wants to gain in % of total market share. 
               
               
                   
                 Gain of Market 
                 1 to 5 
               
               
                   
                 Shares Importance 
               
               
                   
                 Performance 
                   
                 How important is the performance improvement required by 
               
               
                   
                 Improvement 
                   
                 the custcmer? 
               
               
                   
               
            
           
         
       
     
     Tables 27 and 28 below show the input data relating to customer interest and business analysis elements including interest and business, excess industry capacity, and product standardization. Input variables for these analysis elements include application growth, profitability, sales, market share, potential for product differentiation, capacity utilization, selling/marketing cost, price variation, and ability to brand. 
     
       
         
           
               
             
               
                 TABLE 27 
               
             
            
               
                   
               
               
                 Customer Interest &amp; Business 
               
            
           
           
               
               
               
               
            
               
                 Elements of 
                 Input 
                   
                   
               
               
                 Analyses 
                 Variables 
                 Values 
                 Contexts 
               
               
                   
               
               
                 Interest &amp; 
                 Application 
                 0 to 5 
                 The application growth is compared to the customer&#39;s 
               
               
                 Business 
                 Growth 
                 times 
                 total company growth: e.g., the application growth is 
               
               
                   
                   
                   
                 3.5 times the total company growth. 
               
               
                   
                 Application 
                 0% to 
                 The application profitability corresponds to the return on 
               
               
                   
                 Profitability 
                 100% 
                 sales of the application. It is the profit as a % of sales 
               
               
                   
                   
                   
                 for the application. 
               
               
                   
                 Application 
                 0% to 
                 The application sales is expressed in terms of a % of 
               
               
                   
                 Sales 
                 100% 
                 the total company sales. 
               
               
                   
                 Application 
                 0% to 
                 The application Market Share, expressed in % of total 
               
               
                   
                 Market Share 
                 100% 
                 market shares, represents the customer&#39;s shares of the 
               
               
                   
                   
                   
                 total market shares for the application. 
               
               
                   
                 Potential 
                 Low 
                 The Potential Differentiation represents the customer&#39;s 
               
               
                   
                 Differentiation 
                 Average 
                 product potential to differentiate itself in the market 
               
               
                   
                   
                 Significant 
                 place. 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 28 
               
             
            
               
                   
               
               
                 Customer Interest &amp; Business (Continued) 
               
            
           
           
               
               
               
               
            
               
                   
                 Elements of 
                   
                   
               
               
                   
                 Analyses 
                 Input Variables 
                 Values 
               
               
                   
                   
               
               
                   
                 Excess 
                 Capacity 
                 0% to 150% 
               
               
                   
                 Industry 
                 Utilization 
               
               
                   
                 Capacity 
               
               
                   
                 Product 
                 Selling/Mktg. 
                 0% to 40% 
               
               
                   
                 Standardization 
                 Cost 
               
               
                   
                   
                 Price Variation of 
                 0% to 30% 
               
               
                   
                   
                 Average 
               
               
                   
                   
                 Ability to Brand 
                 Low 
               
               
                   
                   
                   
                 Average 
               
               
                   
                   
                   
                 High 
               
               
                   
                   
               
            
           
         
       
     
     Table 29 below show the input data relating to customer direct competition and pressure analysis elements including competitor concentration, market maturity, and customer bargaining leverage. Input variables for these analysis elements include: top  2  and  5  share of market for competitor concentration analysis; market growth for market maturity analysis; and top  3  customers, cost to switch to plastics, backward integrate, alternative suppliers and differentiation position for the customer bargaining leverage analysis. 
     
       
         
           
               
             
               
                 TABLE 29 
               
             
            
               
                   
               
               
                 Customer Direct Competition and Pressure 
               
            
           
           
               
               
               
               
            
               
                 Elements of 
                 Input 
                   
                   
               
               
                 Analyses 
                 Variables 
                 Values 
                 Contexts 
               
               
                   
               
               
                 Competitor 
                 Top 2 Share of 
                 0% to 
                 Market share of the 2 top suppliers in the market. 
               
               
                 Concentration 
                 Market 
                 100% 
               
               
                   
                 Top 5 Share of 
                 0% to 
                 Market share of the 5 top suppliers in the market. 
               
               
                   
                 Market 
                 100% 
               
               
                 Market Maturity 
                 Market Growth 
                 −10% to 
                 This corresponds to the market growth for the 
               
               
                   
                   
                 50% 
                 application. 
               
               
                 Customer 
                 Top 3 
                 0% to 
                 The Top 3 Customer corresponds the % of the total 
               
               
                 Bargaining 
                 Customer 
                 100% 
                 market controlled by the top 3 players in the business (if 
               
               
                 Leverage 
                   
                   
                 the top 3 customers represent a majority of the market, 
               
               
                   
                   
                   
                 they really control price). 
               
               
                   
                 Cost to Switch 
                 Low 
                 The cost to switch plastic is low when: 
               
               
                   
                 Plastic 
                 High 
                 the customer has the ability to switch plastic 
               
               
                   
                   
                   
                 easily. 
               
               
                   
                   
                   
                 the customer has the technology and the 
               
               
                   
                   
                   
                 resources to be able to switch back and forth between 
               
               
                   
                   
                   
                 plastic suppliers: they control pricing. 
               
               
                   
                 Backward 
                 Low 
                 The customer has the ability to make the material as 
               
               
                   
                 Integrate 
                 High 
                 opposed to buy it from a supplier; in that scenario, there 
               
               
                   
                   
                   
                 is competition against production economics. 
               
               
                   
                 Alternative 
                 Few 
                 The customer has the choice to purchase plastic from 
               
               
                   
                 Suppliers 
                 Many 
                 many or few suppliers. 
               
               
                   
                 Differentiation 
                 None 
                 This element corresponds to the product contribution to 
               
               
                   
                 Position 
                 High 
                 the customer&#39;s differentiation position; it is subjective 
               
               
                   
                   
                   
                 and difficult to evaluate. 
               
               
                   
               
            
           
         
       
     
     Tables 30 and 31 below show input data related to customer pressure and soft issues elements of analysis: customer price sensitivity and soft issues. Customer price sensitivity input variables include customer profitability, plastic cost, plastic sold at discount, and real price growth. Soft issues input variables include credibility history of customer to develop products, innovation history of customer, and any personal issues. 
     
       
         
           
               
             
               
                 TABLE 30 
               
             
            
               
                   
               
               
                 Customer Pressure and Soft Issues 
               
            
           
           
               
               
               
               
            
               
                 Elements of 
                   
                   
                   
               
               
                 Analyses 
                 Input Variables 
                 Values 
                 Contexts 
               
               
                   
               
               
                 Customer Price 
                 Customer 
                 −10% to 
                 A profitable customer will not pressure too much into lower pricing. The 
               
               
                 Sensitivity 
                 Profitability 
                 25% 
                 ROC (Return On Capital or Profitability) can be obtained from the 
               
               
                   
                   
                   
                 customer Annual Report for a publicly traded company; the division of the 
               
               
                   
                   
                   
                 company in which the plastic is used matters really, but the ROC for a 
               
               
                   
                   
                   
                 division is difficult to obtain from an Annual Report. 
               
               
                   
                 Plastic Cost 
                 0% to 80% 
                 The plastic cost is meant as a % of the total application cost. 
               
               
                   
                 Plastic Sold at 
                 0% to 80% 
                 This element represents the % of plastic of the application which is 
               
               
                   
                 Discount 
                   
                 obtained at discount; It Indicates the customer pricing options for the 
               
               
                   
                   
                   
                 plastic. 
               
               
                   
                 Real Price 
                 −10% to 
                 The real customer price growth corresponds to the customer&#39;s history of 
               
               
                   
                 Growth 
                 20% 
                 price growth; It is the history of price sensitivity. 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 31 
               
             
            
               
                   
               
               
                 Customer Pressure and Soft Issues (Continued) 
               
            
           
           
               
               
               
               
            
               
                 Elements of 
                 Input 
                   
                   
               
               
                 Analyses 
                 Variables 
                 Values 
                 Contexts 
               
               
                   
               
               
                 Soft Issues 
                 Credibility 
                 Low Average 
                 Credibility or lack of credibility? Do we have any reason to believe 
               
               
                   
                   
                 High 
                 everything the customer tells us? 
               
               
                   
                 Development 
                   
                 Has the Customer developed its last 2 or 3 products with the competitors 
               
               
                   
                 Partners History 
                   
                 or with us? Select: 
               
               
                   
                   
                 None 
                 None if the Customer has not yet developed a product with Dow; 
               
               
                   
                   
                 Recent 
                 Recent if the Customer has developed its most recent products with 
               
               
                   
                   
                   
                 Dow; 
               
               
                   
                   
                 Long 
                 Long if the Customer has developed its last products with Dow. 
               
               
                   
                 Innovation 
                 Follower 
                 Is the customer recognized as an innovative technology 
               
               
                   
                 History 
                 Average 
                 leader? 
               
               
                   
                   
                 Leader 
               
               
                   
                 Personal 
                 Against 
                 Is there any knowledge about relationships, people and 
               
               
                   
                 Issues 
                 Neutral 
                 personal issues that can strongly affect the decision 
               
               
                   
                   
                 In Favor 
                 process? 
               
               
                   
               
            
           
         
       
     
     Table 32 below shows input data relating to customer support and commitment elements, including input variables: internal agreement, organization functions, organization levels, partnership (%), and resources and investments (%). 
     
       
         
           
               
             
               
                 TABLE 32 
               
             
            
               
                   
               
               
                 Customer Support &amp; Commitment 
               
            
           
           
               
               
               
               
            
               
                 Elements of 
                   
                   
                   
               
               
                 Analyses 
                 Input Variables 
                 Values 
                 Contexts 
               
               
                   
               
               
                 Support &amp; 
                 Internal 
                 Somewhat 
                 Does it look like the various functions involved in 
               
               
                 Commitment 
                 Agreement 
                 Reasonably 
                 the decision process as well as the different 
               
               
                   
                   
                 Definitely 
                 levels of the Customer&#39;s organization are in 
               
               
                   
                   
                   
                 agreement regarding the project? 
               
               
                   
                 Organization 
                 Application Development Engineering 
                 Are the necessary Customer&#39;s organization 
               
               
                   
                 Functions 
                 Corporate Management 
                 functions (e.g., R&amp;D) involved in the decision 
               
               
                   
                   
                 Manufacturing 
                 process? 
               
               
                   
                   
                 Marketing 
               
               
                   
                   
                 Research &amp; Development 
               
               
                   
                   
                 Sales 
               
               
                   
                   
                 Technical Services 
               
               
                   
                 Organization 
                 Low Levels 
                 Does it look like the proper levels of the 
               
               
                   
                 Levels 
                 Middle Levels 
                 Customer&#39;s organization are Involved in the 
               
               
                   
                   
                 Upper Levels 
                 process? (e.g., Is upper management involved?) 
               
               
                   
                 Partnership 
                 0% to 80% 
                 What is the balance between what the Customer 
               
               
                   
                   
                   
                 (the Original Equipment Manufacturer) is going 
               
               
                   
                   
                   
                 to supply and what Dow is going to provide? 
               
               
                   
                   
                   
                 Indicate the Customer contribution to the 
               
               
                   
                   
                   
                 development project in % of the total project 
               
               
                   
                   
                   
                 cost. 
               
               
                   
                 Resources &amp; 
                 0% to 20% 
                 What percentage of the potential sales of the 
               
               
                   
                 Investments 
                   
                 application does the Customer seem to be ready 
               
               
                   
                   
                   
                 to commit to the development project? 
               
               
                   
               
            
           
         
       
     
     Table 33 below shows input data relating to the User&#39;s (illustrated as Dow in the table) revenue element. Input variables for this element include volume of units, pounds of plastic per unit, application lifetime, expansion potential, and options to maximize revenue. 
     
       
         
           
               
             
               
                 TABLE 33 
               
             
            
               
                   
               
               
                 Dow Revenue 
               
            
           
           
               
               
               
            
               
                 Elements of 
                   
                   
               
               
                 Analyses 
                 Input Variables 
                 Values 
               
               
                   
               
               
                 Dow Revenue 
                 Volume 
                 Units/year 
               
               
                   
                 Lb Plastic/Unit 
                 Lb 
               
               
                   
                 Application 
                 Years 
               
               
                   
                 Lifetime 
               
               
                   
                 Expansion 
                 $ 
               
               
                   
                 Potential 
               
               
                   
                 (Options to) 
                 Development Agreement 
               
               
                   
                 Maximize 
                 Exclusive Rights to the Technology 
               
               
                   
                 Revenue 
                 Part Fabrication 
               
               
                   
                   
                 Rename Plastic 
               
               
                   
                   
                 Resin Compounding/Filling/Coloring 
               
               
                   
                   
                 Tiered Pricing 
               
               
                   
                   
                 Volume Commitment 
               
               
                   
               
            
           
         
       
     
     Table 34 below shows input data relating to the User&#39;s (illustrated as Dow in the table) assets/strategies element. Input variables for this element include user&#39;s (Dow in the table) competitive advantage and project fit with the user&#39;s (Dow) strategies. 
     
       
         
           
               
             
               
                 TABLE 34 
               
             
            
               
                   
               
               
                 Dow Assets/Strategies 
               
            
           
           
               
               
               
               
            
               
                 Elements of 
                 Input 
                   
                   
               
               
                 Analyses 
                 Variables 
                 Values 
                 Contexts 
               
               
                   
               
               
                 Assets 
                 Dow 
                 Availability/Delivery: Lead Times 
                 What applies the most to 
               
               
                 Strategies 
                 Competitive 
                 Availability/Delivery: Meet Delivery Dates 
                 the present business 
               
               
                   
                 Advantage 
                 Availability/Delivery: Packaging/Shipping 
                 situation? 
               
               
                   
                   
                 Business Contacts: Industry Knowledge 
               
               
                   
                   
                 Business Contacts: Product Knowledge 
               
               
                   
                   
                 Pricing: Fairness 
               
               
                   
                   
                 Pricing: Responsiveness 
               
               
                   
                   
                 Problem Handling: Attitude 
               
               
                   
                   
                 Problem Handling: Communications 
               
               
                   
                   
                 Problem Handling: Responsiveness 
               
               
                   
                   
                 Problem Handling: Return Policy 
               
               
                   
                   
                 Products: Consistency 
               
               
                   
                   
                 Products: Processibility 
               
               
                   
                   
                 Products: Product Lines 
               
               
                   
                   
                 Products: Purity 
               
               
                   
                   
                 Technical Support: Accessibility 
               
               
                   
                   
                 Technical Support: Application 
               
               
                   
                   
                 Development 
               
               
                   
                   
                 Technical Support: Product Development 
               
               
                   
                   
                 Technical Support: Responsiveness 
               
               
                   
                   
                 Technical Support: Technical Expertise 
               
               
                   
                 Project Fit 
                 Somewhat 
                 How does the project fit with 
               
               
                   
                 with Dow 
                 Reasonably 
                 the Corporate Strategies &amp; 
               
               
                   
                 Strategies 
                 Definitely 
                 Visions? Are we going after 
               
               
                   
                   
                   
                 markets or products that we 
               
               
                   
                   
                   
                 want to emphasize? 
               
               
                   
               
            
           
         
       
     
     Table 35 below shows input data relating to the User&#39;s (illustrated as Dow in the table) differentiation element. Input variables for this element include account penetration, design assistance, global supply, historical industry presence, technical assistance, unique delivery options, and unique product performance. 
     
       
         
           
               
             
               
                 TABLE 35 
               
             
            
               
                   
               
               
                 Dow Differentiation 
               
            
           
           
               
               
               
               
            
               
                   
                 Elements of 
                 Input 
                   
               
               
                   
                 Analyses 
                 Variables 
                 Values 
               
               
                   
                   
               
               
                   
                 Dimensions 
                 Account 
                 Competitor Advantage 
               
               
                   
                   
                 Penetration 
                 Neutral 
               
               
                   
                   
                   
                 Dow Advantage 
               
               
                   
                   
                 Design 
               
               
                   
                   
                 Assistance 
               
               
                   
                   
                 Global Supply 
               
               
                   
                   
                 Historical 
               
               
                   
                   
                 Industry 
               
               
                   
                   
                 Presence 
               
               
                   
                   
                 Technical 
               
               
                   
                   
                 Assistance 
               
               
                   
                   
                 Unique Delivery 
               
               
                   
                   
                 Options 
               
               
                   
                   
                 Unique Product 
               
               
                   
                   
                 Performance 
               
               
                   
                   
               
            
           
         
       
     
     Table 36 below shows input data relating to the User&#39;s (illustrated as Dow in the table) cost position including the elements of analysis manufacturing costs, production capability and requirements. Input variables for these elements include conversion costs and raw materials for the manufacturing costs element; capacity utilization, plant age, and process technology for the production capability element; and cost of capital for the requirements element. 
     
       
         
           
               
             
               
                 TABLE 36 
               
             
            
               
                   
               
               
                 Dow Cost Position 
               
            
           
           
               
               
               
               
            
               
                 Elements of 
                 Input 
                   
                   
               
               
                 Analyses 
                 Variables 
                 Values 
                 Contexts 
               
               
                   
               
               
                 Manufacturing Costs 
                 Conversion 
                 Higher 
                 Are Dow conversion costs lower than the 
               
               
                   
                 Costs 
                 Lower 
                 competition? 
               
               
                   
                 Raw Materials 
                   
                 Are Dow raw materials costs lower than the 
               
               
                   
                   
                   
                 competition? 
               
               
                 Production Capability 
                 Capacity 
                   
                 Is Dow&#39;s capacity of utilization higher than 
               
               
                   
                 Utilization 
                   
                 the competition? 
               
               
                   
                 Plant Age 
                 Older 
                 Is Dow&#39;s plant newer than the competition&#39;s? 
               
               
                   
                   
                 Newer 
               
               
                   
                 Process 
                 Easily Copied 
                 Is Dow process technology unique compared 
               
               
                   
                 Technology 
                 Unique 
                 to the competitors? 
               
               
                 Requirements 
                 Cost of Capital 
                 Higher 
                 Is Dow&#39;s cost of capital lower than the 
               
               
                   
                   
                 Lower 
                 competition? 
               
               
                   
               
            
           
         
       
     
     Table 37 below shows input data relating to the User&#39;s (illustrated as Dow in the table) development project including the analysis elements development project. Input variables for this element include activities, person-time forecast, resources, and time frame. 
     
       
         
           
               
             
               
                 TABLE 37 
               
             
            
               
                   
               
               
                 Dow Development Project 
               
            
           
           
               
               
               
               
            
               
                 Elements of 
                 Input 
                   
                   
               
               
                 Analyses 
                 Variables 
                 Values 
                 Contexts 
               
               
                   
               
               
                 Development 
                 Activities 
                 Consulting &amp; 
                 The activities that will probably need to be done by 
               
               
                 Project 
                   
                 Concepts 
                 Dow during the project, e.g.: 
               
               
                   
                   
                 Engineering 
                 Tooling; 
               
               
                   
                   
                 Design 
                 FEA; 
               
               
                   
                   
                 Materials 
                 Mold Flow; 
               
               
                   
                   
                 Processes &amp; 
                 Trials; 
               
               
                   
                   
                 Tooling 
                 Samples, and others. 
               
               
                   
                   
                 Prototyping 
                 Prototype. 
               
               
                   
                   
                 Sampling 
               
               
                   
                   
                 Trials 
               
               
                   
                 Person- 
                 Person-years 
                 Several elements need to be taken into the picture 
               
               
                   
                 Time 
                   
                 when evaluating the person-time necessary to 
               
               
                   
                 Forecast 
                   
                 complete the project, such as: 
               
               
                   
                   
                   
                 the department(s) that will be involved 
               
               
                   
                   
                   
                 the number of people that will have to be 
               
               
                   
                   
                   
                 committed. 
               
               
                   
                   
                   
                 the approximate time that these people 
               
               
                   
                   
                   
                 will spend. 
               
               
                   
                 Resources 
                 Difficult 
                 For Dow, the resources for the project may depend 
               
               
                   
                   
                 Feasible 
                 on many factors such as, but not exclusive to: 
               
               
                   
                   
                 Easy 
                 the number and the type of departments 
               
               
                   
                   
                   
                 the number of people. 
               
               
                   
                 Time 
                   
                 What is the Customer time frame? Is it feasible to 
               
               
                   
                 Frame 
                   
                 meet the Customer time frame? The customer&#39;s 
               
               
                   
                   
                   
                 goal is to beat the competitors and deliver first. The 
               
               
                   
                   
                   
                 distribution of resources is an important element and 
               
               
                   
                   
                   
                 should be carefully planned: typically, being 6 
               
               
                   
                   
                   
                 months late means a 50% loss in profit potential for 
               
               
                   
                   
                   
                 the application (lifetime)! 
               
               
                   
               
            
           
         
       
     
     4. Output Data 
     In the practice of the present invention, experts&#39; knowledge is used to process the information, explore alternatives, weight importance, make judgments, and reach conclusions. The outcome of the opportunity identification module takes the form of detailed sets of recommendations in terms of two cornerstones: 
     (1) the customer&#39;s technical and business needs which include: 
     Market Attractiveness, 
     Project Importance, 
     Customer Commitment, and 
     Technical Feasibility. 
     and, 
     (2) the User&#39;s business potential which includes: 
     Development Project Management, 
     User&#39;s Revenue and Business, 
     User&#39;s Corporate Strategies, 
     User&#39;s Competitive Advantage. 
     Tables 38-40 reflect these sets analysis elements and list all the output variables, including possible values, definitions, and contexts associated with each analysis element. Table 38 below shows information relating to opportunity analysis (OA) results for understanding the customer. Output variables include market attractiveness, project importance, customer commitment, and technical feasibility. 
     
       
         
           
               
             
               
                 TABLE 38 
               
             
            
               
                   
               
               
                 OA Results: Understanding the Customer 
               
            
           
           
               
               
               
            
               
                 Elements of 
                   
                   
               
               
                 Analyses 
                 Output Variables 
                 Values 
               
               
                   
               
               
                 Understanding 
                 Market Attractiveness 
                 Due to the complexity 
               
               
                 Customer&#39;s 
                   
                 of the problem and 
               
               
                 Technical and 
                   
                 the large number of 
               
               
                 Business 
                   
                 input parameters, the 
               
               
                 Needs 
                   
                 number of soft values 
               
               
                   
                   
                 for the output 
               
               
                   
                   
                 variables is large. 
               
               
                   
                 Project Importance 
               
               
                   
                 Customer Commitment 
               
               
                   
                 Technical Feasibility 
               
               
                   
               
            
           
         
       
     
     Table 39 below shows information relating to opportunity analysis (OA) results for the user&#39;s (illustrated as Dow in the table)business. Output variables include development and project management, revenue and business, corporate strategies, and competitive advantage. 
     
       
         
           
               
             
               
                 TABLE 39 
               
             
            
               
                   
               
               
                 OA Results: Dow Business 
               
            
           
           
               
               
               
               
            
               
                   
                 Elements of 
                   
                   
               
               
                   
                 Analyses 
                 Output Variables 
                 Values 
               
               
                   
                   
               
               
                   
                 Dow 
                 Development Project 
                 Due to the complexity 
               
               
                   
                 Business 
                 Management 
                 of the problem and the 
               
               
                   
                   
                   
                 large number of input 
               
               
                   
                   
                   
                 parameters, the 
               
               
                   
                   
                   
                 number of soft values 
               
               
                   
                   
                   
                 for the output variables 
               
               
                   
                   
                   
                 is large. 
               
               
                   
                   
                 Dow Revenue &amp; 
               
               
                   
                   
                 Business 
               
               
                   
                   
                 Dow Corporate 
               
               
                   
                   
                 Strategies 
               
               
                   
                   
                 Dow Competitive 
               
               
                   
                   
                 Advantage 
               
               
                   
                   
               
            
           
         
       
     
     Table 40 below shows information relating to the overall opportunity analysis (OA) results. Output variables include understanding of the customer, and user business potential. 
     
       
         
           
               
             
               
                 TABLE 40 
               
             
            
               
                   
               
               
                 OA Overall Results 
               
            
           
           
               
               
               
               
            
               
                 Elements of 
                   
                   
                   
               
               
                 Analyses 
                 Output Variables 
                 Values 
                 Contexts 
               
               
                   
               
               
                 Overall 
                 Understanding of 
                 Due to the complexity of 
                 These output variables are an attempt 
               
               
                   
                 the Customer 
                 the problem and the large 
                 to summarize the results for the two 
               
               
                   
                   
                 number of input 
                 corner stones of the opportunity 
               
               
                   
                   
                 parameters, the number 
                 identification analyses. 
               
               
                   
                   
                 of soft values for these 
               
               
                   
                   
                 output variables is large. 
               
               
                   
                 Dow Business 
               
               
                   
                 Potential 
               
               
                   
               
            
           
         
       
     
     V. Models and Database 
     A. Overview 
     Most applications with traditional materials involve fabrication by “reform and assembly” processes. These processes produce standard shapes that are assembled, soldered, welded, or bolted together. The assembly phase is costly and eventually can be eliminated with plastic materials when the product is fabricated with “net shape” or “near net shape” processes. 
     In the “durable goods” market, one of the challenges resides in finding the competitive design which addresses the required mechanical properties, meets or exceeds the other functional requirements, and is compatible with a “near net shape” to “net shape” fabrication process. As such, plastic materials can offer competitive solutions over traditional materials. The results of the mechanical and economic analyses include part costs and weights for the selected grades and corresponding chosen processes. Fundamental mechanical models provide the amount of material require to make the application depending on the shape, the mechanical constraints, and the material grade strength. 
     The fundamental models utilized in the PAMS system are adequately expressed, implemented and used in spreadsheets. For the PAMS system of the present invention, third party and in-house applications software were integrated into spreadsheet format, and normalized to allow for meaningful comparisons between scenarios. As a result, the numerical processing was left to the Microsoft Excel for Windows spreadsheet components. 
     B. Models 
     1. Mechanical Models 
     For the SYS 1  embodiment of the present invention, mechanical models were included for the following standard shapes: equal-legged angle, thin annular, hollow circular, solid circular, symmetric hat, hollow rectangular, solid rectangular, I profile, L profile, hollow square rotated 45°, solid square, diamond, tee, and U profile. In addition to the SYS 1  models, the SYS 2  embodiment of the present invention included the following shell/plate models: (1) solid circular plate all-edges fixed; (2) solid circular plate simply supported; (3) rectangular plate fixed; (4) rectangular plate simply supported; and (5) triangular plate. The models solve only for part thickness based on other required dimensions and the Young Modulus. 
     In addition, the following four mechanical models were simplified in SYS 2  so that they calculate a uniform part thickness rather than multiple part thicknesses: (1) Hollow Rectangle cross section; (2) TEE cross section; (3) Channel cross section; and (4) I-Profile cross section. 
     The mechanical models can be used either stand-alone or as part of the selection process to derive a part dimension based on other known dimensions, maximum part deflection under load, and the material Young Modulus. Primarily, the mechanical models coupled with a database containing the Young Modulus for each grade allow users to compare the required thicknesses for various selected materials. Also, in the PAMS embodiment, part thickness, surface area, projected area and volume derived in the mechanical models are used as a primary input into the economic models for determining cost per part. 
     The present models assume a bending mode with elastic response, two fixed points boundary conditions and constant wall thickness. They include validity checks for the length to depth ratio and the beam slope. 
     The input variables for the mechanical models include: (1) list of the grades of materials and their tensile modulus; (2) shape; (3) beam span; (4) load; (5) axis about which the load is applied; and (6) maximum deflection, and beam dimensions, with one dimension to solve for. 
     The fundamental models utilized in the system are as follows where Equations (1), (2), and (3) are solved for one of the dimensions X i  and where the moment of inertia I depends on the beam shape. 
     
       
         I=I(L i X i )  (1) 
       
     
     The value for the moment of inertia I is obtained from equation (2) where E is the tensile modulus of the material.              I   =     OverallStiffness   E             (   2   )                         
     The overall stiffness is calculated using equation (3) and assumes bending mode with elastic response, two fixed points boundary conditions and constant wall thickness. Q is the load applied to the beam, L the beam span, and D the maximum beam deflection.              OverallStiffness   =       Q   ×     L   3         192      D               (   3   )                         
     The model validity check is provided by the beam slope and the length to depth ratio. Equation (4) gives the beam slope in radians.                  Q   ×   L2       64      I   ×   E       &lt;   0.277           (   4   )                         
     The normalized length to depth ratio is expressed by equation (5) where α and Depth are factors depending on the beam shape.                L     α   ×   Depth       ≥   I           (   5   )                         
     The moment of inertia I, the Depth and α factors for each shape are calculated in the mechanical models spreadsheet. 
     2. Economic Models 
     The economic models of the PAMS systems of the present invention provide a “first pass” approximation that will allow users to compare the cost per part of various combinations of materials and processes. The SYS 1  embodiment utilized selected commercially available IBIS Associates, thermoplastics processes economic models and an in-house economic model for SRIM (structural reaction injection molding) processes. 
     The SYS 2  embodiment utilizes economic models that are scaled down versions of the comprehensive process cost models provided by IBIS Associates. The models include: thermoplastic injection molding; extrusion blow molding; structural reaction injection molding (SRIM); reaction injection molding (RIM); extrusion thermoforming; gas assisted injection molding; and die casting. 
     Each economic model supplied by IBIS Associates is self-contained in individual Excel 4.0 worksheets. A simplified version of the models was created for use in the present embodiment. In this version, default values have been substituted for some of the user inputs required by the full models in order to provide a good “first-pass” cost per part estimation. For the SYS 2  embodiment, all the models, tables, and model inputs were combined into a single Excel 4.0 workbook. This workbook has the following worksheets: 
     a. Model Spreadsheets 
     Economic models for each process are contained in individual spreadsheets. Material information originally contained in each model was moved to a single common table called the “Engineering Properties Table.” 
     b. Engineering Properties Table 
     The Engineering Properties Table is used as a “look-up” table for each material specified by the embodiments of the present invention for a certain process. The look-up table includes information about cost per pound, scrap cost per pound, Young Modulus and other process relevant properties for each generic grade of material. The Engineering Properties Table contains only the appropriate information required to determine the material cost per pound for compatible processes for the specified material grade. Consequently, some blow molding grades most likely may not contain the necessary information for determining a cost per part in the injection molding model. 
     c. Additives Properties Table 
     The additives property table contains information about additives used in the SRIM and RIM processes. Because there is a large possibility of combination of filled thermoset resins for these processes, users are queried via an Excel dialog box for the appropriate filler type, percentage composition and layers. See FIG. 40 for an example of a material specific entry screen for the economic models of the present invention. Based on information about filler density and cost/pound contained in the additives property table, the system can calculate adjusted weights and cost per part used by the SRIM and RIM models. 
     d. Input Sheet 
     The input sheet provides a common data source for all the economic models, see Table 41. Part thickness, volume, surface area, projected area, production volume and product life are provided to the models by the system and/or through user input. For any other processing dimensions specific to a process model (i.e., length, width, height, etc.) the user is required to enter the information via a dialog box in Excel, see FIG.  41 . The system uses the information to determine the appropriate weights and thus the approximate cost per part. 
     
       
         
           
               
             
               
                 TABLE 41 
               
             
            
               
                   
               
               
                 Input Table for All Economic Models 
               
            
           
           
               
               
               
               
               
            
               
                 Description 
                 Value 
                 Name 
                 Units 
                 Model 
               
               
                   
               
               
                 Model 
                 Reaction Injection Molding 
                 MODEL 
                   
                 N/A 
               
               
                 Family Name 
                 RIM_PolyUrethane 
                 Family 
                   
                 ALL 
               
               
                 Average Wall 
                 0.25 
                 THKAIN 
                 in. 
                 ALL 
               
               
                 Thickness 
               
               
                 Surface Area 
                 200 
                 SAREASQIN 
                 sq in. 
                 Die Casting, Injection 
               
               
                   
                   
                   
                   
                 Molding,RIM,SRIM,SMC 
               
               
                 Projected Area 
                 100 
                 PAREASQIN 
                 sq in. 
                 Die Casting, Injection 
               
               
                   
                   
                   
                   
                 Molding,RIM,SRIM,SMC 
               
               
                 Part Volume 
                 200 
                 PARTVOL 
                 cu in. 
               
               
                 Product Life 
                 5 
                 PRODLIFE 
                 Years 
                 ALL 
               
               
                 Production Volume 
                 200 
                 PRODVOL 
                 Thousand/Year 
                 ALL 
               
               
                 Contained Volume 
                 5 
                 CONTVOL 
                 cu in. 
               
               
                 Length 
                 1 
                 LEN 
                 in. 
                 Profile Extrusion,SRIM,RIM, 
               
               
                   
                   
                   
                   
                 Extrusion Thermoforming 
               
               
                 Width 
                 1 
                 WID 
                 in. 
                 SRIM,RIM 
               
               
                 Depth 
                 1 
                 DEP 
                 in. 
                 Extrusion Thermofirming 
               
               
                 Number of Hollows 
                 1 
                 HOL 
                   
                 Profile Extrusion 
               
               
                 In-Mold Coating 
                 1 
                 IMCOAT 
                   
                 SMC 
               
               
                 Mat 1 
                 RIM_Calcium 
                 MAT1 
                   
                 SRIM,RRIM 
               
               
                   
                 Carbonate_Precip. 
               
               
                 Piles 1 
                   
                 PLI1 
                   
                 SRIM 
               
               
                 WT % 1 
                 20% 
                 MATWT1 
                 Percentage 
                 SRIM,RRIM 
               
               
                 Mat2 
                   
                 MAT2 
                   
                 SRIM 
               
               
                 Piles 2 
                   
                 PLI2 
                   
                 SRIM 
               
               
                 WT %2 
                   
                 MATWT2 
                 Percentage 
                 SRIM 
               
               
                 Mat 3 
                   
                 MAT3 
                   
                 SRIM 
               
               
                 Piles 3 
                   
                 PLI3 
                   
                 SRIM 
               
               
                 WT %3 
                   
                 MATWT3 
                 Percentage 
                 SRIM 
               
               
                 GA Injection Molding 
                 5% 
                 GAIMWTPT 
                 Percentage 
                 Gas Assisted Injection 
               
               
                 Wt Reduction 
                   
                   
                   
                 Molding 
               
               
                 Cross Sectional Area 
                 200 
                 XAREASQIN 
                 sq in. 
                 Profile Extrusion, Extrusion 
               
               
                   
                   
                   
                   
                 Thermoforming 
               
               
                 Cost/Part 
                 $6.48 
                 COST 
                 Per Part 
                 ALL 
               
               
                 Weight 
                 2.65 
                 WGTLBS 
                 Pounds 
                 ALL 
               
               
                 Model Exists 
                 FALSE 
                 MODELEXIST 
               
               
                 Data Complete 
                   
                 Data Complete 
               
               
                   
               
            
           
         
       
     
     C. Shape Selection/Decomposition Module 
     Tables 42 to 48 provide the Overall Shape Relations 1 to 56 which are utilized in the shape selection protocol of this invention. Table 49 provides the Additions Relations 1 to 19, which determine the necessary additions needed to fit the criteria for the selected application domain. Tables 50 to 58 provide the Shape Decomposition Relations 1 to 23 utilized to decompose the shape. FIGS. 76 and 81 illustrate the screen triggered from menu item “overall shape”. FIG. 77 illustrates the screen triggered from menu item “additions”. FIG. 78 shows GUI input dynamics logic. FIG. 79 shows the shape selection/decomposition screen output, with legend provided in FIG.  80 . 
     The shape selection/decomposition protocol of the present invention is an innovative set of rules for defining and characterizing the overall shape relationships of the selected durable goods application. Once the use inputs the information to this module, the SYS 2  PAMS system utilizes the input information to generate possible new solutions to the durable goods application of interest or for analyzing the possibility to new solutions in a given durable goods application domain. The rules and their interdependencies for the shape selection/decomposition protocol are summarized and set forth in Tables 42-58. 
     
       
         
           
               
             
               
                 TABLE 42 
               
               
                   
               
               
                 Relations 
               
               
                 From Idea to Overall Shape &amp; Additions 
               
               
                 Overall Shape 
               
               
                 Opened or Closed? 
               
               
                 Based on Functions 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
               
            
               
                 Overall Shape Relation 1 
                   
                   
               
               
                 ∃ object(s) inside 
                 → 
                 access(es) become necessary 
               
               
                 object(s) need to be accessed 
               
               
                 Overall Shape Relation 2 
               
               
                 ∃ object(s) go in/out 
                 → 
                 access(es) become necessary 
               
               
                 Overall Shape Relation 3 
               
               
                 NO objects inside at any time 
                 → 
                 access(es) NOT necessary 
               
               
                 Overall Shape Relation 4 
               
               
                 ∀ object(s) inside 
                 → 
                 access(es) NOT necessary 
               
               
                 object(s) do NOT need to be accessed 
               
               
                 Overall Shape Relation 5 
               
               
                 NO objects go in/out 
                 → 
                 access(es) NOT necessary 
               
               
                 Overall Shape Relation 6 
               
               
                 access(es) necessary 
                 → 
                 opening(s) need to be 
               
               
                 during-use 
                   
                 considered 
               
               
                 Overall Shape Relation 7 
               
               
                 access(es) necessary 
                 → 
                 decomposition into opened 
               
               
                 during-use 
                   
                 shapes needs to be considered 
               
               
                 overal shape is is closed 
               
               
                 Overall Shape Relation 8 
               
               
                 access(es) NOT necessary 
                 → 
                 opening(s) are NOT necessary 
               
               
                 during-use 
               
               
                 Overall Shape Relation 9 
               
               
                 opening(s) necessary 
                 → 
                 overall shape is closed 
               
               
                 MAX(order of magnitude of size of 
               
               
                 all openings) &lt; order of magnitude 
               
               
                 of longer dimension of part in a plane 
               
               
                 perpendicular to the axis of the 
               
               
                 opening 
               
               
                 Overall Shape Relation 10 
               
               
                 opening(s) necessary 
                 → 
                 overall shape is opened 
               
               
                 MAX(order of magnitude of size of 
               
               
                 at least one opening) ≅ order of 
               
               
                 magnitude of longer dimension of 
               
               
                 part in a plane perpendicular to the 
               
               
                 axis of the opening 
               
               
                 Overall Shape Relation 11 
               
               
                 opening(s) NOT necessary 
                 → 
                 overall shape could be closed 
               
               
                 Overall Shape Relation 12 
               
               
                 part partially encloses objects 
                 → 
                 overall shape is opened 
               
               
                 Overall Shape Relation 13 
               
               
                 ∃ object(s) inside 
                 → 
                 overall shape hollow 
               
               
                 Overall Shape Relation 14 
               
               
                 ∃ object(s) go in/out 
                 → 
                 overall shape hollow 
               
               
                 Overall Shape Relation 15 
               
               
                 part partially encloses objects 
                 → 
                 overall shape hollow 
               
               
                 Overall Shape Relation 16 
               
               
                 part is in contact with a solid 
                 → 
                 opening(s) could be necessary 
               
               
                 supporting surface 
                   
                 ( . . . to provide orientation 
               
               
                 part shape provides orientation with 
                   
                 with the supporting 
               
               
                 respect to the supporting surface 
                   
                 surface . . . ) 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 43 
               
               
                   
               
               
                 Based on geometry 
               
               
                 2-D or 3-D? 
               
               
                 Based on Functions 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
               
            
               
                 Overall Shape Relation 17 
                   
                   
               
               
                 load is imporant 
                 → 
                 overall shape could be 2-D 
               
               
                 aesthetics is NOT a factor 
               
               
                 Overall Shape Relation 18 
               
               
                 aesthetics is a factor 
                 → 
                 overall shape could be 3-D 
               
               
                 Overall Shape Relation 19 
               
               
                 aesthetics is important 
                 → 
                 overall shape is 3-D 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 44 
               
               
                   
               
               
                 Based on Geometry 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
               
            
               
                 Overall Shape Relation 20 
                   
                   
               
               
                 part lies approximately in one plane (i.e. 
                 → 
                 overall shape is 2-D 
               
               
                 approximately flat) 
               
               
                 part is NOT hollow 
               
               
                 Overall Shape Relation 21 
               
               
                 can find a direction about which the cross- 
                 → 
                 overall shape is 2-D 
               
               
                 section is constant 
               
               
                 part does NOT have a surface 
               
               
                 approximately perpendicular to the 
               
               
                 direction 
               
               
                 Overall Shape Relation 22 
               
               
                 opened-shape cross-section about the 
                 → 
                 overall shape is 2-D 
               
               
                 longer direction 
               
               
                 canNOT find a direction about which the 
               
               
                 cross-section is constant 
               
               
                 part does NOT have a surface 
               
               
                 approximately perpendicular to the longer 
               
               
                 direction 
               
               
                 Overall Shape Relation 23 
               
               
                 opened-shape cross-section about the 
                 → 
                 overall shape is 3-D 
               
               
                 longer direction 
               
               
                 canNOT find a direction about which the 
               
               
                 cross-section is constant 
               
               
                 part has at least one surface 
               
               
                 approximately perpendicular to the 
               
               
                 direction 
               
               
                 Overall Shape Relation 24 
               
               
                 closed-shape cross-section 
                 → 
                 overall shape is 3-D 
               
               
                 canNOT find a direction about which the 
               
               
                 cross-section is constant 
               
               
                 Overall Shape Relation 25 
               
               
                 can find a direction about which the cross- 
                 → 
                 overall shape is 3-D 
               
               
                 section is constant 
               
               
                 part has at least one surface 
               
               
                 approximately perpendicular to the 
               
               
                 direction 
               
               
                 Overall Shape Relation 26 
               
               
                 overall shape is closed 
                 → 
                 closed-shape 
               
               
                 has a direction about which the cross- 
                   
                 cross-section 
               
               
                 section varies simply 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 45 
               
               
                   
               
               
                 Symmetry, Planes, Curvatures, Cross-sections, and Profiles? 
               
               
                 Based on Functions 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
               
            
               
                 Overall Shape Relation 27 
                   
                   
               
               
                 part movement is rotation 
                 → 
                 part has symmetry of revolution 
               
               
                 during-use 
               
               
                 Overall Shape Relation 28 
               
               
                 part is in contact with a solid supporting 
                 → 
                 part surface could include approximately flat 
               
               
                 surface 
                   
                 portions 
               
               
                 part shape provides orientation with 
               
               
                 respect to the supporting surface 
               
               
                 Overall Shape Relation 29 
               
               
                 ∃ objects inside 
                 → 
                 part surface could include approximately flat 
               
               
                 part shape provides orientation for the 
                   
                 portions 
               
               
                 objects 
               
               
                 Overall Shape Relation 30 
               
               
                 load direction is torsion 
                 → 
                 cross-section is approximately thin-walled 
               
               
                   
                   
                 circular (100), rectangular (93), or thick-walled 
               
               
                   
                   
                 circular (41) 
               
               
                 Overall Shape Relation 31 
               
               
                 load direction is compression 
                 → 
                 cross-section is approximately thin-walled 
               
               
                   
                   
                 circular (100), rectangular (93), or thick-walled 
               
               
                   
                   
                 circular (41) 
               
               
                 Overall Shape Relation 32 
               
               
                 load direction Is bending only 
                 → 
                 cross-section is approximately I-profile (100), 
               
               
                   
                   
                 U-profile (81), wide I-profile (58), or 
               
               
                   
                   
                 rectangular (57) 
               
               
                 Overall Shape Relation 33 
               
               
                 load direction is bending and compression 
                 → 
                 cross-section is approximately I-profile (100), 
               
               
                   
                   
                 U-profile (81), wide I-profile (58), or 
               
               
                   
                   
                 rectangular (57) 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
               
               
             
               
                 TABLE 46 
               
               
                   
               
             
            
               
                 Overall Shape Relation 34 
                   
                   
               
               
                 load direction is bending and torsion 
                 → 
                 cross-section is approximately rectangular or 
               
               
                   
                   
                 thin-walled circular 
               
               
                 Overall Shape Relation 35 
               
               
                 load direction is pressure only 
                 → 
                 overal shape approximates body-of- 
               
               
                   
                   
                 revolution (e.g., sphere or cylinder) 
               
               
                 Overall Shape Relation 36 
               
               
                 load direction is pressure and bending 
                 → 
                 cross-section approximates circular or hollow 
               
               
                   
                   
                 rectangular 
               
               
                 Overall Shape Relation 37 
               
               
                 aesthetics is a factor 
                 → 
                 simple variation of standard cross-section 
               
               
                   
                   
                 profile made up of straight lines and simple 
               
               
                   
                   
                 curves 
               
               
                 Overall Shape Relation 38 
               
               
                 aesthetics is important 
                 → 
                 complex variation of approximation of 
               
               
                   
                   
                 standard cross-section 
               
               
                   
                   
                 profile made up of free-from curves 
               
               
                 Overall Shape Relation 39 
               
               
                 aesthetics NOT important 
                 → 
                 could be standard cross-section 
               
               
                   
                   
                 could be constant cross-section (i.e., profile is 
               
               
                   
                   
                 a straight line) 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 47 
               
               
                   
               
               
                 Based on Geometry 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
               
            
               
                 Overall Shape Relation 40 
                   
                   
               
               
                 basic shape of the part has symmetry of 
                 → 
                 overall shape is body-of-revolution 
               
               
                 revolution 
               
               
                 Overall Shape Relation 41 
               
               
                 part surfaoe has several different portions 
                 → 
                 overall shape is folded-plate 
               
               
                 approximately flat 
               
               
                 part does NOT lie approximately in one 
               
               
                 plane or is NOT approximately flat 
               
               
                 Overall Shape Relation 42 
               
               
                 basic shape of the part has symmetry of 
                 → 
                 overall shape is double-curvature 
               
               
                 revolution 
               
               
                 basic shape of the profile about the axis 
               
               
                 of revolution is curved 
               
               
                 Overall Shape Relation 43 
               
               
                 cross-section includes curves 
                 → 
                 overall shape is double-curvature 
               
               
                 profile is curved in locations where the 
               
               
                 cross-section is curved 
               
               
                 Overall Shape Relation 44 
               
               
                 canNOT find a direction about which the 
                 → 
                 overall shape is double-curvature 
               
               
                 cross-section varies simply 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 48 
               
               
                   
               
               
                 Combinations 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
               
            
               
                 Overall Shape Relation 45 
                   
                   
               
               
                 overall shape 2-D 
                   
                 overall shape is 2-D opened 
               
               
                   
                   
                 cross-section 
               
               
                 overall shape opened 
                 → 
               
               
                  Overall Shape Relation 46 
               
               
                 overall shape 2-D 
                   
                 overall shape is 2-D closed 
               
               
                   
                   
                 cross-section 
               
               
                 overall shape closed 
                 → 
               
               
                  Overall Shape Relation 47 
               
               
                 overall shape 3-D 
                   
                 overall shape is 3-D opened 
               
               
                 overall shape opened 
                 → 
               
               
                  Overall Shape Relation 48 
               
               
                 overall shape 3-D 
                   
                 overall shape is 3-D closed 
               
               
                 overall shape closed 
                 → 
               
               
                  Overall Shape Relation 49 
               
               
                 overall shape 3-D closed 
                   
                 overall shape is 3-D closed 
               
               
                   
                   
                 folded-plate 
               
               
                 overall shape folded-plate 
                 → 
               
               
                  Overall Shape Relation 50 
               
               
                 overall shape 3-D closed 
                   
                 overall shape is 3-D closed 
               
               
                   
                   
                 double-curvature 
               
               
                 overall shape double-curvature 
                 → 
               
               
                  Overall Shape Relation 51 
               
               
                 overall shape 3-D closed 
                   
                 overall shape is 3-D closed body- 
               
               
                   
                   
                 of-revolution 
               
               
                 overall shape body-of-revolution 
                 → 
               
               
                  Overall Shape Relation 52 
               
               
                 overall shape 3-D-opened 
                   
                 overall shape is 3-D-opened 
               
               
                   
                   
                 folded-plate 
               
               
                 overall shape folded-plate 
                 → 
               
               
                  Overall Shape Relation 53 
               
               
                 overall shape 3-D- opened 
                   
                 overall shape is 3-D-opened 
               
               
                   
                   
                 double-curvature 
               
               
                 overall shape double-curvature 
                 → 
               
               
                  Overall Shape Relation 54 
               
               
                 overall shape 3-D- opened 
                   
                 overall shape is 3-D-opened body- 
               
               
                   
                   
                 of-revolution 
               
               
                 overall shape body-of-revolution 
                 → 
               
               
                  Overall Shape Relation 55 
               
               
                 overall shape body-of-revolution 
                   
                 flat surfaces are perpendicular to 
               
               
                   
                   
                 the axis of revolution 
               
               
                 part includes flat surfaces 
                 → 
               
               
                  Overall Shape Relation 56 
               
               
                 x could be a 
                   
                 (destroy “x could be a”) 
               
               
                 x is b 
                 → 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 49 
               
               
                   
               
               
                 Additions 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
               
            
               
                 Additions Relation 1 
                   
                   
               
               
                 opening(s) necessary 
                 → 
                 additions necessary: panels, attachments 
               
               
                   
                   
                 (bosses, inserts, snap fits . . . ) 
               
               
                 ∃ opening(s) to be protected, closed, or 
               
               
                 covered 
               
               
                 Additions Relation 2 
               
               
                 opening(s) necessary 
                 → 
                 additions necessary: holes, slots 
               
               
                 overall shape is closed 
               
               
                 Additions Relation 3 
               
               
                 ∃ objects inside 
                 → 
                 additions necessary: inside projections (walls) 
               
               
                 objects need to be separated 
               
               
                 Additions Relation 4 
               
               
                 ∃ objects inside 
                 → 
                 additions necessary: inside projections (walls) 
               
               
                 objects need to be located 
                   
                 OR inside attachements OR holes 
               
               
                 Additions Relation 5 
               
               
                 ∃ objects outside 
                 → 
                 additions necessary: outside projections (walls) 
               
               
                 objects need to be separated 
               
               
                 Additions Relation 6 
               
               
                 ∃ objects outside 
                 → 
                 additions necessary: outside projections 
               
               
                 objects need to be located 
                   
                 (walls) OR outside attachements OR holes 
               
               
                 Additions Relation 7 
               
               
                 part is 3-D 
                 → 
                 additions necessary: inside projections (walls) 
               
               
                 dividing sections are necessary 
               
               
                 Additions Relation 8 
               
               
                 inside surface must be completly smooth 
                 → 
                 NO additions inside except holes 
               
               
                 Additions Relation 9 
               
               
                 NO additions inside except holes 
                 → 
                 additions necessary: holes only 
               
               
                 additions necessary: inside projections 
               
               
                 (walls) OR inside attachements OR holes 
               
               
                 Additions Relation 10 
               
               
                 outside surface must be completely 
                 → 
                 NO additions outside except holes 
               
               
                 smooth 
               
               
                 Additions Relation 11 
               
               
                 NO additions outside except holes 
                 → 
                 additions necessary: holes only 
               
               
                 additions necessary: outside projections 
               
               
                 (walls) OR outside attachements OR 
               
               
                 holes 
               
               
                 Additions Relation 12 
               
               
                 ∃ objects inside 
                 → 
                 additions necessary: inside attachments 
               
               
                 objects need to be attached 
               
               
                 Additions Relation 13 
               
               
                 ∃ objects inside 
                 → 
                 additions necessary: outside attachments 
               
               
                 objects need to be attached 
               
               
                 Additions Relation 14 
               
               
                 ∃ objects outside 
                 → 
                 additions necessary: outside attachments or 
               
               
                 objects handle or manipulate the part 
                   
                 external projections (e.g., handle) 
               
               
                 Additions Relation 15 
               
               
                 part is in contact with a supporting solid 
                 → 
                 additions necessary: ouside attachments OR 
               
               
                 surface 
                   
                 exterior projections (e.g. legs) 
               
               
                 orientation with respect to the supporting 
               
               
                 surface is required 
               
               
                 part shape does NOT provide the 
               
               
                 orientation with respect to the supporting 
               
               
                 surface 
               
               
                 Additions Relation 16 
               
               
                 part is in contact with a supporting solid 
                 → 
                 additions necessary: exterior projections 
               
               
                 surface 
                   
                 (e.g., legs) 
               
               
                 part provides the gap between the part 
               
               
                 and the supporting surface 
               
               
                 Additions Relation 17 
               
               
                 load magnitude is large 
                 → 
                 additions may be necessary: ribs 
               
               
                 cross-section is simple variation of 
               
               
                 standard cross-section 
               
               
                 Additions Relation 18 
               
               
                 load magnitude is large or medium 
                 → 
                 additions may be necessary: ribs 
               
               
                 cross-section is complex variation of 
               
               
                 approximation of standard cross-section 
               
               
                 Additions Relation 19 
               
               
                 ribs are necessary 
                 → 
                 ribs are internal 
               
               
                 outside aesthetics is a factor or important 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 50 
               
               
                   
               
               
                 Shape Decomposition 
               
               
                 From a Manufacturing Standpoint 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
               
            
               
                 Shape Decomposition Relation 1 
                   
                   
               
               
                 overall shape is 3-D-closed 
                 → 
                 decompose into 2 or more 
               
               
                 ∃ objects inside 
                   
                 3-D-opened 
               
               
                 Shape Decomposition Relation 2 
               
               
                 overall shape is 3-D-closed 
                 → 
                 decompose into 2 or more 
               
               
                 inside additions (except holes) 
                   
                 3-D-opened 
               
               
                 required 
               
               
                 Shape Decomposition Relation 3 
               
               
                 a shape is double-curvature 
                 → 
                 canNOT be decomposed into 2-D 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 51 
               
               
                   
               
               
                 From a Shape Standpoint Only 
               
               
                 2-D 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
               
            
               
                 Shape Decomposition Relation 4 
                   
                   
               
               
                 overall shape is 2-D 
                 → 
                 can be decomposed into a series of 
               
               
                   
                   
                 FLAT 2-D 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 52 
               
               
                   
               
               
                 3-D-opened Folded-plate 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
               
            
               
                 Shape Decomposition Relation 5 
                   
                   
               
               
                 overall shape is folded-plate 
                 → 
                 can be decomposed into series of 3-D-opened 
               
               
                   
                   
                 folded-plate 
               
               
                 Shape Decomposition Relation 6 
               
               
                 overall shape is folded-plate 
                 → 
                 orientation of cutting planes is: any planes 
               
               
                   
                   
                 OR preferably contains the plates 
               
               
                 Shape Decomposition Relation 7 
               
               
                 overall shape is folded-plate 
                 → 
                 3-D-opened folded-plates can be decomposed 
               
               
                   
                   
                 into a series of 2-D shapes 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 53 
               
               
                   
               
               
                 3-D-opened Body-of-revolution 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
               
            
               
                 Shape Decomposition Relation 8 
                   
                   
               
               
                 overall shape is 3-D-opened body-of- 
                 → 
                 orientation of cutting planes is: 
               
               
                 revolution only 
                   
                 contains the axis of revolution OR 
               
               
                   
                   
                 perpendicular to the axis of 
               
               
                   
                   
                 revolution 
               
               
                 Shape Decomposition Relation 9 
               
               
                 overall shape is 3-D-opened body-of- 
                 → 
                 can be decomposed into 2 or more 3-D- 
               
               
                 revolution 
                   
                 opened shapes 
               
               
                 Shape Decomposition Relation 10 
               
               
                 overall shape is 3-D-opened body-of- 
                 → 
                 3-D-opened shapes can be further 
               
               
                 revolution 
                   
                 decomposed into a series of 2-D, each 
               
               
                   
                   
                 correspending to a straight line segment 
               
               
                 profile includes straight line segments 
               
               
                 Shape Decomposition Relation 11 
               
               
                 overall shape is 3-D-opened body-of- 
                 → 
                 the 3-D-opened shapes corresponding to the 
               
               
                 revolution 
                   
                 curves are 3-D-opened double-curvature 
               
               
                 profile includes curves 
               
               
                 Shape Decomposition Relation 12 
               
               
                 overall shape is 3-D-opened body-of- 
                 → 
                 orientation of cutting planes is: 
               
               
                 revolution 
                   
                 1. contains the axis of revolution OR 
               
               
                   
                   
                 2. perpendicuiar to the axis of 
               
               
                   
                   
                 revolution 
               
               
                   
                   
                 3. do not matter once shape 
               
               
                   
                   
                 decomposed by 1 &amp; 2 
               
               
                 overall shape is 3-D-opened double- 
               
               
                 curvature 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 54 
               
               
                   
               
               
                 3-D-opened Double-curvature 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
               
            
               
                 Shape Decomposition Relation 13 
                   
                   
               
               
                 overall shape is 3-D-opened double- 
                 → 
                 orientation of cutting planes: do not matter 
               
               
                 curvature only 
               
               
                 Shape Decomposition Relation 14 
               
               
                 overall shape is 3-D-opened double- 
                 → 
                 can be decomposed into a series of 3-D- 
               
               
                 curvature 
                   
                 opened double-curvature shapes 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 55 
               
               
                   
               
               
                 3-D-closed Folded-plate 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
               
            
               
                 Shape Decomposition Relation 15 
                   
                   
               
               
                 overall shape is 3-D-closed folded-plate 
                 → 
                 orientation of cutting planes: 
               
               
                   
                   
                 does not matter OR 
               
               
                   
                   
                 contains a plate 
               
               
                 Shape Decomposition Relation 16 
               
               
                 overall shape is 3-D-closed folded-plate 
                 → 
                 can be decomposed into a 2-D and a 3-D- 
               
               
                   
                   
                 opened folded-plate 
               
               
                 orientation of cutting plane contains a 
               
               
                 plate 
               
               
                 Shape Decomposition Relation 17 
               
               
                 overall shape is 3-D-closed folded-plate 
                 → 
                 can be decomposed into 2 or more 3-D- 
               
               
                   
                   
                 opened folded-plate 
               
               
                 orientation of cutting plane does not 
               
               
                 matter 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 56 
               
               
                   
               
               
                 3-D-closed Body-of-revolution 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
               
            
               
                 Shape Decomposition Relation 18 
                   
                   
               
               
                 overall shape is 3-D-closed body-of- 
                 → 
                 orientation of cutting planes: 
               
               
                 revolution 
                   
                 contains the axis of revolution OR 
               
               
                   
                   
                 perpendicular to the axis of revolution 
               
               
                 Shape Decomposition Relation 19 
               
               
                 overall shape is 3-D-closed body-of- 
                 → 
                 decomposition is the same as a 3-D-opened 
               
               
                 revolution 
                   
                 body-of-revolution 
               
               
                 orientation of cutting plane contains the 
               
               
                 axis of revolution 
               
               
                 Shape Decomposition Relation 20 
               
               
                 overall shape is 3-D-closed body-of- 
                 → 
                 could be decomposed into 2 or more 3-D- 
               
               
                 revolution 
                   
                 closed body-of-revolution AND/OR 3-D- 
               
               
                 orientation of cutting planes is 
                   
                 opened body-of-revolution 
               
               
                 perpendicular to the axis of revolution 
               
               
                 Shape Decomposition Relation 21 
               
               
                 overall shape is 3-D-closed body-of- 
                 → 
                 orientation of cutting planes is: 
               
               
                 revolution 
                   
                 contains the axis of revolution OR 
               
               
                   
                   
                 perpendicular to the axis of 
               
               
                   
                   
                 revolution 
               
               
                 overall shape is 3-D-closed double- 
               
               
                 curvature 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 57 
               
               
                   
               
               
                 3-D-closed Double-curvature 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
               
            
               
                 Shape Decomposition Relation 22 
                   
                   
               
               
                 overall shape is 3-D-closed double- 
                 → 
                 orientation of cutting planes: 
               
               
                 curvature only 
                   
                 do not matter 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
               
               
             
               
                 TABLE 58 
               
               
                   
               
             
            
               
                 Shape Decomposition Relation 23 
                   
                   
               
               
                 overall shape is 3-D-closed double- 
                 → 
                 can be decomposed into a series 
               
               
                 curvature 
                   
                 of 3-D-opened double-curvature 
               
               
                   
                   
                 shapes 
               
               
                   
               
            
           
         
       
     
     Referring now to FIG. 110 there is shown a flowchart showing a macro view of the operation of the present invention. As shown in FIG. 110, the PAMS system  110  of the present invention can be accessed by several avenues depending on when the user chooses the application  112 , enters criteria  114 , enters required part features  116 , or enters a known shape class  118 . 
     Where an application is chosen, default parameters  113  are utilized. Where part features  116  are selected, a shape selection is made by the system. All of these various avenues feed the PAMS system  110 . From all of the input, calculated, assumed, and defaulted information, the PAMS system  110  determines the structural analysis for each material option. Once this is known, the part thickness can be determined. From the part thickness, economic models are executed, resulting in a part cost for each option. 
     Referring now to FIGS. 111A-111G, there is shown a detailed flowchart of the present invention. Boxes  200 ,  202 ,  205 ,  207  and  209  relate to the initialization of the program in which the programs, data, and default values are loaded, and the GUI is started. It must be understood that this flowchart does not have to be linearly followed, and the user can jump from point to point at the user&#39;s desire. For example, the user can next enter application requirements at  211 , enter shape selection at  231 , expand or reduce selection lists at  301 . 
     Referring now to the application requirements box  211 , the user is presented with a variety of predefined applications in Box  213 , and if application(s) is(are) selected in Box  215 , the system will load default values at  218 . Box  220  shows that the user can refine or modify the default values. The system now utilizes the values for the selected application and feeds the desired material profile, the process filter and the mechanical models into Boxes  225 ,  227 , and  230 . 
     Referring now to the shape selection boxes  231 ,  233 ,  236 ,  238 ,  240 ,  241 ,  243 ,  245  and  247 , it can be seen that the user selects shapes and can modify default values, as with the application section. 
     Boxes  249 ,  251 ,  253 ,  255  and  258  are for deriving a desired material profile. 
     Boxes  260 ,  263 ,  265 ,  267 ,  268  and  270  relate to selecting materials. 
     Boxes  275 ,  278 ,  280 ,  281 ,  283 ,  287 ,  290 ,  293  and  298  relate to selecting fabrication processes. 
     At Boxes  301 ,  303 ,  305 , and  307 , the user may reduce or expand the pre-selection lists. 
     Boxes  309 ,  311 ,  312 ,  315 ,  317 ,  319  and  320  relate to mechanical properties, selection and analysis. 
     Boxes  322 ,  324 ,  328 , and  330  relate to generating a process filter using information from the application requirements, from the shape selection and from the mechanical model calculations. 
     Boxes  331 ,  333 ,  335  and  337  relate to the process filter defined in the previous set of boxes. 
     Boxes  339 ,  340 ,  342 ,  344  are utilized to reconcile results of the filtration process, the pre-selected list of materials and process and eliminating process and materials without corresponding materials or processes, respectively. 
     With Boxes  348 ,  350 ,  351 ,  353 ,  356 ,  358 ,  360 ,  368 ,  369 ,  370  and  371 , the user can override the system forcing certain selections by eliminating or retaining processes or materials with the process filter being applied to warn the user of processes without materials and visa-versa. 
     Boxes  372 ,  374 ,  375 ,  378 ,  380   381  and  382  relate to economics. 
     Box  384  relates to the presentation of the economic evaluation results for the materials and processes that survived the requirements of the chosen durable goods application. 
     EXAMPLES 
     The following examples are provided merely to illustrate this invention and are not to limit the claims of this invention. These examples were obtained utilizing the PAMS-SYS 1  software developed by the inventors. 
     Example 1 
     Opportunity Identification 
     In this example expert knowledge is utilized to process the information, explore alternatives, weigh importance, make judgments, and reach conclusions regarding opportunity identification. 
     FIGS. 42 and 43 show the input screens for inputting technical constraints and requirements. Data relating to aesthetics, durability, ergonomics, environmental, mechanical, reliability and weight are input. Data values have been input as shown in FIGS. 42 and 43. The screen is further explained in Tables 22 and 23 above. 
     FIG. 44 shows the input screen for data relating to comparing existing versus new products. Data input for existing product includes material used and process types, and data input for the new solutions includes the users material and application type. Data values have been input as shown in FIG.  44 . The screen is further explained in Table 24 above. 
     FIG. 45 shows the input screen for data relating to technical capacity, which data includes material, process and design analysis data. Data in each category is input for both the customer and the user. Data values have been input as shown in FIG.  45 . The screen is further explained in Table 25. 
     FIG. 46 shows the input screen for data relating to the business customer&#39;s major goals. Major goal data includes percentage of cost reduction value, importance of cost reduction, percent gain of market share, importance of market share gain, and performance improvement. Data values have been input as shown in FIG.  46 . The screen is further explained in Table 26 above. 
     FIG. 47 shows the input screen for data relating to customer interest and business. Input variables include application growth, profitability, sales, market share, potential for product differentiation, capacity utilization, selling/marketing cost, price variation, and ability to brand. Data values have been input as shown in FIG.  47 . The screen is further explained in Tables 27 and 28 above. 
     FIG. 48 shows the input screen for data relating to customer direct competition and pressure. Input variables include: top  2  and  5  share of market for competitor concentration analysis; market growth for market maturity analysis; and top  3  customers, cost to switch, backward integrate, alternative suppliers; and differentiation position for the customer bargaining leverage analysis. Data values have been input as shown in FIG.  48 . The screen is further explained in Table 29 above. 
     FIG. 49 shows the input screen for data relating to customer pressure and soft issues. Input data includes customer price sensitivity of customer profitability, plastic cost, discount cost, real price growth. Input data also includes soft issues such as credibility of customer, history of customer to develop products, innovation history of customer, and any personal issues. Data values have been input as shown in FIG.  49 . The input screen is further explained in Tables 30-31 above. 
     FIG. 50 shows the input screen relating to customer support and commitment, including input variables relating to internal agreement, organization functions and levels, partnership, and resources and investments. Data values have been input as shown in FIG.  50 . The input screen is further explained in Table 32 above. 
     FIG. 51 shows the input screen relating to the User&#39;s (illustrated as Dow in the figure) revenue. Input variables relate to volume of units, plastic per unit, expansion potential, and options to maximize revenue. Data values have been input as shown in FIG.  51 . The input screen is further explained in Table 33 above. 
     FIG. 52 shows the input screen for data relating to the User&#39;s (illustrated as Dow in the figure) assets/strategies. Input variables relate to the user&#39;s competitive advantage and whether the project fits with the user&#39;s strategy. Data values have been input as shown in FIG.  52 . The input screen is further explained in Table 34 above. 
     FIG. 53 shows the input screen for data relating to the User&#39;s (illustrated as Dow in the figure) differentiation. Input variables relate to account penetration, design assistance, global supply, historical industry presence, technical assistance, unique delivery options, and unique product performance. Data values have been input as shown in FIG.  53 . The input screen is further explained in Table 35 above. 
     FIG. 54 shows the input screen data relating to the User&#39;s (illustrated as Dow in the figure) cost position. Input variables include conversion costs, raw materials, capacity utilization, plant age, process technology, and cost of capital. Data values have been input as shown in FIG.  55 . The input screen is further explained in Table 36 above. 
     FIG. 55 shows input screens data relating to the User&#39;s (illustrated as Dow in the figure) development project. Input variables include activities, person-time forecast, resources, and time frame. Data values have been input as shown in FIG.  55 . The input screen is further explained in Table 37 above. 
     The results for this example are presented in output screens shown in FIGS. 56,  57 ,  58 . 
     FIG. 56 shows an output screen with information relating to opportunity analysis (OA) results for understanding the customer. Output variables include market attractiveness, project importance, customer commitment, and technical feasibility. Output values are as shown in FIG.  56 . This output screen is further explained in Table 38 above. 
     FIG. 57 shows an output screen with information relating to opportunity analysis (OA) results for the user&#39;s (illustrated as Dow in the table) business. Output variables include development and project management, revenue and business, corporate strategies, and competitive advantage. Output values are as shown in FIG.  57 . The input screen is further explained in Table 39 above. 
     FIG. 58 shows an output screen with information relating to the overall opportunity analysis (OA) results. Output variables include understanding of the customer, and user business potential. Output values are as shown in FIG.  58 . The input screen is further explained in Table 40 above. 
     Example 2 
     Processes and Materials Selection—“Carpet Cleaner” 
     In this example experts&#39; knowledge is utilized to process the information, explore alternatives, weigh importance, make judgments, and reach conclusions regarding a “carpet cleaner” application. 
     Referring now to FIG. 59 there is shown an input screen for selecting the type of application. Selection may be made according to various levels “ 35 ”, “ 45 ”, “ 55 ” and “ 65 ”, with the specificity of the levels increasing with the designation number. 
     The customer application selection is very important, as the information displayed and the questions asked to the user during the rest of the consultation depend on the particular customer application selected. Specifically, functional values do not appear on the screens and are not asked to the user because they are not relevant to the selected customer application. For example, “Weatherability” and “Transparency” listed in Table 16, for the “Carpet Cleaner” application. 
     Additionally, some functional values do not appear on the screens but are requested from the user because they are judged relevant but may be not as important or at a more detailed level for the selected customer application. For example, “Wear/Abrasion” as shown in Table 18 for the “Carpet Cleaner” application. 
     Referring now to FIG. 60 there is shown the input screen for the part specification environment. More detail regarding this screen may be found in Table 16 above. Input data for the “carpet cleaning” application includes chemical exposure, chemical types, hydrolytic stability, HDT, and ignition resistance. Input data is as shown on the screen. 
     Referring now to FIG. 61 there is shown the input screen for part specifications surface and electrical. More detail regarding this screen may be found in Table 17 above. Input data for the “carpet cleaning” application includes surface finish, color and texture. Input data is as shown on the screen. 
     Referring now to FIG. 62 there is shown the input screen for mechanical and environmental and legal. More detail regarding this screen may be found in Table 18 above. Input data for the “carpet cleaning” application includes ambient toughness, creep resistance, fatigue resistance, part toughness, part stiffness, emissions, environmental impact, recyclability. Input data is as shown on the screen. 
     Referring now to FIG. 63 there is shown the input screen for part specifications shape. More detail regarding this screen may be found in Table 19 above. Input data for the “carpet cleaning” application includes additions, complexity, constraints/dimensionality, degrees of draft, inside tolerances control, and shape control accuracy. Input data is as shown on the screen. 
     Referring now to FIG. 64 there is shown the input screen for shape (continued) and production volume. More detail regarding this screen may be found in Table 20 above. Input data for the “carpet cleaning” application includes size, undercuts and volume. Input data is as shown on the screen. 
     Referring now to FIG. 65, there is shown the Pre-Selection Dialog Box in which the system informs the user that it will take some time to process the information that has been provided. 
     Referring now to FIG. 66, there is shown the Cold Temperature Toughness Dialog Box in which the system requests more information from the user. 
     Referring now to FIG. 67, there is shown the Wear/Abrasion Dialog Box in which the system requests more information from the user. 
     Referring now to FIG. 68, there is shown the Legal Constraints Dialog Box in which the system requests more information from the user. 
     Before providing the final output of the selection in terms of selected or rejected materials and processes, the PAMS system informs the user about sensitive issues such as process recyclability, harmful chemical handling, material environmental impact, and FDA approval. Referring now to FIGS. 69,  70 ,  71 ,  72  and  73 , there are shown dialog screens for Recyclability, Sheet Molding Compound (SMC), Reaction Injection Molding (RIM), Structural Reaction Injection Molding (SRIM) and Resin Transfer Molding (RTM). 
     The results from the processes and materials selection are expressed in terms of lists of appropriate or rejected processes and materials, and explanations on how the conclusions were reached. The output screens are shown in FIGS. 74 and 75, respectively. The detailed explanation of the reasoning is provided not only in terms of the main elements of the selection but also for each individual process and material. The user is given the opportunity to overwrite the results. Further detail regarding FIGS. 74 and 75, is provided in Table 21 above. 
     While the illustrative embodiments of the invention have been described with particularity, it will be understood that various other modifications will be apparent to and can be readily made by those skilled in the art without departing from the spirit and scope of the invention. Accordingly, it is not intended that the scope of the claims appended hereto be limited to the examples and descriptions set forth herein but rather that the claims be construed as encompassing all the features of patentable novelty which reside in the present invention, including all features which would be treated as equivalents thereof by those skilled in the art to which this invention pertains.