LEGO Product Design and Manufacturing Simulations for Engineering Design and Systems Engineering Education

© American Society for Engineering Education, 2019. This paper describes a hands-on classroom activity to introduce students to engineering design and systems engineering concepts by simulating product design and manufacturing processes using LEGO bricks. Classroom simulations, especially those involving simple physical components, help to engage students and communicate abstract concepts. The proposed simulation platform requires modest one-time capital investment, supports real-time data collection, analysis, and visualization, and can be tailored to suit a variety of educational objectives and audiences ranging from pre-college to professional education. The activity models a three-tier vehicle manufacturing logistics system with suppliers, manufacturers, and customers. A simple software product lifecycle management system implemented using Google Forms and Google Sheets allows participants to record time-stamped events such as purchases or sales using phones, tablets, or laptops. Applications focus on specific topics such as product platforms, commonality, and design for manufacturing where participants experience tradeoffs between speed and quality, standardization and product variety, monotony and specialization, manufacturing learning curves, and how to identify and improve bottlenecks in production lines