1.

In terms of assignment documentation method, please follow the

Documentation section of the 3D eBook in your eLearning Pack.
2. Title, Author (Name, Class, Date, your eLearning Pack ID number, and
the 4 collab. companies you have ( a MUST!)
Daniel Roberts, February 14th, 2016.
My eLearning Pack ID is IE655-Spring 2016-36-32.
Four Collaborative Companies:
1.
2.
3.
4.

Sea-Doo
Modern Machine Shop
HJC Helmets
Schmalz

3. Statement on who has done the work, even if done in a team: EACH
individual, and this is true for all assignments, must submit an
assignment by himself/ herself!
I have completed all of this work on my own.
4. Contents
The contents of the project are the requirements for Assignment One.
5. Introduction and Objectives of the Project
What is Concurrent Engineering (CE) and Green PLM (Product Lifecycle
Management) and why is this subject important for our future? (As per the
assignment requirements.)
6. A brief description of the methodologies applied.
Information from the textbook and DVD videos were applied to this
project. Case studies and videos were reviewed and appropriate
analysis has been provided.
7. The Main Body of the project:

1. View and study the CE / PLM Lecture and Software Demo

Videos (in the DVD)
2. Show me, that you have seen and understood
the a Sustainable GREEN CE/PLM focus in these videos, by
answering your own 5 questions for each video. (Answer your
own questions with about 3-4 sentences each.)
Videos: Baumer Electric Racing Car
1. How do you design improved tires to monitor them?
User lasers to keep track of the tires. Black box with laser
displacement senor. Use a diode laser as it is more robust. Measures high of
the car off of the ground using a linear laser sensor.
2. How do you integrate the signal from the laser into the on board
computer.
There is continuous monitoring of the single from the box to see
how far from the ground the car is. Much testing must have taken place to
understand what the singles are and what they mean.
3. How do you test the car to make sure the integration works?
Strong reliability testing would be a must. A lot of up front work
would be required to identify what type of data the laser sends to the
computer, and how the computer interprets that data. Simulation of data
would be very beneficial here.
4. How do you make sure there is no interference with the laser?
The laser in not a pin point, but a line. That line naturally sends back an
average, so any very small changes in the ground will not cause a disruption
in the data.
5. How do you ensure the reliability of the sensor?
Once again, a large amount of testing will be required. It will also be
very important to understand the conditions under which all the components
will operate. There will be heat from the engine and the road, there will be
debris from the ground, the car will be moving around and plenty of vibrations.

Video: BigTwin Swift

1. How do they make the bikes so glossy?
Bikes are finished with a chrome finish. This is naturally glossy, but also
resistant to corrosion.
2. Is the main user need performance or the visuals?
For these bikes, the visuals are very important, and the performance
naturally comes along.
3. How many common parts are there from bike to bike? Does it make
sense to have a lot of common parts?
Due to the custom nature of the bikes, there are very few common
parts. This is not ideal, but for this type of market and what the customers
want, it is not practical. For regular bikes off of the assembly line they have
plenty of common parts. But due to the individual nature of choppers, that is
not practical for these bikes.
4. How can the safety of the bikes be improved even though they are
one-off designs?
Even though these are custom bikes, there are many methods to control
their safety. An easy aspect would be to use materials that are well known
and understood. If the same steel is used from bike to bike, the manufacturer
will know how well it functions and how strong the material is. Also, the
manufacturer can identify a baseline envelope for the bikes to operate in, that
will also help control their safety.
5. How do the emissions of a chopper compare to the emissions of a
standard bike?
It would really depend on the quality of the engine. If high quality
engines are used, the emissions should be controlled. However, the
emissions of a motorcycle with one rider will still be less than a car with one
rider.
Video: COGNEX Vision Inspect
1. How is the inspection process validated?

The validation process must be very detailed and comprehensive. The

system is so quick and the accuracy is so high that the validation for the
system must have been massive.
2. What is the reliability of the inspection system?
The reliability of the system must be very high since it has been used in
Pharmaceutical applications.
http://www.cognex.com/customer-stories/when-mistakes-are-not-an-optionprocedural-reliability-in-pharmaceutical-production/
3. Is automated inspection more reliable than human inspection?
Yes. People make mistakes and are prone to human error. As long as
the computer is set up correctly then the inspection should be very reliable.
4. How are operators trained to use the system?
An in-depth knowledge of the system would be required and an
understanding of the capabilities.
5. How accurate is the system?
The system would be as accurate as it needs to be. There are probably
some applications that the system cannot be used for. But for those that it
can be, the accuracy should be in line with the design requirement. If DFM is
applied correctly, the tolerance requirement of the design should be in line
with the accuracy of the vision system.
Video: Ford Concept Car
1. What is the identified users for this car?
Young millennials who are professionals who want to move back
into a urban environment. They want a small car for the urban environment,
but that is also very warm and cool.
2. What type of questions to ask when trying to understand what the
user needs.
It is better to not ask specific questions, but let them talk and
explain themselves so to be understand what drives them and what makes

them tick. That will help to better understand how they function in their lives
and understand what design they need to improve their lives.
3. How do you design a car to better work in an urban environment.
They have automatic shades that go up to provide privacy and
can act as armor from the outside.
4. How do you link modern electronics into a cool and hip car?
Smartphones are the big things now and so any new car should have
smart phone integration. This would include Bluetooth technology. They need
to move forward and allow you to unlock your car with your phone and also
even unlock it!
5. What type of materials are used for this car?
Need to factor in manufacturing needs and low cost materials to
design a car. This car happened to focus on more emotional materials. And
therefore are a little more expense, but it is very soothing to the buyer.
Video: Ford Rouge
1. How do you incorporate Just In Time manufacturing into the factory?
It was not explained in the video, but due to the size of the plant and
Ford, JIT practices are probably very well executed there. They most likely
receiving only the raw materials required for that days, or 2 days of
manufacturing. JIT principals are also used in the line where the truck moves
from site to site, while the operators are allowed to slow down the whole
process if they get behind in the work, so as not to cause a bottle neck.
2. How do you keep people interested in their jobs?
Everyone does everyone elses jobs. People rotate around and
do not do the same thing every day. Operators are multi-skilled and can move
around.
3. How is continuous improvement incorporated into the factory?
Employees are encouraged to identify any ways to improve their job.
4. How do you keep track of the truck while it is going through the line?

There are computers at each section and they keep track of what the
operator is doing. They give the operator all the data they need and it also
flows to the team leader to identify how the line is functioning.
5. How many trucks can the factory make a day?
A newswire identified that ford may sell 700,000 F 150s this year, which
would be about 2,000 trucks per day. They are probably not all made at that
factory, but that is a lot of trucks.
http://news.pickuptrucks.com/2015/02/ford-on-track-to-sell-700000-f-150s.html

8. Based on the 3DeBook in the DVD, answer the following questions:

1. What is CE and PLM?
Concurrent Engineering is developing a system to lower
product/process development time, lower defects, lower
design changes and improve product quality in a
sustainable method.
Product Lifecycle Management is a process to understand
where a design fits within its designing state.
2. What is the difference between CE and PLM?
CE focuses on the specific designing and process systems
that can be implemented to improve and better the design
and product. PLM looks at the entire lifecycle of the product
and understanding where in that state the design currently
is and how it fits in with the rest of the process.
For instance, PLM could involve trying to manufacture a
product that has a better assembly method, while CE would
be the specific process to improve that assembly method.
3. What is green sustainable PLM?
Green PLM is incorporating sustainable and green solutions
into the product lifecycles process. These can include

including the Restriction of Hazardous Substances Directive

(RoHS), Electronic Waste Recycling Act, REACH,
Packaging Directive and other requirements into the design
process.
4. What is digital design & manufacture and why is this such a huge
opportunity?
Digital design and manufacture allows for the identification
and logging of real time data in a manufacturing facility.
This can allow designers to know exactly what is wrong with
the design and what is incorrect with the design. This can
allow for very quick continuous improvement, as issues can
be identified before they even become issues!
5. How is digital design integrated with digital manufacturing in
PLM?
Like above, it is capturing the real time data of what is
happing in a manufacturing site and feeding it back to the
designer. A great example is vision system inspections,
which provide real time data on how a machine is
functioning. You will know what the average output of the
machine is, and you can even know all the statistical
analysis on that data. This data can be fed back to the
designs who can incorporate that analysis into how the
design the process, leading to a higher quality and better
product.
6. What is frontloading, and why is it critical to understand this
process?
Frontloading is setting up a plan for successes. This means
that most of the work for a CE/PLM process should be done
upfront, which includes identify that requirements and how
the project will be executed. Even though this up front work
may be a lot, it leads to more efficient projects because it
takes more resources to fix a problem later on, than spend
more time on it up front.
7. Read Chapters 1, 2 and 3 of the 3DeBook. Find 5 questions in
EACH of these Chapters and answer them. Each answer should

be min. 3-4 sentences long, but it's really up to you if you want to
write more... and even add figures, photos, etc. You are free to
explore.
Chapter 1:
Q1.2: How would you assure, that your designers, employees create
'quality product', 'quality process', 'quality service'?
o The best way to ensure that all employees of a company produce
high quality products is to integrate quality into all aspects of the
company, including but not limited to a Quality Policy, Vision,
Culture and Drive. As a Manager you cannot continually watch
everyone to ensure that they are doing the right thing and the best
thing that they can do. Thats why its so important to ingrain that
quality culture in all aspects of the company, and ensure that
everyone buys in on the quality culture, so that there should never
be any slips.
Q1.3: Why is it important to create and offer 'quality product', 'quality
process', 'quality service'?
o Everyone always wants the best, hence consumers and
customers will always expect to buy the highest quality products
that they can. For any market there is always strong competition
and consumers are willing to switch to any competitor when they
feel that their current brand is no longer high quality. Quality is
even more important when it comes to products that could provide
safety concerns, if a device injures a person due to low quality,
then that will open up the company to potential litigation.
However, as that is a person that would be getting injured, every
company should try its best to lower the safety risks of products
as that is just the right thing to do.
Q2.5: Why is sustainable green and eco-friendlyness important for the
design team?
o It is important for the design team to understand that the output
from their design may not just impact their users, but it may
impact the earth as a whole. If the design team keeps their focus
narrow just looking at their device and consumers, they will not be

able to understand how their product, and all the associated

process, may impact other parts of the worlds. While it might be
easy to create a very fast car, that car will not be able to go fast if
all the roads are flooded. Hence the design team needs to
understand the types of materials used to manufacture the device
and understand how it can minimize the effects to the
environment.
Q2.3 List, and explain the various dimensions of design quality, with
examples.
o Brand Name Quality: Always maintain the high quality standards
that your brand requires.
o Features: What does the product do and how does that related to
what the customer wants/needs.
o Performance: Can it actually do what it is supposed to do, and
does it do it well?
o Reliability: Does the product last as long as it should? When it
does not operate as intended, how does it fail?
o Durability: How strong and long will the product function before it
needs to be serviced?
o Serviceability: If the product does not function as intended, how
can it be fixed? What type of preventative maintenance will be
required for the product.
o Aesthetics: How cool or awesome does the product look?
o Excitement Quality: Wow factor. Does it make someones blood
pressure increase when they look at it?
o Safety Quality: How does the product help prevent the user from
getting injuring while using the device:
o Eco-Standards: Factors to make the product eco-friendlier. This
can include lowering the carbon footprint, non-hazardous
materials, recyclability, toxicity.

 Q3.3: How would you organize a CE/TQM team-brainstorming session

for product / process / service improvement? Explain the key
challenges, issues and steps. How would you run such a session?
o I would first be clear in the objectives, identify the requirements,
make sure we all agree, identify the resource requirements and
determine responsibility. I would review the plan with the entire
team before executing and make any adjustments that are
deemed necessary.
o The session itself will have an appropriate team (not too small,
nor too large) with a clear leader who keeps a relaxed
atmosphere. The team will generate as many ideas as possible
and give everyone the opportunity to contribute, and all
contributions will be written down, no matter how crazy they might
be. Ideally the session should not go longer than an hour, but will
be re-visited if required.
Chapter 2
Q1.1: Organizations depend on their customers, and therefore should
understand their current and future needs, as well as should meet
customer requirements, and strive to exceed customer expectations.
What does this quality principle mean, and how could you implement it?
o This quality principal means that customer should be the major
driver for all organizations. The biggest focus needs to be the
customer. For a product to function correctly at its most basic
element, it needs to fulfil the needs of the customer. If it does not
meet the needs of the customer, then the customer will not buy it.
o This can be implemented via the Quality Policy and vision of the
entire company. By identifying the customer as a main focus in
the Quality Policy and Vision of the company ensures that the
customer will always be satisfied.
Q1.2: Leaders establish unity of purpose and direction of the
organization. They should create and maintain the internal environment
in which people can become fully involved in achieving the
organization's objectives. What does this quality principle mean, and

how could you implement it? What are the key characteristics of quality
leaders?
o Leadership and unity of principal means that the organization is
continuously driven to produce high quality products, and that
vision is shared amongst all employees. This allows everyone to
see the bigger picture and feel like they have an ownership of the
final product and overall outcome of the company.
o Quality leaders provide clear, challenging, yet achievable, goals
and a clear vision of the future. They are trustworthy and can
inspire employees to be quality first as well.
Q1.3: People (or in other words, 'knowledge workers') at all levels are
the essence of an organization and their full involvement enables their
abilities to be used for the organization's benefit. What does this quality
principle mean, and how could you implement it? What are the key
characteristics of quality 'knowledge workers'? How can a 'knowledge
worker' improve his / her quality attributes? Why should he / she do so?
o Involved knowledge workers means that employees are
encouraged to be innovative, to participate and understand the
importance of their work. However, they are also expected to take
ownership of their job, identify any shortcoming and find ways to
solve them. They should be expected to continuously evaluate
their performance and expect it to always be increasing. They
should feel free to be vocal about issues and encourage others to
do the same.
Q2.3: The continual improvement of the organization's overall
performance should be a permanent objective of the organization. What
does this quality principle mean, and how could you implement it?
o Continuous improvement means that there is a constant
companywide imperative to progress the organizations
performance and systems. A continuous improvement
organization will have systems that are geared to execute on the
companys vision and will have clearly identified goals that
everyone is driven to surpass. Every employee should be tracked
and measured on their ability to improve products, processes and
people to demonstrate their adherence to continual improvement.

 Q2.5: Even if an organization and its suppliers are interdependent, a

mutually beneficial relationship enhances their ability to create
value. What does this quality principle mean, and how could you
implement it?
o Mutual beneficial supplier relationships identify that there are
opportunities for both parties to improve from the connection. The
better communication and exchange of ideas between a supplier
and purchaser can only increase the overall relationship between
the two and be a positive for each party. This is implemented via
clear communication, pooling resources, having flexible contracts
and completing joint development projects.
Chapter 3
What are the analytical / mathematical/ material science aspects of the
illustrated DFM, DFA, DFQ, and DFx challenges and solutions? Upon
what scientific principles do they operate?
o DFM: Looks to reduce lead-times and issues with CNC machines
by building the manufacturing process into the design. By
focusing on manufacturing with CNC machines, can lead to a
large reduction in machining, WIP and lead to a drop in scrap.
This can be built on various modeling software and costing
models.
o DFA: Looks to increase efficiency via modular design and product
structure that can be accomplished through standard
components. This is accomplished through many parts having
similar sub components, which allows for a smaller inventory,
cheaper engineering changes and reduced lead times. This also
involves the minimum number of parts for a design, as it lowers
many of the other manufacturing costs as well (inventory, WIP,
assembly)
o DFQ: Focuses on ensuring that the requirements required by the
customer are met and exceeded. This is done by being proactive
in preventing problems and not reactive to problems. This can be

accomplished by continuous improvement for all things related to

the product such as employees, systems, design and practices.
How are these processes integrated and controlled from a quality
perspective? What are the process parameters and the limitations? How
can you measure the process parameters, and then quality control
them?
o They are integrated and controlled by the Japanese KANRI steps
of Plan, Do, Check, Act. The first step should be the longest step,
and that is setting up your plan of what you are going to check,
how you are going to check it, and establishing the rules
surrounding that. The next is doing it, making sure that those
performing the steps are training correctly and know what their
responsibilities are. Next is Check, keep track of how the process
is performing. Understanding if the process is still in control or if
the process is starting to move towards becoming out of control.
The last step is Act when you do find something incorrect,
understating why it is incorrect, and implementing a plan to
prevent it from being incorrect again in the future.
How do you see the future of quality designs, from a concurrent product/
process, or in other words, from a modular, reusable-component design
point of view?
o Future quality design output will be simple, but will be the result of
a very complex design process. Due to the complicated assembly
process and various factors to create a quality design, a lot of
time and analysis will be required to create that end quality result.
There will be many design iterations to go from the initial concept
to the final production design. Due to all the available
streamlining opportunities and availability of tools to improve the
product, it will take additionally time a manpower to design the
product. Though the additionally up front work will lead to
products that are better design, can be assembled and
manufactured better, have less defects and require less inventory
to produce. They will also be eco-friendlier.
As a DFM, DFA, DFQ, and DFx manager in charge, how would you
assure, that quality is designed into the product / process / service?

o I would build all of the DF requirements into my overarching

design process. This would include specific design reviews for
manufacturability, assembly, quality, environment and anything
else required, (i.e. safety). There would be the initial design
reviews for each, and then later reviews to ensure that what we
had planned on previously is being completed and integrated into
the process. It will follow the Plan, Do, Check, Act process which
will allow the specific design and process to be improved and also
future design and processes to be improved.
How would you approach designers, and insurance companies
with DFM, DFA, DFQ, and DFx options in modern automobiles, and
other products and processes?
o Designers and insurance companies will be very excited to review
the DF opportunities for automobiles. A large issue that they both
would be interested in is ways to make cars as safe as possible.
Risk management process can be implemented in all of the DF
process to improve the overall safety of automobiles. During the
DFM process, those processes that are most likely to cause
issues that could lead to harm can be identified and additional
controls can be applied. During DFA, those assembly processes
that could lead to harm can be identified and additional controls
can be applied. During the DFQ process the potential harms can
be identified and mitigated. A Design For Risk Management
process could be initiated that would identified the specific risk
management aspects and find ways to lower the overall risk
profile of the automobile.
9. Summary (i.e. what has been achieved)
Concurrent Engineering and Product Lifecycle Management has been
reviewed and demonstrated in this project.
10.

Further work needed / proposed

No further work is currently proposed.

11.References and Bibliography (including the CDs, Internet as a main

source of information)

Ranky, Paul G. Concurrent / Simultaneous Engineering - Methods,Tools and

Case Studies Within a Lean Six-Sigma Quality and Sustainable, Globally
Collaborative Green PLM (Product Lifecycle Management) Framework. Ver
7.1. CIMware USA Inc and CiMware Ltd., UK.
12.

Appendix (- if necessary)
Not applicable.