Manufacturing Systems

Concurrent Engineering

Concurrent Engineering
Concurrent Engineering:
Is a strategy where all the tasks involved in product development are done in parallel. Collaboration between all individuals, groups and departments within a company. Customer research Designers Marketing Accounting Engineering

Concurrent Engineering
Suppliers R&D Customers

Commercial Design Process

Competitors

Idea Generation

Marketing

Product or Service concept Feasibility Study Performance Specifications

Linear Process
Preliminary Design Form Design
Revising and testing prototypes

Functional Design
Design Specifications

Production Design
Manufacturing Specifications

Pilot run and final tests

Product Launch

Concurrent Engineering

Techniques:
Perceptual mapping Benchmarking Reverse Engineering

Concurrent Engineering
Perceptual Mapping
Good Taste
Coco Pops

Low Nutrition
Rice Krispies

Cheerios

High Nutrition

Shredded Wheat

Bad Taste

Compares customers perception of available products Identifies gap in market

Concurrent Engineering
Benchmarking
Get the best product available Base performance specifications for new product on it

Reverse Engineering
Dismantle and inspect competitors product(s) Select features to incorporate into new product

Concurrent Engineering

Demand for the proposed product? Cost of developing and producing the product? Does company have manufacturing capability? Skilled personnel?

Concurrent Engineering

Form Design: Physical appearance of the product Functional Design: Performance of the product Production Design: How to manufacture product

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Prototype produced Adjustments made Final specification agreed

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Manufacturing process commences Product is marketed to buying public

Concurrent Engineering

Traditional Process = Linear Vs Concurrent Engineering = Team collaboration

Concurrent Engineering
Why Concurrent Engineering?
Pace of market change has increased Companies must keep pace with changing markets Decisions made sooner rather than later Reduces/eliminates repetition of tasks Reduces waste and reworking of design Product quicker to market Maximises company profit Company operates more efficiently

Concurrent Engineering
To make decisions concurrently:
Team knows the design goals/objectives Team is aware of the interrelationships between all aspects of the design process Superior communication between all sections of the company

Method:
Quality Function Deployment (QFD)

Concurrent Engineering
Quality Function Deployment (QFD)
Collection of matrices that converts the needs of the customer into technical specifications at all stages of the design and manufacture process.

Product Planning (most popular) House of Quality

Concurrent Engineering
House of Quality
1. Customer requirements prioritised (scale or %) 2. Competitive product evaluation 3. Engineering characteristics 4. Interrelationships of 1 & 3 5. Relations between engineering characteristics 6. Targets for new product

Concurrent Engineering
Example: Water-pond Alarm 1. Identify customer requirement and prioritise them (scale or %)

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2. Compare product to competitors
weighting
Attribute Sensitive to water level Durable Makes a loud noise Inexpensive Small Looks Good 25 Competitive Assessment

2 A

3 X X A A X A

B
15 10 25 10 15 B B A B B X B A X

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3.Identify engineering characteristics
Complexity of circuit Material for casing
+ + -+ + --

Energy Efficiency

Attribute Sensitive to water level Durable Makes a loud noise Inexpensive Small Looks Good 25 ++ 15 10 25 10 15 + ++

Cost of Sensor

Weighting

Concurrent Engineering
4. Identify strength of interrelationships between customer requirements and the engineering characteristics.
Complexity of circuit Material for casing
+ + -+ + --

Energy Efficiency

Attribute Sensitive to water level Durable Makes a loud noise Inexpensive Small Looks Good 25 ++ 15 10 25 10 15 + ++

Cost of Sensor

Weighting

Legend: Positive correlation + Strong positive correlation ++ None Negative correlation Strong Negative correlation - -

Concurrent Engineering
Interpreting the matrix Sensitivity to water level is likely to be very dependent on complexity of circuit
Complexity of circuit Material for casing
+ + -+ + --

Energy Efficiency

Attribute Sensitive to water level Durable Makes a loud noise Inexpensive Small Looks Good 25 ++ 15 10 25 10 15 + ++

Weighting

Increasing the noise level could reduce the energy efficiency

Cost of Sensor

Concurrent Engineering
A complex circuit and quality sensor could increase cost of product

Complexity of circuit

Material for casing

Energy Efficiency

Attribute Sensitive to water level Durable Makes a loud noise Inexpensive Small Looks Good 25 ++ 15 10 25 10 15 + --+ ++

Weighting

The choice of material will affect the durability of the product

Cost of Sensor

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5. Identify correlation between engineering characteristics.
Increasing complexity of circuit could require a more costly sensor Complex circuit (more parts) could reduce energy efficiency A good quality sensor could improve energy efficiency

Concurrent Engineering
6. Identify targets for new product

120

Target

120

<30

Concurrent Engineering

2002 DRM Associates

Concurrent Engineering
Role of CAD in Design & Manufacture
Model part or assembly being designed Part visualised and manipulated on screen Realistic Function tested Textures & lighting effects can be applied Photorealistic effects Manufacturing drawings generated automatically Modelled part and its manufacturing requirements shared with the entire design and manufacturing team

Concurrent Engineering
Role of CAD in Design & Manufacture
Geometry from CAD system used to produce part on CAM system CAD model used by marketing to create images for packaging Simulate behaviour of product under stresses and forces using CAE system Model data used by rapid prototyping machine

Concurrent Engineering
Role of CAD in Design & Manufacture Advantages:
All above can be done concurrently Manufacturing problems identified early Changes in design can be seen immediately Speeds up design and prototyping processes

Concurrent Engineering
Design for the Environment
There are three major elements of design for the environment: Design for environmental manufacturing Design for environmental packaging Design for disposal and recyclability.

Concurrent Engineering
Design for Environmental Manufacturing:
Non-toxic processes & production materials Minimum energy utilization Minimize emissions Minimize waste, scrap & by-products

Concurrent Engineering
Design for Environmental Packaging:
Minimum of packaging materials Reusable pallets and packaging Recyclable packaging materials Bio-degradable packaging materials

Concurrent Engineering
Design for Disposal & Recycling:
Re-use/refurbishment of components & assemblies Material selection to enable re-use (e.g., thermoset plastics vs. thermoplastics) and minimize toxicity Avoids filler material in plastics such as fibreglass and graphite Minimum number of materials/colours to facilitate separating materials and re-use Design for serviceability to minimize disposal of nonworking products

Concurrent Engineering
Design for Disposal & Recycling:
Material identification to facilitate re-use Design to enable materials to be easily separated Design for disassembly (e.g., fracture points, fastening vs. bonding) Avoid use of adhesives Limit contaminants - additives, coatings, metal plating of plastics, etc. Maximize use of recycled or ground material with virgin material

Concurrent Engineering
Impact of Product Life Cycle on the Environment
Product life cycle = design, manufacture, use & disposal stages of product Minimise a products negative impact on the environment Incorporate DfE considerations into design process of a new product

Concurrent Engineering
Case study 1: Desktop computer
Design Stage: The design could specify the following Reusable components e.g. monitor, keyboard Recycled materials where possible Minimise toxic materials used Manufacture: Use ethical work practices and sources for raw materials Use clean manufacturing processes Minimise transport of components and materials Implement quality procedures to minimise waste etc. Use: Low power consumption Serviceable items rather than replaceable e.g. disk drive, peripherals etc. Disposal: Design for disassembly use easily dismantled fixings etc. Identify materials used for recycling Minimise mixed materials to facilitate separation later

Concurrent Engineering
Role of Testing in Product Design
Cannot predict with absolute certainty how product will perform Need test product before mass production Mass production very costly to setup Changes cannot be made easily Speeds up design and prototyping processes

Concurrent Engineering
Role of Testing in Product Design Possible tests:
Product meets performance specifications Expected life of product Likely cause of failure
Accelerated testing

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Performance test: Pond Alarm
Test Casing Seal Procedure Minimum performance Result Submerge in water for 8 No evidence of water hours ingress Remove, Dry, disassemble and inspect Submerge probes to 8mm Alarm should trigger in sample of pond water before 8mm is reached Retract Alarm should reset within 1 min Trigger alarm and Alarm should sound for 1 measure time until battery hour minimum depletes. Place in freezer at -15C No damage should be and in oven at 50C for 1 apparent to casing or hour function Trigger in an Should be audible up to unobstructed area then 30m move away until alarm is no longer audible

Sensitivity of sensor

Battery life

Ability to withstand extreme weather

Alarm Volume

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Role of Accelerated Testing
Used when expected life is long to capture life data Life data is needed to estimate the reliability of a product Tests are conducted on a sample or prototype Tests cause product to fail in same manner as normal use Test time is greatly reduced Product is quicker to market Low development and warranty costs

Qualitative or Quantitative

Concurrent Engineering
Qualitative Accelerated Tests
To reveal probable failure modes Good tests quickly reveal failure modes Improve design product Performed on small number of samples Product subjected to one severe level of stress
e.g. Stress cycling or hot to cold

Product intact pass Failure - action taken to eliminate cause of failure Only tests conditions encountered in real use Cannot be used to quantify life of product

Concurrent Engineering
Quantitative Accelerated Life Tests
Quantify the life of the product Controlled application of accelerated stress conditions to simulate product failure Reduces the time-to-failure for a product Data used to estimate reliability of product

Concurrent Engineering
Example: A washing machine to last for ten years in normal use. Expected typical household use: three times a week for a wash cycle that will last for 2 hours on average. What type of test should be used? How long must the machine survive during the test? Total hours life required for the machine is: 2 hours/wash x 3 washes/week x 52 weeks/year x 10 years = 3120 hours Use a quantitative accelerated test. Run the machine constantly for 3120 hours

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Sample Paper: HL Explain why accelerated testing is used on some products.
Some products have a long life need to test reliability quantify life of product - warranty

A washing machine will be used for two hours per day, three days per week in normal use. What type of accelerated testing will determine the lifetime of the washing machine?
Quantitative test data is used to determine expected normal life time of product

During testing, the washing machine ran for 3000 operating hours before failing. Recommend a suitable guarantee period for the washing machine and give reasons for your recommendation.
2hrs/day x 3days/week = 6hrs/week 3000/6 = 566.67 weeks 566.67/52 = 10.8975 Guarantee period = 10 years.