Concurrent Engineering

1
Concurrent Engineering
2
Concurrent Engineering

• Design Product and Process simultaneously
• Lift Cycle of Product

3
Product Life-span
4
Sales and Market Share
5
Unit Cost/Price
6
Life Cycle Revenues
7
The Importance of Early Design
8
Timing and Impact of Management Attention
9
Cost for Making Design Changes
Source Dataquest
10
Cost for Fixing a Mistake
Source CAM International Data
11
Comparison of Engineering Changes
Source American Supplier Institute Data
12
Key Constituents in Concurrent Engineering
13
Organization for Concurrent Engineering

• Task Force is formed by members from functional
  departments.
• Team members cooperate on developing related
  design and processes currently.
• Team is controlled by a single project leader.
• Team directly reports to the manager of the main
  project.

Program Manager
System Design
Administrative Support
Component Design
Mainten-ance
Team Leader
Marketing
Manufacturing
Quality Control
Procurement
14
Collaborative Design Conceptual Integration
15
Collaboration on Various Items

• Collaborative on goal
• Are goals consistent or conflicting?
• Loyalty of customers and vendors?
• Personnel collaboration
• Sales, engineering and procurement personnel
• Collaborate with customers
• Collaborate with vendors
• Tool collaboration
• High-level CAD software and low-level CAD
  software
• High-level digital equipment and low-level
  digital equipment

• Data collaboration
• Data sharing and conflict of secrecy
• Difficulty on data acquisition
• How to proceed with KM?
• Time collaboration
• Design Anywhere,Design Anytime?
• Deadlines and check-points settings

16
Assignment of RD Schedule
Design Modification
Initial Design
Concept Design
Information Transfer
Sequential
3
27
55
15
Concurrent Engineering
5
20
13
22
40 shorter

• CE Focusing on overall consideration at early
  RD stage, reducing the cost and time consumption
  in process design modification in later stages.

17
Product Lifecycle Costs
18
Product Design Guidelines

• Reduce the number of parts to minimize the
  opportunity for a defective part or an assembly
  error, to decrease the total cost of fabricating
  and assembling the product, and to improve the
  chance to automate the process
• Foolproof the assembly design (poka-yoke) so that
  the assembly process is unambiguous
• Design verifiability into the product and its
  components to provide a natural test or
  inspection of the item
• Avoid tight tolerances beyond the natural
  capability of the manufacturing processes and
  design in the middle of a part's tolerance range
• Design "robustness" into products to compensate
  for uncertainty in the product's manufacturing,
  testing and use

19
Product Design Guidelines

• Design for parts orientation and handling to
  minimize non-value-added manual effort, to avoid
  ambiguity in orienting and merging parts, and to
  facilitate automation
• Design for ease of assembly by utilizing simple
  patterns of movement and minimizing fastening
  steps
• Utilize common parts and materials to facilitate
  design activities, to minimize the amount of
  inventory in the system and to standardize
  handling and assembly operations
• Design modular products to facilitate assembly
  with building block components and sub-assemblies
  
• Design for ease of servicing the product

20
Design for Manufacturability/Assembly Guidelines

• Simplify the design and reduce the number of
  parts
• Standardize and use common parts and materials
• Design for ease of fabrication.
• Design within process capabilities and avoid
  unneeded surface finish requirements.
• Mistake-proof product design and assembly
• Design for parts orientation and handling
• Minimize flexible parts and interconnections.
• Design for ease of assembly
• Design for efficient joining and fastening.
• Design modular products
• Design for automated production.
• Design printed circuit boards for assembly

21
Material and Process Selection

• A priori conditions from functional
  specifications to detailed design

Initial Design
Process Choices
Function Requirements Application Scenario
Casting Forming
22
Manufacturing Process Selection and Decision
Factors

• Material Selection
• Mechanical characteristics (strength, elasticity
  vs. hardness)
• Physical characteristics (heat transitivity and
  erosion-resistance)
• Cost considerations
• Manufacturing processes
• Environment of use
• Regulation constraints
• Market factors (sense of touch, life-span)
• Possibility of recycle and reuse
• Geometric Requirements
• Shape, dimensions, weight
• Dimension accuracy, surface roughness
• Dimension of the smallest cross-section

• Near Form Manufacturing Processes
• Sheet Forming
• Casting
• Extrusion
• Forging
• Injection Molding
• Powder Metallurgy
• Secondary Operation
• Processing of dimension accuracy
• Processing of surface roughness processing
• Processing of local features (holes, slots)

23
Design for Ease of Fabrication

• For higher volume parts, consider castings or
  stampings to reduce machining
• Use near net shapes for molded and forged parts
  to minimize machining and processing effort.
• Design for ease of fixturing by providing large
  solid mounting surface parallel clamping
  surfaces
• Avoid designs requiring sharp corners or points
  in cutting tools - they break easier
• Avoid thin walls, thin webs, deep pockets or deep
  holes to withstand clamping machining without
  distortion
• Avoid tapers contours as much as possible in
  favor of rectangular shapes
• Avoid undercuts which require special operations
  tools
• Avoid hardened or difficult machined materials
  unless essential to requirements
• Put machined surfaces on same plane or with same
  diameter to minimize number of operations
• Design workpieces to use standard cutters, drill
  bit sizes or other tools
• Avoid small holes (drill bit breakage greater)
  length to diameter ratio gt 3 (chip clearance
  straightness deviation)

24
Experiencing Principles for Design for
Fabrication (Sand Casting)

• Decrease the number of ribs intersecting at a
  single point to reduce heat concentration effect.

25
Design for Ease of Injection Molding

• Uniform thickness of cross sections

26
General Motors Case
The original and redesigned air intake manifolds.
The body of the original manifold (top) is made
of cast aluminum. The redesigned manifold
(bottom) is made of molded thermoplastic
composite.
27
Design for Manufacturing

• General Motors Powertrain Division manufactures
  about 3,500 3.8-liter V6 engines every day.
  Facing such high production volumes, the company
  had a strong interest in reducing the cost of the
  engine while simultaneously enhancing its
  quality. A team was formed to improve the most
  expensive subassemblies in the engine the air
  intake manifold.

The General Motors 3.8-liter V6 engine.
28
DFM is Performed throughout the Development
Process

• DFM begins during the concept development phase,
  when the products functions and specifications
  are being determined.
• When choosing a product concept, cost is always
  one of the criteria on which the decision is
  madeeven though cost estimate at this phase are
  highly subjective and approximate.
• When product specifications are finalized, the
  team makes trade-offs between desired performance
  characteristics.
• During the system-level design phase of
  development, the team makes decisions about how
  to break up the product into individual
  components, based in large measure on the
  expected cost and manufacturing complexity
  implications.
• Accurate cost estimates finally become available
  during the detail design phase of development,
  when many more decisions are driven by
  manufacturing concerns.

29
Overview of the DFM Process

• Estimate the manufacturing costs.
• Reduce the costs of components.
• Reduce the costs of assembly.
• Reduce the costs of supporting production.
• Consider the impact of DFM decisions on other
  factors.

The design for manufacturing (DFM) method.
30
The Bill of Materials with Cost Estimates
Indented bill of materials showing cost estimates
for the original intake manifold and related
components. The EGR (exhaust gas recirculation),
PCV (positive crankcase ventilation), and vacuum
block components are included here to facilitate
comparison with the redesigned manifold assembly.
31
Integrate Parts
Integrations of several features into a single
component. The EGR return and vacuum source
ports are molded into the redesigned intake
manifold.
32
Results
The redesigned intake manifold.
33
Results

• The improvements over the previous design
  include
• Unit cost savings of 45 percent.
• Mass savings of 66 percent (3.3 kilograms).
• Simplified assembly and service procedures.
• Improved emissions performance due to routing of
  EGR into the manifold.
• Improved engine performance due to reduced air
  induction temperatures.
• Reduced shipping costs due to lighter components.
• Increased standardization across vehicle programs.

34
Results
Cost estimate for the redesigned intake manifold.
35
Design for Parts Orientation and Handling

• Parts must be designed to consistently orient
  themselves when fed into a process.
• Product design must avoid parts which can become
  tangled, wedged or disoriented. Avoid holes and
  tabs and designed "closed" parts. This type of
  design will allow the use of automation in parts
  handling and assembly such as vibratory bowls,
  tubes, magazines, etc.
• Part design should incorporate symmetry around
  both axes of insertion wherever possible. Where
  parts cannot be symmetrical, the asymmetry should
  be emphasized to assure correct insertion or
  easily identifiable feature should be provided.
• With hidden features that require a particular
  orientation, provide an external feature or guide
  surface to correctly orient the part.
• Guide surfaces should be provided to facilitate
  insertion.
• Parts should be designed with surfaces so that
  they can be easily grasped, placed and fixtured.
  Ideally this means flat, parallel surfaces that
  would allow a part to picked-up by a person or a
  gripper with a pick and place robot and then
  easily fixtured.

36
Design for Parts Orientation and Handling

• Minimize thin, flat parts that are more difficult
  to pick up. Avoid very small parts that are
  difficult to pick-up or require a tool such as a
  tweezers to pick-up. This will increase handling
  and orientation time.
• Avoid parts with sharp edges, burrs or points.
  These parts can injure workers or customers, they
  require more careful handling, they can damage
  product finishes, and they may be more
  susceptible to damage themselves if the sharp
  edge is an intended feature.
• Avoid parts that can be easily damaged or broken.
  
• Avoid parts that are sticky or slippery (thin
  oily plates, oily parts, adhesive backed parts,
  small plastic parts with smooth surfaces, etc.).
• Avoid heavy parts that will increase worker
  fatigue, increase risk of worker injury, and slow
  the assembly process.
• Design the work station area to minimize the
  distance to access and move a part.
• When purchasing components, consider acquiring
  materials already oriented in magazines, bands,
  tape, or strips

37
Reduce the Number of Components

• Benefits from the Reduction
• Shorter assembly time
• Lower management cost
• Requirements retaining original design
  functionalities.
• Side effects increase component complexity and
  manufacturing cost

38
DFA Examples
39
DFA Examples
Ease of Handling
Fasteners
Orientable Surfaces
40
Post Manufacturing Processes

• Product warrantee costs are influenced not only
  by quality, but also maintenance labor cost as
  well as product serviceability. The increase of
  maintenance cost not only increase product
  lifecycle costs but also influence the degree of
  satisfaction of customers to products.
• Due to the rise of awareness of environment
  protection, manufacturers are responsible for the
  recycle of the product after their disposal. Ease
  of disassembly and classified products are good
  for reducing product recycle cost.
• Methods
• Design for Serviceability
• Design for Recycleability

41
Serviceability

• The contact between products and customers begins
  from the completion of manufacturing. Product
  serviceability directly influences the warrantee
  cost and the faith of customers to the product.
• American Big Three auto makers spent over US9
  billions in 1992 for warrantee expenses.
• Henry Ford, 1928
• In the Ford Motor Company, we emphasize service
  equal with sales
• We are as much interested in your economical
  operation of the car as you are in the economical
  manufacture of it.

• Main factors of serviceability
• Diagnoseability the difficulty and speed of
  making problem diagnosis without using
  specialized and expensive devices.
• Accessibility Sufficient space for maintain or
  adjust a specific component or sub-assembly.
• Replaceability the feasibility of replacing a
  component or sub-assembly with the easiest tool,
  the simplest technology and the shortest amount
  of time.
• Repairability the feasibility of repairing a
  sub-assembly without replacing the entire set or
  sending to the customer service for repair.

42
Design for Environment Protection

• Definition
• In the early product design stage, analyze
  potential impact of the product to the ecological
  environment during its lifecycle, reducing its
  negative impact to the minimum.
• Synonymous
• Design For Environment
• Design for Recycleability
• Design for Recycling and Reuse
• Green Design
• Main Steps for Design for Environment Protection
• Green Design
• Design for Material Management and Disassembly
• Design for Recycling

43
Design for The Life Cycle

• Life cycle factors that may need to be addressed
  during product design include
• Design For Environment
• Testability/Inspectability
• Reliability/Availability
• Maintainability/Serviceability/Supportability
• Design for the Environment
• Upgradeability
• Installability
• Safety and Product Liability
• Human Factors

44
Pneumatic Piston Before and After Improvement
45
Pressure Recorder Before and After Improvement
46
Product Lifecycle Management
47
AKA

• Product Lifecycle Management (PLM)
• Product Data Management
• Product Information Management (PIM)
• Product Knowledge Management (PKM)
• Total Data Management (TDM)
• Technical Data Management (TDM)
• Technical Information Management (TIM)
• Engineering Data Management (EDM)
• Enterprise Data Management (EDM)
• Configuration Management (CM)

48
Engineering Data and Systems
49
Functional View
50
System Architecture

• Data Vault (repository)
• product data, control information (meta-data)
• User Function
• document control, change control, product
  structure management, classification, project
  management
• Utility Function
• communications, data transport, data translation,
  image service, system administration

51
Data Vault (Repository)

• product data, control information(meta-data)
• data processed
• Engineering document
• Engineering drawing
• CAD files
• Engineering analysis data
• Quality control data
• Bill of material data
• Manufacturing process data (NC programs,
  scheduling, etc.)
• Product related instruction documentation
  (operation manual, catalog, etc.)

52
Data Managed (continued)

• Product configuration
• Part definitions and other design data
• specifications
• CAD drawings
• Geometric models
• Images
• Engineering analysis models and results
• Manufacturing process plans and routings
• NC part programs
• Software components of products

• Electronically stored documents, notes, and
  correspondence
• Audio and live video annotations
• Hardcopy (paper-based and microform) documents
  (by reference)
• Project plans
• Others

53
Meta-Data

• Information about product data so that changes,
  release levels, approval authorizations, and
  other data controls can be tracked and audited.

54
User Functions

• document control
• register, invoke, review, approve, check-in,
  check-out, release
• change control
• process definition, revision and version control
  
• product structure management
• part lists, material tables, part definition,
  part attributes, E-BOM, M-BOM
• classification
• retrieval of standard parts
• project management
• work breakdown, schedule control

55
Workflow Management
56
Engineering Change Process
57
Configuration Management

• A product configuration describes an end product,
  from the point of its initial definition through
  its entire intended life, and identifies all
  items needed to design, manufacture, and service
  the end productsuch as vendors, components,
  features, jigs, fixtures, part lists, and quality
  status. (CV)
• CM The process of defining and controlling a
  product structure and its related documentation,
  including maintaining revision control and
  history information about all changes to a
  document or product. (CIMData)

58
Product Structure Views
59
Classification of Standard Parts
60
PLM Suppliers

• Agile Software Agile PLM
• IBM (Dassault Systems)
• CATIA collaborative product development
• Smarteam
• ENOVIA IP management
• MatrixOne
• Matrix PLM Platform
• Lifecycle Applications
• Collaborative Applications
• PTC
• Pro/ENGINEER
• Windchill
• ProjectLink
• PartsLink
• DynamicDesignLink
• PLMLink
• Supplier Collaboration

• SAP AG
• mySAP PLM lifecycle data mgt program and
  project mgt asset lifecycle mgt quality mgt
  lifecycle collaboration environment, health, and
  safety.
• Baan
• iBaan PDM
• iBaan PartnerNet
• iBaan Product Packager
• iBaan Lifecycle Analyzer
• HP WorkManager
• EDAS Matra Datavision
• think3
• thinkdesign
• thinkshape
• thinkteam

61
PLM Suppliers

• UGS PLM Solutions
• Unigraphics Suite
• Unigraphics
• I-DEAS
• Femap
• Imageware
• Solid Edge
• Teamcenter Suite
• Teamcenter Enterprise (Metaphase)
• Teamcenter Engineer (iMAN)
• E-Vis
• Teamcenter Integrator
• Teamcenter Project
• Teamcenter Visualization
• Slate
• Teamcenter Requirements
• Teamcenter Manufacturing

• E-factory
• Data management system
• FactoryCAD
• Factory Flow
• FactoryView
• Jack
• Stamping
• Unigraphics CAM
• Information structure management
• Process planner
• Resource manager
• Parasolid
• Experteam Solutions
• Experteam Knowledge Management Solution
• Experteam Engineering Collaboration Solution
• Experteam Manufacturing Collaborative Solution

62
Mass Customization
63
Mass Customization
Product Design Phase Design product with modular
components
Mass Customization 1. Customer selects pager
options and places order through phone or via
Internet. 2. Manufacturing plants computer
aggregates customer information, sorts them and
plans manufacturing schedule. 3. The components
are selected according to customer
specifications. 4. The components are
assembled. 5. The customized pager is shipped to
customer.
Product Manufacturing Phase
2
3
1
Plants computer

4
5
64
Smart
65
Mass Customization Procedure

• In this mode, the above dialog, including the
  price and delivery quoting, occurs in a matter of
  minutes, not weeks.
• The products and processes have been concurrently
  designed for broad ranges of customizations.
  Information about what is possible is well
  defined and quickly available to the sales
  person, facilitator, integrator, or actual
  customer. The cost of the delivery can be
  determined quickly by standard algorithms.
• The above capability is a key attribute to Mass
  Customization and BTO, since the reactive process
  is too slow and expensive.
• The information must be complete enough to
  confirm the configuration and quote price and
  delivery on the spot without the lengthy back
  and forth dialogs.
• The available features and options would be
  presented. However, certain rules may have to
  be taken into account because the options may be
  incompatible with other options.

66
Research for Product Design

• Modular Design
• Postponing Product Differentiation
• Standardization
• Modular Design
• Process Reconstruction

67
Green Design
68
Disintegration Time for Various Products

• tickets (24 weeks)
• cotton clothes (15 months)
• ropes (314 months)
• cotton socks (1 year)
• bamboo (13 years)
• painted wood board (13 years)
• tin can (100 years)
• aluminum can (200500 years)
• 6-pack aluminum can package (450 years)
• glass bottle (? years)

69
Traces of Green Development of Product
Correction Technology
1st Generation
2nd Generation
3rd Generation
Correction tape (Without using solvent)
Green correction fluid
White paint Solvent
2 in 1
Di-chloro ethylene
Tri-chloro ethylene
Methylcyclopentane
70
Traces of Green Development of Product
100 limonene-recycled polystyrene foam packaging
Pens made from limonene-recycled plastics
71
EU Product Green Regulation Trend
WEEE
Products
RoHS
Packing packing wastes
End-of-life automobile
Energy for Product Usage
Manufacturing
1994 focused on Control of released pollution
from manufacturing process
1995
1940s
2000
2005
72
Green Trend in the Globalization
Green Product Label
2E
TCO92
Energy Efficiency
Emission
Ergonomic
Ecology

• monitor

• CRT/Flat/portable
• System unit
• keyboard

• CRT/Flat/portable
• System unit
• Keyboard
• Printer

73
Laws and Regulations

• Regional, International
• RoHS, Restriction of the Use of Certain Hazardous
  Substances in Electrical and Electronic Equipment
  (2002/95/EC)
• Packaging and Packaging Waste (94/62/EC)
• WEEE, Waste Electrical Electronic Equipment
  (2002/96/EC)
• EU RESTRICTIONS ON THE USE OF CADMIUM PIGMENTS
  (91/338/EEC)
• EuP, Energy-Using Products and amending Council
  Directive 92/42/EEC
• Country, States
• Ministry of information Industry (MII, China)
• Green Supply Chain (Taiwan)
• Pro. 65 (USA, CA) Proposition 65
• Chemicals Listed as Known to the State of
  California to Cause Cancer
• Local Government
• .
• Company, Customers
• .

74
WEEE Waste Electrical Electronic Equipment 10
Categories of Electrical and Electronic Equipment

• Large household appliances
• Small household appliances
• IT telecommunications equipment
• Consumer equipment
• Monitoring and control instruments
• Automatic dispensers
• Toys, leisure and sports equipment
• Medical devices (Except where implanted or
  contaminated)
• Lighting equipment (Except filament light bulbs
  household luminaries)
• Electrical and electronic tools (Except large
  stationary industrial tools)

• Applied for
• Product design
• Separate collection
• Treatment
• Recovery
• Financing
• Information labeling

75
WEEE Waste Electrical Electronic Equipment Key
Provisions

• The aim of the directive is to place
  responsibility on the producers to reduce
  electrical waste, increase recovery and recycling
  and minimize environmental impact. (from Aug.
  13, 2005)
• The alternative proposal was that producers of
  electrical goods should bear collective legal and
  financial responsibility for recycling.
• A requirement that producers provide guarantees
  prior to the release for sale of goods in order
  to ensure that sufficient funds are available
• Free take back enable householders and
  distributors to return household WEEE free of
  charge.
• Recovery targets recovery targets have been set
  at 4kg average per inhabitant by Dec.31, 2006
• Separate collection must adopt measures to
  minimize disposal of WEEE from household waste.
• Treatment standards WEEE must be treated only at
  authorized treatment facilities.
• Historical waste producers will be able to
  recoup recycling costs for WEEE generated before
  the directive enters into force.
• Hazardous substances certain hazardous
  substances will be banned including lead, mercury
  and cadmium for example, in new products from
  July 2006.

76
RoHS Restriction of the Use of Certain Hazardous
Substances in Electrical and Electronic Equipment

• RoHS directive was approved in EU on Feb. 13th,
  2003
• Restricts the use of substance in electrical and
  electronic equipment
• Heavy metals Lead (Pb), Mercury (Hg),
  Cadmium (Cd), Chromium (Cr6)
• Flame retardants Polybrominated biphenyls
  (PBB),
• 
  Polybrominated diphenyl ethers (PBDE)
• Products not complying with RoHS requirements
  cannot be sold in the EU after July 1st, 2006
• Products not complying with RoHS type of
  requirements cannot be sold in China after
  January 1st, 2006
• The member states have taken the view on June
  23rd, 2003 that impurity limits should be defined
  at material level
• For solder alloys used to attach electrical
  components to printed wiring boards, a maximum
  concentration of lead of 0.1 by weight of solder
  alloy shall be tolerated.
• For electrical components attached to the printed
  wiring board, a maximum concentration of lead of
  0.1 by weight of the component shall be
  tolerated.

77
RoHS Restricted Substances

• Maximum allowable impurity levels of the
  restricted substances are
• Mercury 0.1 by weight (1000 ppm)
• Cadmium 0.01 by weight (100 ppm)
• Lead 0.1 by weight (1000 ppm)
• Cr6 0.1 by weight (1000 ppm)
• PBB, PBDE 0.1 by weight (1000 ppm)

78
Green ExperienceSONY
CADMIUM DECREE 1999 (CHEMICAL SUBSTANCES
ACT) RULES FOR THE MANUFACTURE AND SALE OF
PRODUCTS CONTAINING CADMIUM
This factsheet tells you more about the Cadmium
Decree 1999 (Chemical Substances Act). The
Cadmium Decree 1999 prohibits the manufacture and
sale of products containing cadmium. It entered
into force on 1 June 1999, and replaces the
former Cadmium Decree. This factsheet is intended
for all companies which - use cadmium as a
pigment, dye, stabiliser or plating -
manufacture, sell, import or export products
containing cadmium. Prohibitions The Cadmium
Decree 1999 prohibits the use of cadmium as a -
pigment dye stabiliser plating. It also
prohibits the manufacture, import, sale or
possession of - products in which cadmium is
used as a pigment, dye or stabiliser and which
have a cadmium content of over 100 milligrams per
kilo - products with a plating containing
cadmium - products for which plastic or paint
has been used with a cadmium content of over 100
milligrams per kilo - gypsum with a cadmium
content of over 2 milligrams per kilo -
photographic film containing cadmium -
fluorescent lamps containing cadmium. Distribution
number22713/210