Integrated Product Development

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Integrated Product Development

• Igor Fürstner
• ifurst_at_vts.su.ac.yu
• Polytechnical Engineering College
• Vojvodina, Serbia

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Introduction
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Product Development(differences between
classical and modern approach)

• Planning
• Long term 5y-gt1-2y
• Mid term 2-3y-gt6-18m
• Short term 6m-gt1m
• Amoritzation
• 8/y-gt30/y

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Product Development(differences between
classical and modern approach)

• Prototyping, manufacturing planning,
  manufacturing
• 3-9m, lot of mistakes, tools for manufacturing
  are made at the beginning of the manufacturing
  process...
• -gt
• Simulations, direct beginning of the
  manufacturing process, tools for manufacturing
  are made before the beginning of the
  manufacturing process...

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Product Development(differences between
classical and modern approach)

• Training
• Nonsystematic and discontinuous (it happens
  during the work process)
• -gt
• Professional and continuous
• Workplace planning
• The workplace is specialized and static
• -gt
• The workplace is general and dynamic

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Product Development(differences between
classical and modern approach)

• Quality
• The quality monitoring is done after the
  production
• -gt
• The quality assurance is implemented to the whole
  process
• Workflow
• Sequential
• -gt
• Paralell

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Product DevelopmentTime

• Time Money
• Later appearance on the market
• Less demand
• Market changes
• Market is occupied by other manufacturers
• Better quality products
• Classical approach
• The development process is sequential and divided
• Investors are concentrated towards faster
  production
• Modern approach (time is important)
• Attention is paid on the system as a whole
• Development is continuous (faster response to
  customer demands, new products are on the market
  more frequently)
• Investors are concentrated towards time
  shortening

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Product DevelopmentTime and costs

• The basic problem during the development and
  production of a product is finding and using
  different methods, which will result in higher
  profit and bigger market share
• Research has shown that during the first 15 of
  the product realization process up to 85 of the
  product costs is determined and only 15 of the
  cost is spent.
• This leads to the conclusion that the most
  important decisions concerning the product have
  to be made during the development of the product.

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Product DevelopmentTime and costs
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Modern product development

• Aim
• Faster product development process
• Faster production process
• Avoidance of the mistakes as soon as possible
• How to achieve the aim
• Establish an appropriate communication between
  the participants of the whole process
• Establish an appropriate decision making rule

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Communication

• Now days, product development and production is
  commonly organized at several different places
  (production plants)
• Advantages
• Faster processes
• Use of knowledge and technology
• Engagement of development, production and other
  infrastructure
• Mutual cost and risk management

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Communication

• Disadvantages
• Communication (collaboration)
• Geographic distances
• Organizational differences
• Cultural differences
• Religious differences
• Procedural differences

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Communication

• Formal
• Informal
• Written
• Verbal

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Communication type
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CommunicationTypes of development projects
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Distributed network

• Virtual factory
• Attributes
• Geographical dispersion
• Possible cultural differences
• Work is done in time and space using appropriate
  organization boundaries
• Communication and coordination using appropriate
  communication technology
• Lack of hierarchy
• Extreme decentralization
• This kind of organization is not constant, after
  the project is finished the structure is
  decomposed
• High level of flexibility
• Quick response opportunities (possibility to
  react considering the changes in the
  surroundings)

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Distributed network

• Characteristics of the virtual factory
• Space (centralized Decentralized)
• Time (synchronous Non-sinchronous)
• Type of interaction (personal Electronic)
• Social differences (low High)

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Integrated product development

• Integrated product development is based an a
  systematic approach during the development
  process, that fulfills the customers
  requirements, connecting - using the added value
  that results from a team work (cooperation,
  trust)

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The structure of the IPD

• Systematic approach
• The IPD uses the principles and tools of Systems
  Engineering (considering the products lifecycle)

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The structure of the IPDLifecycle
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The structure of the IPD

• The customer is the center of the process
• Cooperation
• Human resources
• Cooperation, collaboration
• (Computer Support Cooperative Work)

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The structure of the IPD

• IPD tools (DFx)
• Design for excellence
• Information and communication technologies
• Product data management (PDM)
• Automation of engineering activities
• CAx technologies
• Organization and control
• Project management (PM)

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Integrated product developmentCustomer
requirements

• The customers behavior considering any product
  (reasons why a customer buys or doesn't buy a
  product) can be divided into 8 categories
• Costs (Can I afford it?)
• Availability (Can I find it?)
• Packaging (Is It attractive?)
• Performance (Does it fulfills my expectations?)
• Ease of the handling (Can I use it?)
• Reliability
• Maintenance (Is it expensive?)
• Social parameters (What the others think about
  the product?)

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Customer requirements

• CR can be divided into four levels
• Universal expectations (Expecters)
• Easily valuable and can be benchmarked
• Specific expectations (Spokens)
• Should be considered in a product
• Unspoken, latent expectation
• Has to be defined by market research, interviews,
  brainstorming
• The customer didnt know, didnt want or forgot
  to tell
• Plus expectations (Exciters)

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Customer requirements

• How to ask the customer
• Dont ask
• What do you like most about our product?
• Ask
• What do you like about this product?
• Dont ask
• Is low cost an attractive feature?
• Ask
• What do you consider when purchasing the product?

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Customer requirements

• How to ask the customer
• Dont ask
• What do you like most about our product?
• Ask
• What do you like about this product?
• Dont ask
• Would you prefer a blue sports car or a red
  convertible?
• Ask
• Would you prefer a red or blue car?
• Would you prefer a sports car or a convertible?

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Customer requirements

• How to ask the customer
• Dont ask
• How often would you travel in space if you had
  your own rocket?
• Ask
• Do you want a device to travel in space?
• Dont ask
• Are you satisfied with this product?
• Ask
• What have your experiences been with this product?

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Customer requirements

• Analyzing the Voice of the customers
• Rank the customer requirenments

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Customer requirements - facts

• You can never know if a product will be easily
  sellable until you try to sell it
• (Leschs rule)
• The defined customer requirements considering a
  product are never 100 sure

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IPDFunctional requirements

• The principles of design
• The design problem (system) should be divided
  into smaller independent functional units, using
  the so called decomposition
• Two approaches can be used for this
• Axiomatic approach
• Functional analysis

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Functional requirements

• FR
• The minimum number of different independent
  requirements, that totally defines the design
  aims based on the defined requirements
• The FR should be independent from each other

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Design parameters

• They show the future produced parts units
  modules
• They should be solution independent
• They should fulfill the FR

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Engineering characteristics

• All measurable parameters of the FR are called EC

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Functional independence
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Example 1

• Two valve (classical) faucet
• It should provide a proper amount of water of the
  right temperature (with separate hot and cold
  water source)
• In this case
• FR1 Provide the proper amount of water
• FR2 Provide the right water temperature
• DP1 Means for the cold water regulation
• DP2 Means for the hot water regulation
• The DPs define a dependent solution for the FRs
  and a defined final solution

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Example 2

• Faucet
• It should provide a proper amount of water of the
  right temperature
• In this case
• FR1 Provide the proper amount of water
• FR2 Provide the right water temperature
• DP1 Means for the water amount regulation
• DP2 Means for the water temperature regulation
• The DPs define an independent solution for the
  FRs and an independent final solution

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Integrated product developmentQFD (Quality
Function Deployment)

• QFD is a method (approach), that connects the
  customer requirements with the products
  characteristics and function
• The house of quality is a multidimensional table
  that shows the interconnection between the CR and
  the EC
• It consists of 12 elements

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House of quality
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House of quality
Correlation matrix
The products aim
EC
CR
Correlation matrix between CR and EC
Benchmarking against the concurrent products
The importance factor
EC value objectives
Technical benchmarking
Production difficulty risk
Absolute relevance
Relative relevance
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Integrated product developmentConcept
generation and embodiment

• The product is a sum of the DPs embodiments
• The phases of the product development are the
  following (they overlap)
• Different concept generation and rating
• Configuration definition (3D in space
  relationships between modules)
• Final embodiment that includes the concepts

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Design for Analysis

• Complex problems are divided into smaller, more
  simple parts, because then the problem can be
  analyzed with more simple methods

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ExampleDetermine the number of teachers at the
university

• Number of students
• 1. y 300
• 2. y 200
• 3. y 150
• Sum 650
• Group size
• Laboratory 20
• Practice 40
• Lecture 60
• Mean 40
• Number of groups 650/4016
• Number of classes per week 30
• Total number of classes 3016480
• Teaching ours for teachers per week
• Lecture 6
• Practice Laboratory 12
• Mean 9
• Number of teachers 480/9 53

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Concept generation

• To each DP, the development team should generate
  as many concepts as it is possible
• To achieve this, the development team can use
• Brainstorming (lot of ideas, that can lead to
  other ideas, no analysis)
• Benchmarking
• Literature...

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Brainstorming (questions for ideas)
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Examples
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Morphological method

• Instead of random solution generation, the
  development team should define the surroundings
  in which the possible solutions can be found
• One of the possibilities is to use a
  morphological method that leads to the filtration
  of all the theoretically possible solutions

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Example

• Energy storage can be different
• Mechanical
• Mass in motion
• Thermodynamic
• Fluid on proper temperature
• Electric
• Battery
• Hydraulic
• Fluid in motion

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Example

• Mechanical solution for converting the rotation
  movement into linear movement

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Configuration definitionExample
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Concept rating and choosing the right solution

• The rating contains
• Defined boundaries (force, movements, dimensions,
  power supply)
• Working surroundings
• Ease of production, possibility of production

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Rating

• The rating can be done in a form of a table
  (columns the possible solutions, rows the
  most important or the whole CRs
• The result of the rating is an important
  information towards the final solution

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Example
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The embodiment

• There can be a lot of different solutions for the
  final embodiment
• Example
• Perpendicular joining element