Integrated Product Development Igor Fürstner [email protected] Polytechnical Engineering College...

Integrated Product Development

Igor Fü[email protected] Engineering CollegeVojvodina, Serbia

Introduction

Product Development

(differences between classical and modern approach)

Planning – Long term 5y->1-2y– Mid term 2-3y->6-18m– Short term 6m->1m

Amoritzation– 8%/y->30%/y

Product Development


Prototyping, manufacturing planning, manufacturing – 3-9m, lot of mistakes, tools for manufacturing are

made at the beginning of the manufacturing process...

->– Simulations, direct beginning of the manufacturing

process, tools for manufacturing are made before the beginning of the manufacturing process...

Product Development


Training– Nonsystematic and discontinuous (it happens

during the work process)– ->– Professional and continuous

Workplace planning– The workplace is specialized and static– ->– The workplace is general and dynamic

Product Development


Quality– The quality monitoring is done after the production– ->– The quality assurance is implemented to the whole

process Workflow

– Sequential– ->– Paralell

Product Development

Time

– 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

Product Development

Time 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.

Product Development

Time and costs

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

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

Communication

– Disadvantages Communication (collaboration)

– Geographic distances– Organizational differences– Cultural differences– Religious differences– Procedural differences

Communication

Formal Informal

Written Verbal

Communication type

In person Documents Telephone E-mail

Synchronization Synchronous in time and space

Non synchronous in time and space

Synchronous in time

Non synchronous in space

Non synchronous in time and space

Type

It depends on the persons

who communicate

Extremely formal It depends on the

persons who communicate

Extremely informal

Social factor Very important Moderately important

Moderately important

Non important

Communication

Types of development projects

Collocated network

Traditional approach

Distributed network

Distributed approach in the

dev. proc.

The geographical centralization of the dev. proc. proc.ontosítása

The organizational centralization of the development process

High Low

Hig

h L

ow

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)

Distributed network

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

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…)

The structure of the IPD

Systematic approach– The IPD uses the principles and tools of Systems

Engineering (considering the product’s lifecycle)


Lifecycle


The customer is the center of the process Cooperation

– Human resources– Cooperation, collaboration– (Computer Support Cooperative Work)


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)


Customer requirements

The customer’s behavior considering any product (reasons why a customer buys or doesn't buy a product) can be divided into 8 categories:

1. Costs (Can I afford it?)2. Availability (Can I find it?)3. Packaging (Is It attractive?)4. Performance (Does it fulfills my expectations?)5. Ease of the handling (Can I use it?)6. Reliability7. Maintenance (Is it expensive?)8. Social parameters (What the others think about the product?)


CR can be divided into four levels1. Universal expectations (Expecters)

• Easily valuable and can be benchmarked

2. Specific expectations (Spokens)• Should be considered in a product

3. Unspoken, latent expectation• Has to be defined by market research, interviews,

brainstorming• The customer didn’t know, didn’t want or forgot to tell

4. „Plus” expectations (Exciters)


How to ask the customer• Don’t ask

• What do you like most about our product?

• Ask• What do you like about this product?

• Don’t ask• Is low cost an attractive feature?

• Ask• What do you consider when purchasing the product?



• What do you like most about our product?• Ask

• What do you like about this product?

• Don’t 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?



• How often would you travel in space if you had your own rocket?

• Ask• Do you want a device to travel in space?

• Don’t ask• Are you satisfied with this product?

• Ask• What have your experiences been with this product?


Analyzing the Voice of the customers Rank the customer requirenments

Customer requirements - facts

You can never know if a product will be easily sellable until you try to sell it

(Lesch’s rule)

The defined customer requirements considering a product are never 100% sure

IPD

Functional 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

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

Design parameters

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

Engineering characteristics

All measurable parameters of the FR are called EC

Functional independence

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

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


QFD (Quality Function Deployment)

QFD is a method (approach), that connects the customer requirements with the product’s 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

House of quality

House of qualityThe product’s aim

CRTh

e

import

ance

fa

ctor

EC

Correlation matrix

EC value objectives

Correlation matrix between CR and EC

Benchmarking against

the concurrent products

Technical benchmarking

Production difficulty risk

Absolute relevance

Relative relevance


Concept generation and embodiment

The product is a sum of the DPs embodiments

The phases of the product development are the following (they overlap):1. Different concept generation and rating

2. Configuration definition (3D – in space relationships between modules)

3. Final embodiment that includes the concepts

Design for Analysis

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

Example

Determine 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 650/40=16• Number of classes per week 30• Total number of classes 30*16=480• Teaching ours for teachers per week

• Lecture 6• Practice Laboratory 12• Mean 9

• Number of teachers 480/9 =53

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...

Brainstorming (questions for ideas)

Examples

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

Example

• Energy storage can be different:• Mechanical

• Mass in motion• Thermodynamic

• Fluid on proper temperature• Electric

• Battery• Hydraulic

• Fluid in motion

Example

Mechanical solution for converting the rotation movement into linear movement

Configuration definition

Example

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

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

Example

The embodiment

• There can be a lot of different solutions for the final embodiment

• Example• Perpendicular joining element

Date post:	20-Dec-2015
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