Integrated Product Development

Integrated Product Development

Igor Fürstner

ifurst@vts.su.ac.yu

Polytechnical Engineering College

Vojvodina, 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

(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...

->

– Simulations, direct beginning of the manufacturing process, tools for manufacturing are made before

Product Development

(differences between classical and modern approach)



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

(differences between classical and modern approach)

 Quality

– The quality monitoring is done after the production

– ->

– The quality assurance is implemented to the whole process

 Workflow

– Sequential

– ->

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

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

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

Communication

Types of development projects

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)

The structure of the IPD

Lifecycle

The structure of the IPD



The customer is the center of the process



Cooperation

– Human resources

– Cooperation, collaboration

– (Computer Support Cooperative Work)

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

Integrated product development 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. Reliability

7. Maintenance (Is it expensive?)

8. Social parameters (What the others think about the product?)

Customer requirements

 CR can be divided into four levels

1. 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

Customer requirements

 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?

Customer requirements

 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

• Would you prefer a blue sports car or a red convertible?

• Ask

• Would you prefer a red or blue car?

Customer requirements

 How to ask the customer

• Don’t ask

• 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?

Customer requirements



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

Integrated product development

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 quality

The product’s aim CR

The importance factor

EC

Correlation matrix

EC value objectives

Correlation matrix between

CR and EC ^Benchmarking against concurrent the

products

Technical benchmarking

Production difficulty risk

Absolute relevance Relative relevance

Integrated product development

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)

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

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