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Design for Time to Market

13. Aug 2016
Design for Time to Market
Design for Time to Market
Design for Time to Market
Design for Time to Market
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Design for Time to Market
Design for Time to Market
Design for Time to Market
Design for Time to Market
Design for Time to Market
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Design for Time to Market
Design for Time to Market
Design for Time to Market
Design for Time to Market
Design for Time to Market
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Design for Time to Market
Design for Time to Market
Design for Time to Market
Design for Time to Market
Design for Time to Market
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Design for Time to Market
Design for Time to Market
Design for Time to Market
Design for Time to Market
Design for Time to Market
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Design for Time to Market
Design for Time to Market
Design for Time to Market
Design for Time to Market
Design for Time to Market
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Design for Time to Market
Design for Time to Market
Design for Time to Market
Design for Time to Market
Design for Time to Market
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Design for Time to Market

  1. 1 CHAPTER DESIGN FOR TIME TO MARKET Nosa. F. O. Evbuomwan 1. INTRODUCTION The success of any product is determined to a large extent by the customers and users within the intended market place. This is more critical for products that thrive mainly on `market pull’. Fashion and style products traditionally are influenced by the speed at which they get to the market place, but in today’s market, many engineering products are now also faced with increasing fierce competition, based on the speed at which they get to the market place. Maximising the paralleling of the various design and other engineering activities, during product development, as well as aiming to increase the speed to market and thus reducing the product development cycle time in a modern manufacturing environment, represents a true concurrent engineering imperative. Several definitions have been given to Concurrent Engineering, the prominent one being that given by Winner et al1 , who define Concurrent Engineering as a systematic approach to the integrated, concurrent design of products and their related processes, including manufacture and support. This approach is intended to cause developers, from the outset, to consider all elements of the product life cycle from conception through disposal, including quality, cost, schedule and user requirements. Concurrent Engineering has been the subject of discussion in several research papers, conferences and books2-10 . It is rapidly gaining ground particularly in the manufacturing industry, and more recently in the construction and petrochemical sectors as a progressive approach for ensuring competitiveness and survival in the market place. A number of issues constitute the ethos of concurrent engineering. Prominent amongst these are: (i) the need to improve and maintain the quality of a product, (ii) the reduction of product development costs, (iii) the removal of barriers (walls) between product development groups, (iv) responding proactively to customers, (v) bringing downstream issues such as manufacturing, production, operation, maintenance, testing, use, etc., which impinge on the design process, upstream to the design stage, and (vi) maximising the
  2. 2 paralleling of the various design and other engineering activities, during product development as well as increasing the speed to market, thus reducing the product development cycle time. Time to market can generally be defined as the elapsed time between product definition and product availability. The current wave and emergence of new and improved products, extensions and expansions of product lines, revisions and enhancements of products, creates additional pressures on manufacturers to keep a steady stream or flow of new products into the market place11 . It is well established that any delays in bringing a product to market, results in greater losses of profit. Hence designing products for fast time to market, ensures the achievement of optimum profitability10 . A key influencing factor in achieving `Time to Market’, is the design process, which has significant impacts on the downstream functions of product development. Faulty, hurried or inadequate product definition and design, usually results in design changes in the form of engineering change orders (ECO’s), which are always very costly in both time and money. Furthermore, the later these design changes are implemented in the development cycle, the more costly the implementation. Time to market is also dependent on the speed of movement of design information across the company. This can be enhanced by the use of computer networking technologies. Research by Kusiak and Yang12 concluded that the implementation of concurrent engineering, although may prolong the initial stages of design, does reduce the overall design cycle (i.e. leads to shorter overall design cycle). This chapter therefore will aim to address within the context of concurrent engineering, the various issues which relate to designing for time to market. It will begin by discussing the goals, objectives and the need for designing for time to market. The benefits as well as the general requirements for achieving time to market will also be elucidated. Design Function Deployment (DFD) a concurrent engineering design system, will then be introduced as a platform for designing for time to market. Further discussions will also cover tools needed for designing for time to market, as well as their management during product development. 2. GOALS, OBJECTIVES AND NEED FOR DESIGN FOR TIME TO MARKET This section will focus on key aspects relating to necessary goals and objectives to be considered in designing for `Time to Market’. The section will also address the rationale for design for Time to Market, and why it is necessary for companies to adopt this approach to product development.
  3. 3 2.1 Goals and Objectives The goals and objectives of designing for time to market are closely aligned to concurrent engineering goals and include inter-alia the following 13 : (i) the need to effectively compete in a global market place, (ii) the necessity of reducing cycle time and cost, (iii) the need to improve quality of product and to develop defect free products and services, (iv) to enable flexibility, manufacturability and reliability both of the design process and the product, (v) to increase product customisation and the number of product options, (vi) to take advantage of new manufacturing strategies and (vii) to achieve cost efficient design flexibility. 2.2 Need A key reason to adopt the approach of designing for time to market, is due to the fact that delayed introduction of new products to the market place, reduces the lifetime profit potential of the products. The research by McKinsey and Co. has shown that a product that is six months late to the market will miss out on one third of the potential profit over the product’s lifetime 11, 14, 15 . Such delay in product introduction to market also makes it harder for manufacturers to enter the market against an established competitor. Companies constantly face the challenge to cope with international competition, as well as competing on the basis of fast time to market. For companies to succeed in their endeavour to remain competitive, they need to adopt a design for fast time to market strategy. 3 BENEFITS OF DESIGN FOR TIME TO MARKET Justification for adopting a design for fast time to market strategy, relates to the financial benefits that can accrue to any particular company that embarks on such endeavour. Such benefits include the following 16, 17 : (i) the extension of the period of product sales, (ii) the possibility of gaining more customers and an increase in market share, (iii) the possibility of higher profit margins and the enjoyment of more pricing freedom, (iv) the exploitation of technical opportunities by synchronising product development with latest technology, (v) the possibility of improving company culture, as design for time to market becomes a company wide attitude, (vi) the possibility of gaining an early access to the market, which can give freedom to set higher prices and capture larger markets, (vii) the enablement of using new technologies and fresh market information, (viii)
  4. 4 the volume of sales can be built up over the entire life cycle of the product and (ix) unforseen problems can be reduced and product predictability can be improved. 4 GENERAL REQUIREMENTS FOR DESIGN FOR TIME TO MARKET To ensure success in designing for time to market, certain general requirements need to be addressed. These represent strategic initiatives to be implemented within an enterprise and are discussed under the broad headings of (a) Top Management Commitment, (b) Organisational Integration, (c) Use of Vendors and Suppliers, (d) Use of Computers and Technology and (e) Market Strategies. 4.1. Top Management Commitment For the successful achievement of `Time to Market’, it is needful for the top management in an enterprise to provide an environment which encourages faster new product introduction. They should provide computer based tools and systems as well as a vision of the future and a time to market goal, to support the adoption of flexible and robust development methodologies. It should also be the prerogative of top management to ensure clear communication within project groups and organisational focus on set goals and tasks. 4.2. Organisational Integration Within the overall organisation, there should be clear, open, timely and free flowing communications flourishing amongst the various divisions and disciplines responsible for product development. These product development teams must ensure clear understanding of customer expectations and continuous customer contacts18 . Close collaboration should be established between the company’s development, production and commercial functions. The company’s modus operandi should be improved by the formation of multi-functional teams to facilitate the management of an integrated design and manufacturing process. It is also important that top management, treats each discipline in the organisation with equal importance. Ensuring `Time to Market’ also requires the improvement of two way and frequent communication amongst the development teams. All life cycle aspects impinging on the product development process should of necessity be integrated, as product development teams are constructed.
  5. 5 This will also involve integrating downstream factors into upstream problem solving19 . Furthermore, an organisational environment should be created and fostered, where change and innovation occur naturally, with the aim to minimize the amount of work and rework to be done in developing a product. 4.3. Use of Vendors and Suppliers It is imperative that in order to achieve early `Time to Market’, vendors and suppliers, should be included early in the product development process. A systematic view of the innovation/development process should be adopted, involving all parties in the development process. It is expected that this team, will use common, consistent, accurate and complete design data. 4.4. Use of Computers and Technology In a modern manufacturing enterprise, the process of integrating the organisation, cannot be done without the aid of computers. There is hence a need for the integration of computerised information systems within such companies, to support the early `Time to Market’ initiative. Such computerised systems should inter-alia, provide and support open communication amongst the various divisions within the organisation. They should enable : (1) early sharing of information, (2) automation (computerisation) of the design process and (3) the adoption of manufacturing strategies aimed at reducing manufacturing lead time20 . Another requirement of the system is the support of advanced technologies, which enable information flow, provide information about new technologies and developments, as well as supporting tools to improve product development and speed of the design department. Such new technologies should be adopted to give employees the most current proven tools to do their jobs. 4.5. Market Strategies The successful achievement of designing for `Time to Market’ imperatively requires an understanding and knowledge of the customers and users within the specific or general market outlets for the proposed product. The emerging windows of opportunity, risks and opportunities as well as the necessary trade-offs to be made between time, quality and cost, need to be clearly understood. In this regard, it is incumbent on a manufacturing company to: (i) carry out adequate market surveys and
  6. 6 strategic explorations, (ii) clearly define key attributes of competitive strategy, (iii) when necessary, focus on a series of incremental improvements in the product rather than new designs and (iv) make available market information about new products to designers/engineers. 5 FUNDAMENTAL ISSUES AND FACTORS AFFECTING DESIGN FOR TIME TO MARKET Depending on the particular type of product, the product planning strategy adopted and the particular approach to be utilised for designing for time to market, certain issues which are fundamental, need to be addressed. These are discussed below under the following headings : (i) Modularisation during conceptual design, (ii) Overlapping and Resequencing of Activities, (iii) Integration of Product Development Activities, (iv) Product Classification, and (v) Strategic Product Planning. This section concludes with a summary of general issues and factors affecting design for `Time to Market’ which should be taken into account within an enterprise in seeking to achieve the objective of early time to market. 5.1. Modularisation During Conceptual Design The conceptual design of a product, to a large extent can decide how fast a product gets to the market. Key issues to be addressed, include : (i) what functions are to be provided by the product and (ii) the interrelationships between the functions and deployment of the functions to different parts of the product. Making the correct decisions at the conceptual design stage is critical to shortening the design cycle. A key decision to be made during conceptual design in support of time to market, is the modularisation of the design of the product. This can involve the division of the product into modules (subsystems, components or parts), based on the modularisation (decompositions) of the desired functions of the product. Each of the modules and submodules, can then be developed concurrently, thus permitting overlapping of activities and hence reducing the length of the design process, while preserving coupling among design activities. The use of appropriate module construction methods, will promote the progress of parallel design teams working on each module. Standard components can be used in the product, and thus concentrating efforts on the most important product characteristics. The above modularisation process, can also enable quick update of designs. In modularising designs, care should be taken to ensure that, design concepts are developed to be insensitive to
  7. 7 minor changes in the interfaces between modules. Features of interaction across and between modules that have an effect on product development speed, must be resolved. 5.2. Overlapping and Resequencing of Activities The product development process is characterised by the performance of many design activities. During product development, it is needful for these activities (tasks) to be divided and their interdependencies, established. In most companies, these activities tend to be performed in a sequential manner, with the engineers being oblivious to the inherent coupling between the activities. The result of this, is costly engineering changes. In sequential design, downstream activities start only after receiving finalised information from their preceding activity. In order to accelerate the product development process within the context of concurrent engineering and designing for time to market, the coupling between activities, need to be removed. This is to enable the performance of the activities in a parallel (simultaneous) manner. In this case, each activity can proceed without waiting for any information from a preceding activity. This requires flexibility and focus from all participants in product development. In instances where, coupling between activities cannot be completely removed, the approach plausible, involves the overlap of the activities, through frequent exchange of preliminary design information21 . Such overlapping process enables downstream activities to begin early by using the preliminary design information from preceding activities. Overlapping activities of the different phases of product development enhances fast cycle development of new products22 . 5.3. Integration of Product Development Activities A key issue in achieving fast time to market, involves the integration of all activities impinging on the product development process, and adopting a co-operative product development approach23 . The integration should be based around people, information, computing technologies and tools. The integration process should therefore support extra input at the early stages of the product development process, particularly from downstream issues (manufacturing, testing, service, etc.). 5.4 Product Classification
  8. 8 The variation between different products primarily arises as a result of the different disciplines (mechanical, electronic, civil, chemical, etc.) from which they are developed. Within each discipline however, product variation can also be attributed to other factors such as : the intended market segment, knowledge available, the integration of disciplines (e.g. as in mechatronic design), the design process and manufacturing capabilities. The nature of bounding constraints, customer demands and competition in the market place, can also result in various product classifications. Such product classifications that have emerged within the recent past are discussed below24 - 26 . 5.4.1. Static Product Designs. These are products whose market share is generally undiminishing and little or no changes are being demanded in the product. They are usually based on well known design concepts, and are hence considered to be conceptually static products. For such products, releasing them early to the market will not necessarily provide a competitive advantage. 5.4.2. Dynamic Product Designs. These products tend to have a limited life before the next generation supercedes it. In this case, developments are focussed on the product, involving the development of new, radical and alternative designs. Products belonging to this class, are generally considered to be conceptually dynamic. In looking at the dynamic - static spectrum of products, Clausing25 highlights the following types of products sandwiched between the two extremes : Genesis Product - This is an original product that has no previously related product, and usually leads to the evolution of diverse families of products. Radical Product - This is a product which although may at the higher (concept) level of abstraction exhibit similarities to previous designs, but is radically different in the final designs of the subsystems. New Product - This is usually less than a radical product, and involves the use of a new or an alternative technology in the development of an already existing product. Clean Sheet (Generational) Product - A clean sheet generational product is usually characterised by a major step forward, and the design process commences from a clean sheet of drawing paper, with little reference or relationship to prior designs. The genesis, radical and new products are by definition clean sheet designs. Market-Segment Entry (New) Product - A market-segment entry product moves a company for the first time into a new market segment, following
  9. 9 an earlier new (or radical) product. This is associated with the staggered window of opportunity case discussed below, in the next subsection. Market- Segment Entry (Generational) Product - This form of product is a new product in a market segment following after a previous product in the same market segment. Associated Product - This is the type of product that changes some technologies to provide a different capability, resulting in an entry into a somewhat different market segment. An example is the case of laser printers, which are based on xerographic copiers. Variant Product - Variant products are those which are based on relatively small changes on the base product. They usually include feature enrichment or removal, dimensional magnification or downsizing, and cost/performance upgrades. Customised Product - Customisation of products extends over a range from adding brand names to fairly major changes on a product for specific customers. Customised products tend to have a limited role in the general subject of product development. 5.4.3. Overconstrained Products. These tend to be products which exist in the high technology markets. Here, the design process evolves around analysing alternative design proposals until the correct (or most acceptable) solution is found. Overconstrained products are usually subjected to several constraints of function, materials, manufacturing processes, some of which might be conflicting, and the product undergoes several analysis and trade- offs. In this case, major changes in the product concept rarely occurs. 5.4.4. Underconstrained Product Designs (Ideas Centred). In the case of underconstrained designs, the design activity is centred around bringing products into the market to satisfy market demands. There are usually not very many constraints, and the designer has ample room for innovation. The focus here is usually on the product concept, and materials and techniques are chosen to satisfy the required function and recognisable market style. Most industrial designs fall into this category, and development is on aesthetics, ergonomics and functionality. 5.4.5 Underconstrained Product Designs (Skill Based). This form of designs focus on the manufacturing aspects of product development. Efforts are usually concentrated on the capabilities and skills available in a company.
  10. 10 5.4.6 Complex Products. Complexity in design and product development can be examined from a number of viewpoints. If a complex product is considered from the viewpoint of a complex system, then it can be described as a product exhibiting complexity in shape and size, having many interacting elements (subsystems, components and parts), which can exist in different and perhaps changing states and which influence each other. The time taken to design and develop the many constituent interacting elements can also be considered to be contributory to a product’s complexity. 5.4.7 Simple Products. A simple product can be described as one having a simple shape and/or size, few interacting or possibly non- interacting elements (subsystems, components and parts), which generally exist in similar and perhaps non-changing states, with little or no influence on each other, and which can be designed and developed within a relatively short time. The above classification can be schematically represented in the form of a cube as shown in Figure 1. This cube comprises eight smaller cubes representing different scenarios of product classification. They are : Cube 1 - Static-Simple-Underconstrained (SSU), Cube 2 - Static-Complex- Underconstrained (SCU), Cube 3 - Dynamic-Simple-Underconstrained (DSU), Cube 4 - Dynamic-Complex-Underconstrained (DCU), Cube 5 - Static-Simple-Overconstrained (SSO), Cube 6 - Static-Complex- Overconstrained (SCO), Cube 7 - Dynamic-Simple-Overconstrained (DSO) and Cube 8 - Dynamic-Complex-Overconstrained (DCO) FIGURE 1. The Three Dimensional Product Classification Matrix 1 2 5 7 8 3 4 6 SIMPLE COMPLEX STATIC DYNAMIC UNDER-CONSTRAINED OVER-CONSTRAINED
  11. 11 5.5 Strategic Product Planning In designing for `time to market’, an issue that needs to be addressed is how a company can go about strategically planning its products for the various market segments and outlets. This issue of strategic product planning will be examined primarily from two dimensions of what can be referred to as Product Design Input and Product Design Output. It will also be examined from the viewpoint of how the interaction of product complexity and product uncertainty affects the need for a company to proactively respond to the market. The discussions in this subsection draws upon the work of Rajczi27 . Based on the first two dimensions, the step towards strategic product planning can be explicated using a `Global Product Design Grid’. This grid in the form of four quadrants can be used to represent the Product Design Input and Product Design Output, as shown in Figure 2a. Product Design Input represents how many markets a company gathers relevant input before embarking on the design of its initial products. Here such inputs can range from customer information gathered from all possible markets to single market or specific subsets of these markets. Product Design Output on the other hand, represents the markets that the initial product will actually be designed for. This can also range from the development of a single product for all markets to different products developed for each market or specific subset of the company’s markets. FIGURE 2a. Global Product Design Grid
  12. 12 The interaction between the two axis of the matrix and the possible location and movements by companies within any of the quadrants, is driven principally by two forces (factors), namely : Opportunity Risk and Right Product Risk. Opportunity Risk refers to the situation where a window of opportunity exists, whereby a company must respond to a new or changing market within a certain period of time, or risk losing the opportunity in that market. If the windows of opportunity are small, then we have a high risk situation, whereas if the window of opportunity is large, we have a low risk situation. In situations where there are small windows of opportunity (high risk), companies tend to be forced to choose product strategies whereby only a few specific markets are polled for input. Furthermore, the alignment of small windows between markets also affect product strategy. Two forms of alignments are discussed here, that is Stacked Windows and Staggered Windows. For Stacked windows (i.e. windows which are open for the same or similar periods of time), companies would need to choose a strategy based on Quadrant 2 (Figure 2b), while for Staggered windows(i.e. windows which are open at different periods of time), a company should choose a strategy based on Quadrant 3 (Figure 2b). In this case, initial products can be sold to few specific markets which they are designed for. Subsequently, the initial product can be taken to other markets as the windows open. This tend to create some form of flexibility for a company, as time is made available for it to design specific products for specific markets. FIGURE 2b. Opportunity Risk Matrix In the case of Right Product Risk, this means the risk taken by a company by not providing the exact product each market wants. High right
  13. 13 product risk relates to situations where (i) products which require enormous development costs are being developed and (ii) a product is introduced in to the market shortly after a previous product's failure. Low right product risk on the other hand, relates to situations where a company's products is able to be redesigned after its initial design, with no major negative impact to the company's reputation or the product. Designing the right product for a global market requires that a company gather all relevant data needed to design a product for those markets. When a company is faced with High right product risk, it tends to be forced to choose a product design strategy that gathers all market information before the initial design is carried out. Thus leading to the choice of strategies in Quadrants 1 and 4 (Figure 2c). The nature of the `Homogeneity’ of markets also affect a company's choice of product strategy, in any of the four quadrants. For markets whose needs (market's tastes, wants, regulatory standards, etc.) are Homogeneous, a single product might meet the criteria for all of the markets. Here the tendency is for a company to move towards Quadrant 1 (Figure 2c) - development of generic products for all markets. For markets whose needs (market's tastes, wants, regulatory standards, etc.) are Heterogeneous, there is need to design multiple products for specific subsets of the markets. The tendency here is for a company to move towards Quadrant 4 (Figure 2c) - development of several market specific products. FIGURE 2c. Right Product Risk Matrix Depending on the adopted strategy within any of the quadrants, a company must of necessity make certain trade-offs. These trade-offs are generally based on three factors, namely : Complexity, Time and Cost. Complexity can be examined from two aspects, that is, Design Complexity
  14. 14 and Co-ordination Complexity. In general, the choice of a product strategy affects design complexity. When market inputs are obtained from many markets, this means more design complexity. Hence strategies based on Quadrants 1 and 4, tend to result in higher design complexity (Figures 2d & 2e). In this case, the only options available, is for the company to (i) look for efficiencies in design (e.g. high or fast performance) and (ii) carry out modular designs of the complex products. The co-ordination complexity of a product design's maintenance and evolution increases with the number of products designed. Hence the adoption of strategies based on Quadrants 3 and 4, results in higher co-ordination complexity. In the case of Time, the trade-off borders on time required to introduce a product to all markets vis-à-vis that required to introduce a product to a single or specific subsets of markets. If therefore there is need to introduce products in key markets quickly, then a company can choose strategies based on Quadrant 2 or 3 (see Figures 2d & 2e). This minimizes the time spent introducing the first product to the first market, and less time is spent upfront in the early stages of product development. More engineering changes, however occur. On the other hand, if the need is to introduce a product in all markets as quickly as possible, then choosing a strategy in Quadrant 1 or 4 (see Figures 2d & 2e), seems to be more appropriate. In this case, more time is spent upfront in the early stages of product development, the result of which is lesser engineering changes. Cost principally relates to the amount of work done as well as time spent upfront in the early stages of product development. Choosing a product design strategy in Quadrant 2 or 3, will minimize short term costs by not polling all markets or developing a complex product design. Here, cost to first market is reduced. Conversely, polling all markets will result in high initial costs. Summarily, factors which can be considered to affect product development speed and early time to market, include the following : (1) Market Input (customer/user survey), (2) Market Output (Product Outlet), (3) Product Classification (Type, Nature, etc.), (4) Product Complexity, (5) Product Uncertainty (window of opportunity, performance and customer satisfaction), (6) The Design and Development Process,
  15. 15 FIGURE 2d. Advantages of Trade-offs FIGURE 2e. Disadvantages of Trade-offs (7) Downstream Processes (Manufacturing, Assembly, Testing, Installation, etc.), (8) Ease and Speed of Manufacture and Assembly, (9) Degree of Reliability before committal to Market, (10) Market Opportunity (Low and High Risk), (11) Product Life Cycle and (12) Design Life Cycle. DESIGN FOR TIME TO MARKET
  16. 16 6. DESIGN FUNCTION DEPLOYMENT - A CONCURRENT ENGINEERING DESIGN SYSTEM The development of Design Function Deployment (DFD) was driven by the need for a design system that will enable the design and manufacture of not only high quality and performance products, but those which are well suited for their intended purpose, affordable and satisfactory to the customer. The research involved in this development, benefited from research into Quality Function Deployment (QFD)28-31 , Design Philosophies, Models, Methods and Systems32-33 , and Concurrent Engineering34-38 . Design Function Deployment, DFD24, 39-40 has been developed as a comprehensive design system, to incorporate the features of a prescriptive design model, and associated design methods for the integration of manufacturing, use and other downstream issues into design, and thus enabling a concurrent engineering approach to product, systems or process development. It uses the fundamental concepts of QFD, to enable the establishment, focussing and satisfaction of customer requirements throughout the product development process. The goals of DFD inter-alia, include the following : (1) to recognize the importance of customer requirements within a specified market, (2) to ensure the change from the `over the wall’ approach to team approach in design and product development, (3) to provide a platform for concurrent engineering, (4) to generate the design solution space, (5) to facilitate design retrieval (aka case-based reasoning and design) of previous design solutions, (6) to maximize the knowledge about performance of product at the design stage, (7) to minimize or eliminate downstream engineering changes, (8) to establish robustness of design, (9) to utilize new materials and technologies and (10) to ensure quality through design. The design model of DFD as shown in Figure 3 proceeds through five stages of (i) Establishment of customer requirements, and determination of design specifications and constraints, (ii) Development of conceptual solutions called `Architectures', (iii) Establishment of viable variant solutions for each plausible architecture, called `Layouts', (iv) Establishment of viable materials and corresponding manufacturing processes for each viable layout and (v) Establishment of production plans for each viable layout. The system is being implemented in a three layer framework, as shown in Figure 3.
  17. 17 FIGURE 3. The Structure of the Design Function Deployment System (Adapted from24 ) The first layer represents the design process model described above, the second layer represents the several design methods, tools and techniques employed as the design progresses from stages 1 to 5, while the third layer contain numerous knowledge bases and databases, which can act as repositories for corporate knowledge, historical design data, proven technologies as well as for generic materials and manufacturing processes. 6.1. The Design Matrix of Design Function Deployment The design matrix in DFD, is examined from a three dimensional viewpoint. The first dimension (z-axis) is referred to here as the morphology of the
  18. 18 design process, and it represents the five stages shown in level 1 of the DFD structure, that is, the minimum prescribed path to be followed during the design process. The second dimension (y-axis) is referred to as the anatomy of the design process within DFD, and this represents the design activities implicitly performed within each of the five stages of DFD. The level 2 of the DFD Structure (Figure 3), contains design modules (methods) which are used in performing the above activities within each of the five stages of DFD. These modules are key to the DFD system and thus represent the third dimension (x-axis) of the DFD design matrix. The three dimensional matrix is shown in Figure 4. It shows the global view of the design matrix within DFD, and it explicates the interactions of the three dimensions. It should be noted that, it is only the morphological dimension of the design process (i.e. DFD design stages), that represents a chronological ordering of distinct steps and that the other two dimensions do not represent any chronological ordering of distinct steps. There would hence be continuous feedback, iteration and revision in performing any of the design activities while using any of the design modules (methods or tools). The matrix can be used to identify the activities that need to be performed at any of the DFD design stages as well as the accompanying tools that can be used for any of the activities, depending on the nature and type of product or designs. 6.2. Design Function Deployment as a Concurrent Engineering Design System This section discusses Design Function Deployment (DFD) as a concurrent engineering design system, within the context of its satisfaction of the main goals and general requirements of concurrent engineering. The DFD design system has been developed to support product development teams in achieving early time to market, by enabling the integration of all life cycle and functional issues under one umbrella. The DFD system at level 1 provides a structured format for carrying out the design process in a planned and controlled way. This ensures that all necessary information generated, analysis performed, evaluations done and decisions made, are recorded and documented accordingly. The first stage of the design process in level 1 ensures that elicited requirements (customer, user, manufacturing, finance, marketing, etc.) are all considered in an integrated and concurrent manner, before translation into design requirements.
  19. 19 FIGURE 4 The Three Dimensional Design Matrix Level 2 of the DFD system contains many design modules (methods and techniques) which can be used in a parallel manner, as the design activity proceeds from conceptual to detailed design stages. These modules in their use, ensure that design concepts are not only functional, but can be manufactured, assembled, sold and used to the satisfaction of customers. The third level of the DFD system contains databases and rulebases, some of which are associated with the level 2 modules. These modules store various design knowledge and information in the form of design rules, materials and manufacturing data and previous design information that can be retrieved and used for new designs. The databases and rulebases will ensure concurrent access to both past and present design information by all interest groups involved in the product development process. This will help to remove unnecessary interfaces between the groups, and hence reducing delays in the product development process. The link of the level 3 modules with levels 1 and 2 in the DFD structure, also helps in the implementation of concurrent engineering, by the integration of conceptual design,
  20. 20 geometric modelling, materials and manufacturing process selection, as well as permitting the increase of product performance knowledge in the early stages of the design process, when costs are committed. 7. DESIGN FOR TIME TO MARKET WITHIN DESIGN FUNCTION DEPLOYMENT The aim of this subsection, is to enunciate a rational approach for paralleling the design process within the taxonomy of the design stages of Design Function Deployment. The benefits of this approach, in terms of separating the overall design into modular groups and activities, managing the complexity and interactions between the separate design tasks and subsequent reduction of the design cycle will be discussed. 7.1. Review of Design and Project Management Techniques The adoption of the concurrent engineering approach in product development, implies that engineers, designers and product development managers, have to cope with a larger amount of design data and information. The scenario where the designers not only uses engineering information, but additional information from other disciplines involved in the product development process, leads to further complexity of the design process. Engineers and designers in this present climate, therefore need to adopt techniques for planning, organising and monitoring the large and complex network of design tasks arising in the product development process. Over the years, several techniques have evolved for managing complex and large projects as well as the design process. Such techniques include : Directed Graphs (DG) 41, 42 , Project Evaluation and Review Technique/Critical Path Method (PERT/CPM) 43, 44 , Structured Analysis and Design Technique (SADT) 45, 46 and Design Structure Matrix (DSM). The above three networking techniques (Directed Graphs, PERT/CPM and SADT) suffer from size limitations and an inability to explicitly represent circuits (coupling) of the design tasks. They are usually based on one way progression along paths, with no feedback or iteration and no feedforward of information part-way through task 41, 44 . They tend to be used primarily or documenting design practices and do not handle interactions that occur within design tasks.
  21. 21 7.2. Design Structure Matrix (DSM) The philosophy of the Design Structure Matrix (DSM) technique is that the design project can be divided into individual tasks, and the relationships and interactions among the tasks analysed to identify the underlying structure of the project. There is some belief that studying relationships between individual tasks can improve the overall design process, as well as being an effective way of analysing alternative design strategies 47 . DSM with the aid of a graphical representation (matrix) uses the structure of design information flow to guide the decomposition of the design activity. In this matrix, the links and relations between the tasks are mapped out in such a way that makes their interdependence explicit. The design activity which consists of for instance m tasks, can be represented as an m x m matrix. Each of the tasks are labelled along the side of the matrix as row headings and across the top of the matrix as column headings, in an identical manner. The matrix element aij is non- zero if node i provides information to node j. A typical matrix is shown in Figure 5a. Interpreting the task ordering as a time sequence helps to make the timing of information flow explicit. The marked elements within each row of the matrix identify the other tasks that must contribute information for proper completion of the design. FIGURE 5a. A Typical Design Structure matrix In the matrix, marks below the diagonal represent information transferred to later tasks (i.e. task A must be completed before task C); while marks above the diagonal depict information which are fed to earlier tasks (i.e. task G must be performed before task B). The primary goal of design structure management is to find a sequence of these design tasks which allows this matrix to become lower triangular.
  22. 22 Once the design process has been established into a design structure matrix, the analysis proceeds in two separate stages, known as Partitioning and Tearing 41, 44, 48 . The process of partitioning aims at resequencing the design tasks, in order to maximise the availability of information required at each stage of the design process. Partitioning helps to identify tasks which are coupled in a loop, and then clusters them as blocks on the diagonal of the design structure matrix (Figure 5b). The strategies of the partitioning algorithm include: scheduling independent design tasks as early as possible and then simultaneously identifying tasks which are coupled for further analysis. Once partitioning has placed the design structure in a block-triangular form, the tearing analysis then begins. The goal of tearing is to resequence within the groups (blocks) of coupled tasks to find an initial ordering to start the iteration. The algorithms employed in tearing includes tearing with shunt diagrams and tearing with heuristics. This form of matrix discussed above, represents what is known as the activity-activity incidence matrix. FIGURE 5b. The Partitioned Design Structure Matrix Other forms of incidence matrices have also been discussed by 49, 50 . These include the module-activity incidence matrix and the procedure (formula)-parameter (variable) incidence matrix. In these two cases, the analysis of the matrix, involves the use of suitable clustering algorithms 51, 52 . Decomposition of the design process and using the algorithms described above, has been considered to lead to the following advantages 50 : (i) separation of the overall design task into groups design tasks and/or groups of modules and activities, (ii) potential activities that can be performed
  23. 23 concurrently are detected, (iii) the complexity of managing the design task is reduced and (iv) the design cycle time is reduced. 7.3 Concurrent Design Within Design Function Deployment The process of bringing design influencing downstream issues early upstream to the design stage, as part of fulfilling the ethos of concurrent engineering, does lead to an increase in the activities to be performed in the product development process. This factor coupled with the basic idea of shortening the product development cycle time, lends weight to the need to manage the design process and the associated interactions and complexities, more effectively. In Design Function Deployment, the process of concurrent (parallel) design, is considered from two main viewpoints, which are :(i) Concurrent design associated with the design process (CDDP) though stages 1 to 5 and (ii) Concurrent design associated with the design artifact (CDDA). Considering the first case, that is, CDDP, the flow through the five stages of DFD, as shown in Figure 6, represent the minimum prescribed path (critical path) to be followed in the design process, and is generally not subject to any form of concurrency. However, at each of the stages, several design activities are performed, with some of them somewhat repeated down the later stages, and in other situations somewhat overlapping. It is these activities that can be explored for possible concurrency, and to speed up the design process within each of the stages. Tables 1 to 3 shows typical activities for each of the five stages of the DFD design model. Some of these activities (or design tasks) which take place in each of the DFD stages, would be inter-disciplinary, relating to for instance (marketing, design, manufacturing, finance, testing, etc.), while others will be intra-disciplinary (stress analysis, geometric modelling, feature-based design, thermal analysis, etc. - all within for instance the design group). The above implies that the larger inter-disciplinary team would be involved in the inter-disciplinary activities, while the smaller design team would be responsible for the intra-disciplinary activities. Irrespective of whether these activities are inter- or intra-disciplinary, it is needful to decompose all the activities within each DFD stage and then to establish those that can be done in parallel and those to be carried out serially to precede other activities.
  24. 24 FIGURE 6. The Flow of the Design Process in Design Function Deployment In this concurrent design case, the applicable form of incidence matrix is the activity-activity matrix, which can be employed at each of the DFD stages. With this form of matrix, the triangularisation algorithm (Partitioning and Tearing) can then be used to decompose the activities into groups of activities, thus simplifying the entire design process and these activities can then be sequenced in such a way as to speed up the product development time. This results in the overlapping situation that occurs between the inter- and intra-disciplinary activities as they are being performed, with activities belonging to either of them being performed in parallel or in series.
  25. 25 TABLE 1. Design Activities in Stages 1 and 2 of DFD Stage 1 Stage 2 1. Elicit Requirements 2. Analyse Requirements 3. Categorise Requirements 4. Prepare Quality Plan 5. Derive Design Functions 6. Analyse & Group Design Functions 7. Set Target Values for Design Functions 8. Complete Correlation Matrix 9. Complete Relationship Matrix 10. Rate Design Functions 1. Establish subsystems from stage 1 Design Functions 2. Generate and Synthesise concepts (Architectures) 3. Derive Design Functions 4. Analyse & Group Design Functions 5. Set Target Values for Design Functions 6. Complete Correlation Matrix 7. Complete Relationship Matrix 8. Rate Design Functions 9. Explore Materials and Manufacturing Processes 10. Evaluate each Architecture 11. Select viable Architectures TABLE 2. Design Activities in Stages 3 and 4 of DFD Stage 3 Stage 4 1. Generate Layouts for each Architecture 2. Derive Design Functions for each part of Layout 3. Analyse & Group Design Functions 4. Set Target Values for Design Functions 5. Complete Correlation Matrix 6. Complete Relationship Matrix 7. Rate Design Functions 8. Materials Selection 9. Evaluate & Select Viable Layouts 10. Create Solid Models of Layouts 11. Finite Element Analysis/Mechanism Analysis 12. FMEA/FTA Analysis 13. Robust Engineering Design 14. Evaluate against DF`Xs' 15. Select Optimal Layout 1. Establish Viable Materials and Manufacturing Process 2. Derive Manufacturing Design Functions for each part of Layout. 3. Analyse & Group Design Functions 4. Set Target Values for Design Functions 5. Complete Correlation Matrix 6. Complete Relationship Matrix 7. Rate Design Functions 8. Establish Critical Manufacturing Processes 9. Manufacturing Process Planning 10. Simulate Manufacturing Process Plans 11. Assembly Planning 12. Rapid Prototyping 13. Evaluate against DFM, DFA and DFDisassembly 14. Materials Resource Planning
  26. 26 TABLE 3. Design Activities in Stage 5 of DFD Stage 5 1. Job Scheduling 2. Line Balancing 3. Batch Size Determination 4. Routing Procedures 5. Capacity Analysis 6. Planning for Inspection 7. Simulation of Production Plans 8. Layout, Machine and Tooling Procedures It is worth noting that the number and type of activities that would be carried out in parallel or in series would depend not only on the engineering domain of the design, but also on the nature, type or class of the product. In the second case, that is, CDDA, the performance of concurrent design depends to a large extent on the type and nature of the product. Products can generally be classified as static (fixed concept) or dynamic (short life cycle and requires new concepts), as well as overconstrained or underconstrained (could be ideas or skills based). For this case, four forms of concurrent design are considered. The first form involves the design of competing alternative architectures (at stage 2 of DFD) in parallel, as shown in Figure 7 and the second form involves the design of competing alternative layouts (at stage 3 of DFD) in parallel. The third form of concurrent design relates to designing in parallel the individual subsystems that constitute an architecture (between stages 2 and 3), while the fourth form is associated with the parallel design of the individual parts of a particular layout (between stages 3 and 4). For the third and fourth forms of concurrent design above, necessary interactions, conflicts, dependencies and trade-off scenarios between either the subsystems or parts, should be explored. Necessary steps can then be taken to provide solutions to any bottlenecks. This can be done through a process of elimination, combination, modification, transference, simplification and standardisation of the subsystems or parts. Depending on the product type, either one or a combination or all of the four forms of CDDA, will be applicable. In the case of the third and fourth forms of concurrent design, the applicable incidence matrix would be the module-activity matrix, where module refers to either subsystems of an architecture or parts of a layout.
  27. 27 FIGURE 7. Concurrent Design for Time to Market within Design Function Deployment The size of this matrix would depend on the scale and complexity of the product. Discussions of these four forms of CDDA will be based on Figure 1. For static-simple (small scale)-underconstrained (SSU) products, the second form of CDDA would be more applicable. In the case where the SSU product has several and/or fairly sizeable parts that can be designed independently and if considerable effort is required, then there would be need to employ the fourth form of CDDA. In the case of static- simple(small scale)-overconstrained (SSO) products (e.g. beverage cans), no form of CDDA is applicable. The focus for manufacturers of such products, is usually to improve the manufacturing process. The fourth form may however be applicable, if a similar condition to that of SSU occurs. For static-complex-underconstrained (SCU) and static-complex- overconstrained (SCO) products, the third and fourth forms of CDDA, are more applicable. The second form may also be applicable to SCU products, if sufficient resources are available, or if the parallel design can be done by a different arm or division of the enterprise. Dynamic products are to all
  28. 28 intents and purposes underconstrained products. In the case of dynamic- simple-underconstrained (DSU) products, the first, second and fourth forms of CDDA are more applicable, while in the case of dynamic- complex-underconstrained (DCU) products, all four forms of CDDA are applicable. For both innovative and creative designs, the four forms of CDDA are also applicable, while in the case of adaptive and variant designs, only the second, third and fourth forms of CDDA are relevant. It should be noted that all the four forms of CDDA, go hand in hand with CDDP. 7.4 Dimensionality of Concurrent Design in Design Function Deployment The employment of only CDDP, represents a one- dimensional case in design concurrency, irrespective of the DFD design stage, and this relates to SSO products. Here there is no occurrence of CDDA. When either of the four forms of CDDA are employed in addition to CDDP, then we have a two-dimensional case of design concurrency, occurring between stages 2 and 4. In the situation where either the third or fourth or both forms of CDDA are employed in addition to either the first or second or both forms of CDDA, in addition to CDDP, then we have a three-dimensional concurrency case, as in DSU and DCU products. For SSU, SCU and SCO products, the two-dimensional case predominates. This research work is on-going, and the next stage of the work will be focussed on how to implement the concepts developed in this section, within the DFD software system. This is represented as the design management module in the DFD software architecture shown in Figure 8. Other research efforts will also go on in parallel as regards modelling and simulating the design process within DFD using cases studies, as well as testing the techniques with current practices in industry. 8. MANAGEMENT OF TOOLS FOR TIME TO MARKET The objectives here are to examine (i) the goals of managing the tools and resources and (ii) how the management process can be done in line with concurrent engineering practices. In looking at how the management process is carried out, the first issue to consider is that the tools and resources required for each of the activities need to be established. After this, the explication of the dependencies if any, between the tools, that is, establish which tool has to be employed to precede another tool (e.g. solid modelling before Finite element analysis) also need to be explored.
  29. 29 FIGURE 8 The Design Function Deployment System Software Architecture These dependencies will be influenced mainly by the dependencies that might exist between each of the design activities. The goal of managing the design activities is to establish which tasks can be done in parallel and those that must of necessity be done in series. Having established the precedence relationships of the design activities, the necessary tools and resources that have to be employed for each task, can also be established, using necessary task-tools/resources matrix relationships (tasks listed along rows, and corresponding tools or resources listed along columns). What we have here are two matrices of design task-design tools and design task- resource incidence matrices, where the former shows the tools that are
  30. 30 needed to perform particular tasks and the later shows the resources needed for particular tasks. For more efficient management, these relationships have to be established for each design stage in DFD. 9. CONCLUSION It is widely accepted in the manufacturing industry that the speed at which a product gets to the market place, is a major factor affecting how a company performs in the market place and represents a key basis for competition. The main focus of this chapter therefore, has been to address this major constituent of the ethos of concurrent engineering, that is, the need to design products for early release to the market place. This has involved a discussion of the meaning of `Time to Market’, the goals, objectives, need for and benefits of designing for time to market. The general requirements which form a basis for achieving the objectives of design for time to market, have also been discussed. Design Function Deployment (DFD) - a concurrent engineering design system, which provides the framework for designing for time to market, was comprehensively elucidated. Further discussions also involved how to design for time to market within the platform of DFD. This included discussions on product classifications, strategic product planning and fundamental issues affecting design for time to market. The recommended approach to designing for time to market, was explicitly enunciated. The chapter concluded with discussions on tools needed to support the process of designing for time to market, as well as their classifications and management. The central theme of this chapter, that is, designing for “Time to Market”, has been demonstrated to be a concurrent engineering imperative. 10. REFERENCES 1. R. I. WINNER. ET AL., The Role of Concurrent Engineering in Weapons System Acquisition, (IDA Report R-338, Institute of Defense Analysis, Alexandria, Virginia, USA, 1988). 2. S.G. SHINA, IEEE Spectrum, July, 23 - 26 (1991). 3. J. R. HARTLEY, Concurrent Engineering (Productivity Press, Cambridge, Massachusetts, USA, 1990). 4. J. MOTIMER and J. R. HARTLEY, Simultaneous Engineering, (The DTI, Enterprise Initiative, London, UK, 1990).
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