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Integrated Product Development
IPD - Concurrent engineering
Thomas J. Howard
https://sites.google.com/site/thomasjameshowardhomepage/
thow@mek.dtu.dk
                            Unless otherwise stated, this material is under a Creative
                            Commons 3.0 Attribution–Share-Alike licence and can be
                            freely modified, used and redistributed but only under the
                            same licence and if including the following statement:
“Original material by Thomas J. Howard for course 42629 – Innovation and Product Development
Department of Mechanical Engineering, The Technical University of Denmark”

Thanks to Thorkild Ahm, IPU for providing DfA samples
Concurrent Engineering

         Designing the Product and
         Production simultaneously

                               Market
                              Product                                                             Business

                             Production

2   Original material by Thomas J. Howard for course 42629 – Innovation and Product Development       2012
    Department of Mechanical Engineering, The Technical University of Denmark
What are DFX methods?
                                    DFX: Design For X
• where „X‟ is an important aspect related to the product lifecycle,
• and „Design For‟ means to design the product in order to improve


Important DFXs:
DFE – Design for the Environment
DFM – Design for Manufacturability
DFA – Design for Assembly
DFS – Design for Serviceability
DFC – Design for Changeover
DFD – Design for Disassembly
DFQ – Design for Quality (QFD method)

3    Original material by Tim C. McAloone adapted for course 42629 – Innovation and Product   2012
     Development Department of Mechanical Engineering, The Technical University of Denmark
DfX and Life Cycle




                                                                                                Environment
                                                       Flexibility




                                                                                   Efficiency
                                             Quality




                                                                            Time
                                      Cost




                                                                     Risk
                                                                                                              Design for …
                                                                                                               Df – Cost
                                                                                                               Df – Assembly
                                                                                                               Df – Manufacturing
                                                                                                               Df – Usability
                                                                                                               Df – Quality
                                                                                                               Df – Serviceability
                                                                                                               Df – Environment
                                                                                                               Platform development
                                                                                                               …



                                                                                                              [Score model from
                                                                                                              Olesen, 1992]


4   Original material by Tim C. McAloone adapted for course 42629 – Innovation and Product                                        2012
    Development Department of Mechanical Engineering, The Technical University of Denmark
Trade-offs
… require knowledge of all DFX-areas

    Acceleration                                                        User-
ability 0-100km                                                 experienced Q
             [s]




                                Petrol useage                                                    Weight [g]
                                       [km/L]

                                                                                                          [From McAloone,
Assembly speed                                                   Running costs
                                                                          [kr]                            Inspired by Allen Ward]
            [s]




                             Amount of                                                   Manufacturing costs
                         components [n]                                                                 [kr]


5       Original material by Tim C. McAloone adapted for course 42629 – Innovation and Product                      2012
        Development Department of Mechanical Engineering, The Technical University of Denmark
Design for Serviceability (DFS)
“Don‟t make „em start all over”
DFS improvements...

                                                Original            Redesign




7   Original material by Thomas J. Howard for course 42629 – Innovation and Product Development   2012
    Department of Mechanical Engineering, The Technical University of Denmark
Think about service in advance...
Headlamp bulb replacement example




                                                       This side up




       [Case from Winston Knight, Rhode Island]

8   Original material by Thomas J. Howard for course 42629 – Innovation and Product Development   2012
    Department of Mechanical Engineering, The Technical University of Denmark
Here’s what it takes...
    Disassemble:                                               Reassemble:
    2 Screws (left side light)                                 Headlamp bulb
    Cover (left side light)                                    Headlamp glass
    Cable connector                                            Headlamp trim
    Housing (left side light)                                  4 Screws (headlamp trim)
    2 Screws (right side light)                                Radiator panel
    Cover (right side light)                                   14 Screws (radiator panel)
    Cable connector                                            Housing (right side light)
    Housing (right side light)                                 Cable connector
    14 Screws (radiator panel)                                 Cover (right side light)
    Radiator panel                                             2 Screws (right side light)
    4 Screws (headlamp trim)                                   Housing (left side light)
    Headlamp trim                                              Cable connector
    Headlamp glass                                             Cover (left side light)
    Headlamp bulb                                              2 Screws (left side light)
    32 items                                                   32 items

    [Case from Winston Knight, Rhode Island]
9   Original material by Thomas J. Howard for course 42629 – Innovation and Product Development   2012
    Department of Mechanical Engineering, The Technical University of Denmark
Design for Manufacture and
Assembly (DFMA)
“That‟s all well and good but how are we gonna make it?”
Boeing Helicopter
(formerly McDonnell Douglas Helicopter Systems)



                              Apache Longbow Helicopter
                                      Redesign

                                                        Estimated savings

                                                       $1.3 billion over life of program



                                                       One aircraft per month

                                                       Increased to five per month




     [Case from Winston Knight, Rhode Island]
11   Original material by Thomas J. Howard for course 42629 – Innovation and Product Development   2012
     Department of Mechanical Engineering, The Technical University of Denmark
Anti-Flair Bracket Assembly for the
Boeing Longbow Apache Helicopter

                     Before                                                        After




                                                               1 high-speed machined part
         5 sheet metal parts                                   2 hours manufacturing
         19 rivets                                             10% less weight
         20 tools needed                                       45% less cost
         32 hours manufacturing                                Tooling cost virtually eliminated


                                Source: Alfredo Herrera,1998 International DFMA forum, Newport, RI

12   Original material by Thomas J. Howard for course 42629 – Innovation and Product Development   2012
     Department of Mechanical Engineering, The Technical University of Denmark
Jump Seat for Extended Cab Pick-up

                                                                          Base line analysis
                                                                          105 separate parts
                                                                          Total assembly time estimate
                                                                          1440 s, excluding paint
                                                                          application
                                                                          Many tubular parts and small
                                                                          tabs hand welded during
                                                                          assembly
                                                                          Many reorientations of product
                                                                          during assembly




     [Case from Winston Knight, Rhode Island]
13   Original material by Thomas J. Howard for course 42629 – Innovation and Product Development   2012
     Department of Mechanical Engineering, The Technical University of Denmark
Jump Seat for Extended Cab Pick-up

                                                          Phase 1 Proposal
                                                          Objective to reduce parts and assembly time
                                                          while maintaining essential functions
                                                          Most welding steps eliminated
                                                          Cams and rolling components replaced by
                                                          slides guided in slots
                                                          Part count reduced to 19 , with 5 major
                                                          subassemblies
                                                          Assembly time estimate reduced to 258 s
                                                          A more radical Phase 2 proposal that loses
                                                          some functionality was also developed



     [Case from Winston Knight, Rhode Island]
14   Original material by Thomas J. Howard for course 42629 – Innovation and Product Development   2012
     Department of Mechanical Engineering, The Technical University of Denmark
DfMA – Housing corner piece




                           Lønstrup

     [Andreasen, Kähler & Lund, 1988 – “Design for Assembly”]
15   Original material by Thomas J. Howard for course 42629 – Innovation and Product Development   2012
     Department of Mechanical Engineering, The Technical University of Denmark
DfA – Water sprinkler




     [Andreasen, Kähler & Lund, 1988 – “Design for Assembly”]
16   Original material by Thomas J. Howard for course 42629 – Innovation and Product Development   2012
     Department of Mechanical Engineering, The Technical University of Denmark
DfA – ‘Stacking’




     [Andreasen, Kähler & Lund, 1988 – “Design for Assembly”]
17   Original material by Thomas J. Howard for course 42629 – Innovation and Product Development   2012
     Department of Mechanical Engineering, The Technical University of Denmark
GNT Automatic



     [Andreasen, Kähler & Lund, 1988 – “Design for Assembly”]
18   Original material by Thomas J. Howard for course 42629 – Innovation and Product Development               2012
     Department of Mechanical Engineering, The Technical University of Denmark
DfA – Plastic integration




19   Original material by Thomas J. Howard for course 42629 – Innovation and Product Development   2012
     Department of Mechanical Engineering, The Technical University of Denmark
DFMA exercise                                                                     2 small screws
                    end plate -
                    sheet steel
                                                                                         bushing -
                                                                                         plastic


                                                                                 2 standoffs -
                  motor                                                          steel - machined

                                                                                      sensor

                    2 motor
                    screws
                                                                                small screw

                  2 bushings -
                                                                              base - machined
                  powder metal - brass
                                                                              aluminum


                     cover - sheet
                     steel - welded                                                   4 small
                                                                                      screws


     [Case from Winston Knight, Rhode Island]
20   Original material by Thomas J. Howard for course 42629 – Innovation and Product Development     2012
     Department of Mechanical Engineering, The Technical University of Denmark
DFA Analysis data sheet




                   [Case from Winston Knight, Rhode Island]

21   Original material by Thomas J. Howard for course 42629 – Innovation and Product Development   2012
     Department of Mechanical Engineering, The Technical University of Denmark
Re-designed solution




                                                                                        cover -
                                                                                        injection
                                                                                        molding
      motor

     2 motor                                                                             sensor
     screws                                                                             small screw


                                                                                 base - nylon

     [Case from Winston Knight, Rhode Island]
22   Original material by Thomas J. Howard for course 42629 – Innovation and Product Development      2012
     Department of Mechanical Engineering, The Technical University of Denmark
Questions




                                                   ?
23   Original material by Thomas J. Howard for course 42629 – Innovation and Product Development   2012
     Department of Mechanical Engineering, The Technical University of Denmark

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42629 lecture 3 pt3

  • 1. Integrated Product Development IPD - Concurrent engineering Thomas J. Howard https://sites.google.com/site/thomasjameshowardhomepage/ thow@mek.dtu.dk Unless otherwise stated, this material is under a Creative Commons 3.0 Attribution–Share-Alike licence and can be freely modified, used and redistributed but only under the same licence and if including the following statement: “Original material by Thomas J. Howard for course 42629 – Innovation and Product Development Department of Mechanical Engineering, The Technical University of Denmark” Thanks to Thorkild Ahm, IPU for providing DfA samples
  • 2. Concurrent Engineering Designing the Product and Production simultaneously Market Product Business Production 2 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
  • 3. What are DFX methods? DFX: Design For X • where „X‟ is an important aspect related to the product lifecycle, • and „Design For‟ means to design the product in order to improve Important DFXs: DFE – Design for the Environment DFM – Design for Manufacturability DFA – Design for Assembly DFS – Design for Serviceability DFC – Design for Changeover DFD – Design for Disassembly DFQ – Design for Quality (QFD method) 3 Original material by Tim C. McAloone adapted for course 42629 – Innovation and Product 2012 Development Department of Mechanical Engineering, The Technical University of Denmark
  • 4. DfX and Life Cycle Environment Flexibility Efficiency Quality Time Cost Risk Design for … Df – Cost Df – Assembly Df – Manufacturing Df – Usability Df – Quality Df – Serviceability Df – Environment Platform development … [Score model from Olesen, 1992] 4 Original material by Tim C. McAloone adapted for course 42629 – Innovation and Product 2012 Development Department of Mechanical Engineering, The Technical University of Denmark
  • 5. Trade-offs … require knowledge of all DFX-areas Acceleration User- ability 0-100km experienced Q [s] Petrol useage Weight [g] [km/L] [From McAloone, Assembly speed Running costs [kr] Inspired by Allen Ward] [s] Amount of Manufacturing costs components [n] [kr] 5 Original material by Tim C. McAloone adapted for course 42629 – Innovation and Product 2012 Development Department of Mechanical Engineering, The Technical University of Denmark
  • 6. Design for Serviceability (DFS) “Don‟t make „em start all over”
  • 7. DFS improvements... Original Redesign 7 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
  • 8. Think about service in advance... Headlamp bulb replacement example This side up [Case from Winston Knight, Rhode Island] 8 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
  • 9. Here’s what it takes... Disassemble: Reassemble: 2 Screws (left side light) Headlamp bulb Cover (left side light) Headlamp glass Cable connector Headlamp trim Housing (left side light) 4 Screws (headlamp trim) 2 Screws (right side light) Radiator panel Cover (right side light) 14 Screws (radiator panel) Cable connector Housing (right side light) Housing (right side light) Cable connector 14 Screws (radiator panel) Cover (right side light) Radiator panel 2 Screws (right side light) 4 Screws (headlamp trim) Housing (left side light) Headlamp trim Cable connector Headlamp glass Cover (left side light) Headlamp bulb 2 Screws (left side light) 32 items 32 items [Case from Winston Knight, Rhode Island] 9 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
  • 10. Design for Manufacture and Assembly (DFMA) “That‟s all well and good but how are we gonna make it?”
  • 11. Boeing Helicopter (formerly McDonnell Douglas Helicopter Systems) Apache Longbow Helicopter Redesign Estimated savings $1.3 billion over life of program One aircraft per month Increased to five per month [Case from Winston Knight, Rhode Island] 11 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
  • 12. Anti-Flair Bracket Assembly for the Boeing Longbow Apache Helicopter Before After 1 high-speed machined part 5 sheet metal parts 2 hours manufacturing 19 rivets 10% less weight 20 tools needed 45% less cost 32 hours manufacturing Tooling cost virtually eliminated Source: Alfredo Herrera,1998 International DFMA forum, Newport, RI 12 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
  • 13. Jump Seat for Extended Cab Pick-up Base line analysis 105 separate parts Total assembly time estimate 1440 s, excluding paint application Many tubular parts and small tabs hand welded during assembly Many reorientations of product during assembly [Case from Winston Knight, Rhode Island] 13 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
  • 14. Jump Seat for Extended Cab Pick-up Phase 1 Proposal Objective to reduce parts and assembly time while maintaining essential functions Most welding steps eliminated Cams and rolling components replaced by slides guided in slots Part count reduced to 19 , with 5 major subassemblies Assembly time estimate reduced to 258 s A more radical Phase 2 proposal that loses some functionality was also developed [Case from Winston Knight, Rhode Island] 14 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
  • 15. DfMA – Housing corner piece Lønstrup [Andreasen, Kähler & Lund, 1988 – “Design for Assembly”] 15 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
  • 16. DfA – Water sprinkler [Andreasen, Kähler & Lund, 1988 – “Design for Assembly”] 16 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
  • 17. DfA – ‘Stacking’ [Andreasen, Kähler & Lund, 1988 – “Design for Assembly”] 17 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
  • 18. GNT Automatic [Andreasen, Kähler & Lund, 1988 – “Design for Assembly”] 18 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
  • 19. DfA – Plastic integration 19 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
  • 20. DFMA exercise 2 small screws end plate - sheet steel bushing - plastic 2 standoffs - motor steel - machined sensor 2 motor screws small screw 2 bushings - base - machined powder metal - brass aluminum cover - sheet steel - welded 4 small screws [Case from Winston Knight, Rhode Island] 20 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
  • 21. DFA Analysis data sheet [Case from Winston Knight, Rhode Island] 21 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
  • 22. Re-designed solution cover - injection molding motor 2 motor sensor screws small screw base - nylon [Case from Winston Knight, Rhode Island] 22 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
  • 23. Questions ? 23 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark