Tech innovation s3_tools

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Learn Concurrent, reverse, value engineering concept and tools to facilitate successful innovation

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Tech innovation s3_tools

  1. 1. Technology and InnovationManagement:S3Technology Tools for InnovationRaj C Thiagarajan, PhDToSIBM SIII MBA Students ATOA Scientific Technologies Engineering Simulation For Innovation
  2. 2. Tools are essential for Technology Development• Axe 2
  3. 3. Primates also use tools….• Female Gorilla is using a stick to find the water depth. 3
  4. 4. TIM –S3: Technology Tools for innovation• Technology tools for value creation• Innovation: Quality : Speed: Cost• Engineering Tools – Concurrent Engineering – QFD – DfX – FMEA – Simulation based product Development• Innovation Tools – TRIZ ©ATOA Scientific Technologies Pvt Ltd | SIBM , III Semester MBA| Technology and Innovation Management 4
  5. 5. Wealth Creation Cycle• Tools for Wealth Wealth Basic creation Creation Research• Value = Benefit – Cost Commerci Applied• Technology and alization Research innovation tools for value creation Innovation/ Industrial Product Research development ©ATOA Scientific Technologies Pvt Ltd | SIBM , III Semester MBA| Technology and Innovation Management
  6. 6. Traditional Product Development Product• Product plan to Planning Concept Commercialization Design Concept• Water fall Evaluation Preliminary1. Product Planning Design2. Concept Design Design3. Concept Evaluation Evaluation4. Preliminary Design Final Design5. Design Evaluation6. Final Design Prototyping7. Prototyping Pilot8. Pilot production production9. Mass production Mass10. Product commercialization production• Sequential process Product commercialization Development Cycle Time 6 ©ATOA Scientific Technologies Pvt Ltd | SIBM , III Semester MBA| Technology and Innovation Management
  7. 7. Traditional Product Development• Benefits • Easy Management and control • Uncertainty is minimized • Functional expertise optimization Product Information Flow Pilot Mass Marketing Engineering Testing production production• Drawback Design Changes, Errors, Corrections – Potential to miss customer requirements – Design that can’t be Manufactured – Longer cycle time ©ATOA Scientific Technologies Pvt Ltd | SIBM , III Semester MBA| Technology and Innovation Management 7
  8. 8. Cost of Design Changes Cost of Design change• Cost of Design changes increases exponentially with product development cycle. Product Concept Final Pilot Mass Planning Design Design Production production 100%• 80% of the product Committed cost is determined or Product Cost committed at the concept design stage Actual 0% Product Development Cycle Product Concept Final Pilot Mass Planning Design Design Production production ©ATOA Scientific Technologies Pvt Ltd | SIBM , III Semester MBA| Technology and Innovation Management 8
  9. 9. Cost of fixing @• Cost to find and repair defects Part 1X – @ Part 1X @ – @ Sub assembly 10 X Sub assembly 10 X – @ Final Assembly 100 X @ – @ the Dealer 1000 X Final Assembly 100 X – @ the customer 10000 X @ Dealer 1000 X @ Customer 10000 X ©ATOA Scientific Technologies Pvt Ltd | SIBM , III Semester MBA| Technology and Innovation Management 9
  10. 10. Product Management Influence• Product development and management HIGH• Management Influence Index Activity and activity ratio• Management influence potential Low Product Concept Final Pilot Mass Planning Design Design Production production ©ATOA Scientific Technologies Pvt Ltd | SIBM , III Semester MBA| Technology and Innovation Management 10
  11. 11. Typical Response time of Industry• Aero engine: ~10 Years to 5 Years• Pharma: Drug molecule: ~ 8 Years to 4 years• Medical Technology: ~ 24 months to 12 months• Renewable NPI (Wind ): ~6 months to 1 months• Finance: ~1 week to On the spot ©ATOA Scientific Technologies Pvt Ltd | SIBM , III Semester MBA| Technology and Innovation Management 11
  12. 12. Larger Scope of Product design • ENVIRONMENTAL REGULATIONS Emergency Planning Air Quality Laws Laws Waste & Emissions Hazardous Material Transportation Laws ChemicalsChemical Management Laws Waste Management Laws Water Quality Laws Occupational Contaminated Land Requirements Health & Safety Laws Health & Safety ©ATOA Scientific Technologies Pvt Ltd | SIBM , III Semester MBA| Technology and Innovation Management 12
  13. 13. Product Development Customer Product Product Product Product Real CustomerRequirements Requirements Design Marketing Delivery RequirementsWe definitely need better process…. ©ATOA Scientific Technologies Pvt Ltd | SIBM , III Semester MBA| Technology and Innovation Management 13
  14. 14. Concurrent Engineering• Concurrent consideration of all the product lifecycle requirements at early stage of design. – From functionality, manufacturability, assembly, testing and verification, maintenance, environmental impact, disposal, recycling and sustainability. – Converting hierarchical organizations into teams• Overall goal of concurrent nature of the process – significantly increase productivity and Quality – Reduce development cost and Cycle time – Prevention of problems ©ATOA Scientific Technologies Pvt Ltd | SIBM , III Semester MBA| Technology and Innovation Management 14
  15. 15. Concurrent Engineering• Concurrent Engineering• Simultaneous Engineering• Integrated Product Development ©ATOA Scientific Technologies Pvt Ltd | SIBM , III Semester MBA| Technology and Innovation Management 15
  16. 16. Concurrent Engineering: Definition• “Concurrent engineering methodologies permit the separate tasks of the product development process to be carried out simultaneously rather than sequentially. Product design, testing, manufacturing and process planning through logistics, for example, are done side-by-side and interactively. Potential problems in fabrication, assembly, support and quality are identified and resolved early in the design process.” Izuchukwu, John. “Architecture and Process :The Role of Integrated Systems in Concurrent Engineering.” Industrial Management Mar/Apr 1992: p. 19-23.• “The simultaneous performance of product design and process design. Typically, concurrent engineering involves the formation of cross-functional teams. This allows engineers and managers of different disciplines to work together simultaneously in developing product and process design.” Foster, S. Thomas. Managing Quality: An Integrative Approach. Upper Saddle River New Jersey: Prentice Hall, 2001. ©ATOA Scientific Technologies Pvt Ltd | SIBM , III Semester MBA| Technology and Innovation Management 16
  17. 17. Concurrent Engineering Cycle Performance ManufacturabilityQuality and Cost Pilot Testing and Mass DESIGN production Verification Production Service, Life Environmental • Concurrent Product Design and Development • Lowest overall life cycle costs • Problem prevention from Problem Solving ©ATOA Scientific Technologies Pvt Ltd | SIBM , III Semester MBA| Technology and Innovation Management 17
  18. 18. Benefits Item Benfits• Significant Development Time 30-50% Reduction Engineering changes 60-95% Reduction development time , Scrap and Rework 75% Reduction defects, time to Defects 30-85% Reduction market and failure Time to Market 20-90% Reduction Field Failure Rate 60% Reduction reduction Service Life 100% improvement• Improvements of Overall Quality 100 -600% improvement service life, Quality, Productivity 20 -110% improvement Return on Assets 20 -120% improvement productivity and ROI. BEFORE PLANNING CONCEPT DESIGN FINAL DESIGN PRODUCTION QFD AFTER PLANNING PRE DESIGN FINAL DESIGN PRODUCTION QFD BENEFITS ©ATOA Scientific Technologies Pvt Ltd | SIBM , III Semester MBA| Technology and Innovation Management
  19. 19. CE Environment• People – Team – Project• Process – Process modeling – Process reengineering – Info/ Data integration – Concurrent Engineering• Technology – Problem solving mechanisms – DBMS – PLM – Simulation based Engineering (SBE) ©ATOA Scientific Technologies Pvt Ltd | SIBM , III Semester MBA| Technology and Innovation Management 19
  20. 20. Concurrent Engineering Tools• QFD: Quality Concurrent Engineering Functional Deployment• DfM: Design for QFD manufacturing QFD• FMEA: Failure Mode DfM QFD QFD Effect Analysis FMEA FMEA• DFSS: Design for six VE DfM sigma SPC, LEAN• SPC: Statistical Process DFSS DFSS Control Concurrent Engineering Product Concept Final Pilot Mass Planning Design Design Production production ©ATOA Scientific Technologies Pvt Ltd | SIBM , III Semester MBA| Technology and Innovation Management 20
  21. 21. QFD• QFD: A tool that integrates the “voice of the customer” into the product and service development process.• A QFD matrix: The "house of quality".• Customer requirements• Engineering requirements Trade-off opportunities• Matrix of requirements relations Design How ’s Competitive Bench marking Customer Requirements team response and solutions• Competitive benchmarks What’s• Engineering targets What’s Priorities vs. requirements How’s Technical Ranking requirements flow down Product Targets ©ATOA Scientific Technologies Pvt Ltd | SIBM , III Semester MBA| Technology and Innovation Management 21
  22. 22. Capture Customer RequirementsQFD Example Partition and Quantify Requirements Map Requirements to Product/Process Characteristics (QFD: Quality Function Deployment)• First FRP Materials Develop Product/Process Identify and Characterise Railway sleeper Product/Process Alternatives Selection Criteria, Constraints & Goals to replace Address Structure Pre-selections Wood. entire life-cycle (design Selections• IR,RDSO, DRDO, through disposal) Process DST, IIT Compromise• Planning to Product/Process Specification First prototype ~ 1 year ©ATOA Scientific Technologies Pvt Ltd | SIBM , III Semester MBA| Technology and Innovation Management 22
  23. 23. Load Class: MLC-70Sarvatra Single Span Length: 15/20 m Multi-Span Capability: 75/100 m• Sarvatra, Construction time: 15 minutes developed by DRDO, R&DE(E), can lay a 75-metre- long bridge in 90 minutes.• Prototype: ~ 3years• Completion: ~5years ©ATOA Scientific Technologies Pvt Ltd | SIBM , III Semester MBA| Technology and Innovation Management 23
  24. 24. QFD Flow down PLANNING PRODUCT• Planning Matrix PROCESS • Product Development Matrix OPS • Product manufacturing matrix • Operator instruction matrix ©ATOA Scientific Technologies Pvt Ltd | SIBM , III Semester MBA| Technology and Innovation Management 24
  25. 25. DfX• Design for ‘X’.• X is a variable that can be substituted with, for, Assembly, Cost, Environment, Fabrication, Manufacture, Obsolescence, Procurement, Reliability, Serviceability or Test.• DfM: Design for Manufacturing• DfA: Design for Assembly• DfE: Design for Environment• DfS: Design for Sustainability ©ATOA Scientific Technologies Pvt Ltd | SIBM , III Semester MBA| Technology and Innovation Management 25
  26. 26. Capture CustomerFMEA QFD Satisfaction requirements To MEET CTQ• Failure Modes and Effects Analysis Capture Customer Dissatisfaction • Identifying failure modes, failure FMEA Requirements mechanisms, impact, probability To AVOID and detection• A structured engineering analysis performed on a product or a process Failure Failure modes? Mechanisms? • Addresses the type, effects and severity of failures Effect on The • Results in actions that eliminate Customer? failure modes or reduces their impact Probability of the Detection before • Can reduce liability even for Failure? Failure? failures that are not eliminated• Timing: After a design before Severity of the production Failure? Probability | Consequence | Avoidance ©ATOA Scientific Technologies Pvt Ltd | SIBM , III Semester MBA| Technology and Innovation Management
  27. 27. FMEA Decreasing Failure Constant Failure Rate Increasing Failure Rate Rate Failure Rate• Quality meets the Overall specification failures WEAR OUT when new Early failures failures “Infant Morality”• Reliability continues to meet Time the specification “Infant Morality” through a period WEAR OUT of use Load Strength Load Strength Quality/Reliability intimately tied to variability Deterministic Vs Probabilistic ©ATOA Scientific Technologies Pvt Ltd | SIBM , III Semester MBA| Technology and Innovation Management 27
  28. 28. Risk Priority Scores Effect Severity of Effect RankingRisk Priority Score = Hazardous without Very high severity ranking when a potential failure mode affects safe system operation 10 Impact X Probability X warning and/or involves non compliance with federal safety regulation without warning Detection Hazardous Very high severity ranking when a potential 9 with failure mode affects safe system operation warning and/or involves non compliance with federal safety regulation warningImpact: Severity of effect Very High System/item inoperable with loss of primary function 8 High System/item operable, bit at reduced 7 performance level. User dissatisfiedProbability: Likelihood of Moderate System/item operable, but comfort/convenience item inoperable 6 occurrence Low System/item operable, but 5 comfort/convenience item operable at reduced level Very Low Defect noticed by most customers 4Detection: Difficulty of Minor Defect noticed by average customer 3 identifying failure Very Minor Defect noticed by discriminating customer 2 None No effect 1 ©ATOA Scientific Technologies Pvt Ltd | SIBM , III Semester MBA| Technology and Innovation Management
  29. 29. Other Tools/ Methods• Value Engineering • VA/VE is an approach to productivity improvement that attempts to increase the value obtained by a customer of a product by offering the same level of functionality at a lower cost. • prioritise parts of the total design that are most worthy of attention.• Configuration management • Configuration simply refers to the arrangement of the parts or elements of something, and management refers to the act or practice of managing.• TQM• Total quality management (TQM) is a philosophy of pursuing continuous improvement in each process through the integrated efforts of all individuals in the organization.• DFSS, SPS, LEAN ©ATOA Scientific Technologies Pvt Ltd | SIBM , III Semester MBA| Technology and Innovation Management 29
  30. 30. Simulation Based Engineering (SBE)• SBE product development• Virtual Product Development• Rapid Prototyping• Customer Experience ©ATOA Scientific Technologies Pvt Ltd | SIBM , III Semester MBA| Technology and Innovation Management 30
  31. 31. The Engineering ProcessMATERIAL ENGINEERING PROCESS PRODUCT The Traditional Engineered Process Conceptual Design Fabrication Assembly Testing The Simulation Based Engineered Process Mathematical Virtual Testing for Predictive Computational product/ Validation & Processing Design system verification Simulation Based Engineering Process Minimizes the Uncertainty in the Concurrent Engineering Process For Enabling Faster and low cost Innovative product development ©ATOA Scientific Technologies Pvt Ltd | SIBM , III Semester MBA| Technology and Innovation Management 31
  32. 32. The Simulation for the First time rightMATHEMATICAL MODEL • Captures the THE PHYSICS EMBEDDED IN THE ENGINEERING SCIENCES Real product/ system • Simple closed-form solutions to establish essential relationships, Numerical solutions for complex problems • Properties of different types of differential and integral equations • Closed-form solutions only available for very simple problems • The mathematical model only transforms the available information about the real problem into a Mathematical predictable quantity of interest model• COMPUTATIONAL MODEL • Computers have revolutionized techniques for solving differential and integral equations Computational • Finite element methods, model • Availability of Fast and cheap computing power • Accurate numerical solutions to complex problems • Nonlinearities easily handled Prediction • The purpose of computation to model the real system to output the quantities of interest on (Output) which a decision can be made • NEW PARADIGM: Simulation based engineering Design (SBED) with Multiphysics and Multiscale depth It is a must to incorporate all the known Scientific and or Engineering knowledge for a given problem solving or new product design. Failure by not integrating the known knowledge is not professionally acceptable. ©ATOA Scientific Technologies Pvt Ltd | SIBM , III Semester MBA| Technology and Innovation Management 32
  33. 33. Simulation Based Engineering (SBE)• Engineering is the profession in which a knowledge of the mathematical and natural sciences gained by study experience, and practice is applied with judgment to develop ways to utilize, economically, the materials and forces of nature for the benefit of the society - Accreditation Board for Engineering and Technology• SBE to develop Virtual Innovative Products for unique customer experience with highest performance and reliability at lowest cost .• Studies shows that the Simulation based Product development, reduced the prototyping by 50% and increased the lead time ~60 days ahead of the competition. ©ATOA Scientific Technologies Pvt Ltd | SIBM , III Semester MBA| Technology and Innovation Management 33
  34. 34. Simulation based Engineering Design(SBED)• SBED provides unparalleled access to real-world conditions• SBED is credited with numerous success story• SBED can be used to Predict unknown product performance for first time right• Eventually can be used to predict the future outcome• Simulations has none of the following limitations of experimental designs /tests, – Cost constraints – harsh/unrealistic parameter ranges, and – Environment, Health and Safety concerns.• It has become indispensable for – Weather prediction – Medical diagnosis (Virtual human) – Material modeling – Drug synthesis From: Research Directions In Computational Mechanics, A Report of the United States National Committee on Theoretical and Applied Mechanics, September 2000 – Auto design for crashworthiness Ref: Jaroslav Mackerle Finite-element analysis and simulation of machining: a bibliography (1976– 1996), Journal of Materials Processing Technology 86 (1999) 17–44 ©ATOA Scientific Technologies Pvt Ltd | SIBM , III Semester MBA| Technology and Innovation Management 34
  35. 35. Type of Failure and ExamplesA. Modeling Problem/ Unknown Phenomenon The Tacoma Narrows Bridge. The suspension bridge across Puget-Sound(Washington State) collapsed November 7, 1940.Reason: the model did not properly describe the aerodynamic forces andthe effects of the Von Karman vortices. In addition, the behavior of thecables was not correctly modeled.• The Columbia Shuttle Accident June 2003. It was caused by a piece offoam broken off the fuel tank. After it was observed, the potential of thedamage was judged, upon computations, as nonserious. Reason: themodel used did not take properly into consideration the size of the foamdebris.B. Numerical Treatment Problem• The Sleipner Accident. The gravity base structure of Sleipner, anoffshore platform made of reinforced concrete, sank during ballast testoperation in Gandsfjorden, Norway, August 23, 1991. Reason: finiteelement analysis gave a 47% underestimation of the shear forces in thecritical part of the base structure.C. Computer Science Problem• Failure of the ARIANE 5 Rocket, June 1996. Reason: problem ofcomputer science, implementation of the round offs.D. Human Problem• Mars Climate Orbiter. The Orbiter was lost September 23, 1999, in theMars Atmosphere. Reason: unintended mixture of Imperial and metricunits. Simulations helps to avoid failure & From: Babuška, F. Nobile, R. Tempone, Reliability of make it first time right. Computational Science, Numerical Methods for Partial Differential Equations, DOI 10.1002/num 20263, www.interscience.wiley.com ©ATOA Scientific Technologies Pvt Ltd | SIBM , III Semester MBA| Technology and Innovation Management 35
  36. 36. Reliability of SimulationsEngineering accidents can happen due to, – Modeling Error, – the numerical treatment, – computer science problems, and – human errors.Reliability of simulation depends on• The Mathematical model.• Resources vs performance• Deterministic/ Probabilistic• Prediction/quantification – Failure probability – Confidence level/ Factor of safety• Simulations are moving from Trend prediction to actual and accurate performance prediction Objective is to increase the reliability of simulations. ©ATOA Scientific Technologies Pvt Ltd | SIBM , III Semester MBA| Technology and Innovation Management 36
  37. 37. Simulation and Testing + V&V Real product/ Mathematical Computational PredictionSimulation system model model (Output) Testing Validation Verification • The interplay between Simulation and Testing. • Testing is a process to help validation and verification for first time right. • Validation is a process determining if the mathematical model describes sufficiently well the reality • Verification is a process of determining whether the computational model and the implementation lead to the prediction with sufficient accuracy. • V&V concepts are applicable to all stages of testing…. Reference: Leszek A. Dobrza´nski, Significance of materials science for the future development of societies, Journal of Materials Processing Technology 175 (2006) 133–148 ©ATOA Scientific Technologies Pvt Ltd | SIBM , III Semester MBA| Technology and Innovation Management 37
  38. 38. Virtual Testing• Simulation to predict the experimental properties of systems.• For example, It is difficult to characterize all the anisotropic properties of composites. Numerical models is used to predict the complimentary anisotropic properties.• Simulation to mimic the testing is performed to zoom into the inner working mechanism of materials and products.• The progressive growth, failure, damage mechanics can help to reverse engineer the materials for improved and optimal performance.• Virtual Testing are used to simulate and predict high risk and costly experimental tests for cost effective product development. ©ATOA Scientific Technologies Pvt Ltd | SIBM , III Semester MBA| Technology and Innovation Management 38
  39. 39. Four Stages of Complimentary Simulation andTesting for the Engineering Design of First Time Right Product Development ©ATOA Scientific Technologies Pvt Ltd | SIBM , III Semester MBA| Technology and Innovation Management 39
  40. 40. TIM –S3: Technology Tools for innovation• Technology tools for value creation• Innovation: Quality : Speed: Cost• Engineering Tools – Concurrent Engineering – QFD – DfX – FMEA – Simulation based product Development• Innovation Tools – TRIZ ©ATOA Scientific Technologies Pvt Ltd | SIBM , III Semester MBA| Technology and Innovation Management 40

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