Integrated Product DevelopmentIPD - Concurrent engineeringThomas J. Howardhttps://sites.google.com/site/thomasjameshowardh...
Concurrent Engineering         Designing the Product and         Production simultaneously                               M...
What are DFX methods?                                    DFX: Design For X• where „X‟ is an important aspect related to th...
DfX and Life Cycle                                                                                                Environm...
Trade-offs… require knowledge of all DFX-areas    Acceleration                                                        User...
Design for Serviceability (DFS)“Don‟t make „em start all over”
DFS improvements...                                                Original            Redesign7   Original material by Th...
Think about service in advance...Headlamp bulb replacement example                                                       T...
Here’s what it takes...    Disassemble:                                               Reassemble:    2 Screws (left side l...
Design for Manufacture andAssembly (DFMA)“That‟s all well and good but how are we gonna make it?”
Boeing Helicopter(formerly McDonnell Douglas Helicopter Systems)                              Apache Longbow Helicopter   ...
Anti-Flair Bracket Assembly for theBoeing Longbow Apache Helicopter                     Before                            ...
Jump Seat for Extended Cab Pick-up                                                                          Base line anal...
Jump Seat for Extended Cab Pick-up                                                          Phase 1 Proposal              ...
DfMA – Housing corner piece                           Lønstrup     [Andreasen, Kähler & Lund, 1988 – “Design for Assembly”...
DfA – Water sprinkler     [Andreasen, Kähler & Lund, 1988 – “Design for Assembly”]16   Original material by Thomas J. Howa...
DfA – ‘Stacking’     [Andreasen, Kähler & Lund, 1988 – “Design for Assembly”]17   Original material by Thomas J. Howard fo...
GNT Automatic     [Andreasen, Kähler & Lund, 1988 – “Design for Assembly”]18   Original material by Thomas J. Howard for c...
DfA – Plastic integration19   Original material by Thomas J. Howard for course 42629 – Innovation and Product Development ...
DFMA exercise                                                                     2 small screws                    end pl...
DFA Analysis data sheet                   [Case from Winston Knight, Rhode Island]21   Original material by Thomas J. Howa...
Re-designed solution                                                                                        cover -       ...
Questions                                                   ?23   Original material by Thomas J. Howard for course 42629 –...
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42629 lecture 3 pt3

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IPD: Concurrent Engineering

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42629 lecture 3 pt3

  1. 1. Integrated Product DevelopmentIPD - Concurrent engineeringThomas J. Howardhttps://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 DevelopmentDepartment of Mechanical Engineering, The Technical University of Denmark”Thanks to Thorkild Ahm, IPU for providing DfA samples
  2. 2. Concurrent Engineering Designing the Product and Production simultaneously Market Product Business Production2 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
  3. 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 improveImportant DFXs:DFE – Design for the EnvironmentDFM – Design for ManufacturabilityDFA – Design for AssemblyDFS – Design for ServiceabilityDFC – Design for ChangeoverDFD – Design for DisassemblyDFQ – 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. 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. 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. 6. Design for Serviceability (DFS)“Don‟t make „em start all over”
  7. 7. DFS improvements... Original Redesign7 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
  8. 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. 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. 10. Design for Manufacture andAssembly (DFMA)“That‟s all well and good but how are we gonna make it?”
  11. 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. 12. Anti-Flair Bracket Assembly for theBoeing 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, RI12 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
  13. 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. 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. 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. 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. 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. 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. 19. DfA – Plastic integration19 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012 Department of Mechanical Engineering, The Technical University of Denmark
  20. 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. 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. 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. 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

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