2. Developing product design and process
design simultaneously
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.
3. “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 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.
5. Basic Goals of Concurrent Engineering are:-
-Dramatic improvements in time to
market and costs
-Improvements to product quality and
performance
-Do more with less
6. Concurrent Engineering = Teamwork
-The more communication exists, the
better the product.
Balances Needs
-Customer, Supplier, Engineers,
Marketing, and Manufacturing needs.
7. 3 Main Areas needed to implement Concurrent
Engineering
1) People
2) Process
3) Technology
• Area 1: People
-Formation of teams
-Training
8. Area 2: Process
-Changes in your processes
-Be open to change
Area 3: Technology
-CAD/CAM
-Software. Hardware, and Networking
9. Basic Summary
-Most important aspect is People
-Process and Technology: Don’t be
afraid of change
10. Titan Linkbit
-Old CAD system: 21 weeks to develop
8-layer circuit board.
-Implemented new Computer-aided
engineering (CAE) tools and CE
-New circuit board: 12 weeks to develop, 10
layers, twice the functionality of the 8 layer.
11. Reduces time from design concept by 25% or
more.
Reduces Capital investment by 20% or more.
Continuous improvement of product quality.
Increases Product Life Cycle Profitability.
12. Concurrent Engineering: Simultaneous
development of product and process.
Most important aspect is communication and
formation of teams
Management support is vitally important
Don’t be afraid to change current processes
and technologies
14. Material Requirements Planning Defined
Materials requirements planning (MRP) is a
computerized inventory planning and control system
for determining when (no earlier and no later) and how
many of each of the parts, components, and materials
should be ordered or produced.
It translates master schedule requirements for end
items into time-phased requirements for
subassemblies, components and raw materials.
Dependent demand drives MRP
MRP is a software system
15. When to Use MRP
Dependent and discrete items
Complex products
Job shop production
Assemble-to-order environments
16. Material Requirements Planning System
Based on a master production schedule, a material
requirements planning system:
Creates schedules identifying the specific parts
and materials required to produce end items
Determines exact unit numbers needed
Determines the dates when orders for those
materials should be released, based on lead
times
18. MRP Inputs MRP Processing MRP Outputs
Master
schedule
Bill of
materials
Inventory
records
MRP computer
programs
Changes
Order releases
Planned-order
schedules
Exception reports
Planning reports
Performance-
control
reports
Inventory
transaction
Primary
reports
Secondary
reports
MRP System
19. MRP Inputs 1:
Master Production Schedule
Drives MRP process with a schedule of finished products;
states which end items are to be produced, when these
are needed, and in what quantities
Quantities may consist of a combination of customer
orders & demand forecasts
Quantities represent what needs to be produced, not what
can be produced
20. Master Production Schedule (MPS)
Time-phased plan specifying how many and when the
firm plans to build each end item
Aggregate Plan
(Product Groups)
MPS
(Specific End Items)
21. Master Production Schedule
Item / Week Oct 3 Oct. 10 Oct. 17 Oct.24 Oct. 31
Clipboard 85 95 120 100 100
Lapdesk 0 50 0 50 0
Lapboard 75 120 47 20 17
Pencil Case 125 125 125 125 125
Shows items to be produced
Derived from aggregate plan
Example:
22. MRP Inputs 2: Bill-of-Materials
Bill of materials (BOM): One of the three primary inputs of
MRP; a listing of all of the raw materials, parts,
subassemblies, and assemblies needed to produce one
unit of a product.
Product structure tree: Visual depiction of the requirements
in a bill of materials, where all components are listed by
levels.
23. Product Structure Tree: Example 1
Chair
Seat
Legs (2)
Cross
bar
Side
Rails (2)
Cross
bar
Back
Supports (3)
Leg
Assembly
Back
Assembly
Level
0
1
2
3
25. Product Drawing: Example 3
Top clip (1) Bottom clip (1)
Pivot (1) Spring (1)
Rivets (2)
Finished clipboard Pressboard (1)
Clipboard
26. Product Structure Tree ( Example 3)
Clipboard Level 0
Level 1
Level 2
Spring
(1)
Bottom Clip (1)
Top Clip
(1)
Pivot
(1)
Rivets
(2)
Clip Ass’y
(1)
Pressboard
(1)
27. MRP Inputs 3: Inventory Records File
One of the three primary inputs of MRP
Includes information on the inventory status of
each item by time period
Gross requirements
Scheduled receipts
Amount on hand
Lead times
Lot sizes
And more....
28. Basic MRP Processes
1. Exploding the bill of material
2. Netting out inventory
3. Lot sizing
4. Time-phasing requirements
29. Reduced inventories without reduced customer
service
Ability to track material requirements
Ability to evaluate capacity requirements
Means of allocating production time
Increased customer satisfaction due to meeting
delivery schedules
Faster response to market changes
Improved labor and equipment utilization.
Better inventory planning and scheduling
30. Requirements of MRP
Computer system and necessary software
Mainly discrete products
Stable lead times
Accurate and up-to-date
Master schedules
Bills of materials
Inventory status records
Integrity of data
31. Expanded MRP with emphasis placed on integration of:
Financial planning
Marketing
Engineering
Purchasing
Manufacturing
Human resources
Manufacturing Resources Planning- MRP II
32. Manufacturing Resources Planning
(MRP II)
Goal: Plan and monitor all resources of a
manufacturing firm (closed loop):
manufacturing
marketing
finance
engineering
Simulate the manufacturing system
33. Historical Perspective
Mrp 1 – material
requirements
planning
MRP II – Manufacturing
Resource Planning
ERP- Enterprise
Resource Planning
34. Definition:
It is the basis of Enterprise Resource
Planning (ERP).MRP 2 and ERP are connected
with manufacturing aspects of the expanded
model.
35. MRP II -- Manufacturing Resource
Planning
• “A method for the effective planning of all resources
of a manufacturing company” (APICS def.)
– Financial accounting incorporated
– Sales
– Operations Planning
– Simulate capacity requirements of different possible
Master Production Schedules
37. Rapid Prototyping
Rapid prototyping technologies are able to produce
physical model in a layer by layer manner directly from their
CAD models without any tools, dies and fixtures and also
with little human intervention.
RP is capable to fabricate parts quickly with too complex
shape easily as compared to traditional manufacturing
technology.
RP helps in earlier detection and reduction of design errors.
38. All RP techniques employ the basic five-step process.
1. Create a CAD model of the design
2. Convert the CAD model to STL format (stereolithography)
3. Slice the STL file into thin cross-sectional layers
4. Construct the model one layer atop another
5. Clean and finish the model
Rapid Prototyping Systems
39. • CAD Model Creation:
– First, the object to be built is modeled using a Computer-Aided
Design (CAD) software package.
– Solid modelers, such as Pro/ENGINEER, tend to represent 3-D
objects more accurately than wire-frame modelers such as
AutoCAD, and will therefore yield better results.
– This process is identical for all of the RP build techniques.
Rapid Prototyping Systems
42. Application Range
◦ Visual Representation models
◦ Functional and tough prototypes
◦ cast metal parts
Advantages
◦ Flexibility of materials used
PVC, Nylon, Sand for building sand casting cores, metal and
investment casting wax.
◦ No need to create a structure to support the part
◦ Parts do not require any post curing except when ceramic is used.
Disadvantages
◦ During solidification, additional powder may be hardened at the
border line.
◦ The roughness is most visible when parts contain sloping (stepped)
surfaces.
Rapid prototyping Processes- SLS
43. PT CAM uses a stereolithography
machine produced by 3-D Systems
and shown here:
The Stereolithography Machine
44. • Stereolithography
• Patented in 1986, stereolithography started the
rapid prototyping revolution. The technique
builds three-dimensional models from liquid
photosensitive polymers that solidify when
exposed to ultraviolet light.
Rapid Prototyping Systems
46. • (FDM) is a solid-based rapid prototyping method that extrudes
material, layer-by-layer, to build a model.
• A thread of plastic is fed into an extrusion head, where it is
heated into a semi-liquid state and extruded through a very small
hole onto the previous layer of material.
• Support material is also laid down in a similar manner.
Fused Deposition Modeling
47. • Easy fabrication
• Minimal wastage
• Ease of removal
• Easy handling
Advantages of FDM Process
48. • Designing
• Engineering analysis and planning
• Tooling and manufacturing
Application of FDM process
49. Fused Deposition Modeling
FDM 2000 Specifications Prodigy Specifications
•Build Volume: 10" x 10" x 10"
•Materials:ABS, Casting Wax
•Build Step Size: 0.005" to
0.030"
Build Volume: 8" x 8" x 10"
Materials: ABS, Casting Wax
Build Step Size: 0.007", 0.010",
0.013"
Up to 4x faster than the FDM 2000
50. • As the name implies the process laminates
thin sheets of film (paper or plastic)
• The laser has only to cut/scan the periphery of
each layer
Laminated Object Manufacture
51. • The process:
– The build material (paper with a thermo-setting resin glue on
its under side) is stretched from a supply roller across an anvil
or platform to a take- up roller on the other side.
– A heated roller passes over the paper bonding it to the
platform or previous layer.
– A laser, focused to penetrate through one thickness of paper
cuts the profile of that layer. The excess paper around and
inside the model is etched into small squares to facilitate its
removal.
Laminated Object Manufacture
52. • The process continued:
– The process of gluing and cutting continuous layer by layer
until the model is complete.
– To reduce the build time, double or even triple layers are
cut at one time which increases the size of the steps on
curved surfaces and the post processing necessary to
smooth those surfaces.
Laminated Object Manufacture
53. • Wide range of materials
• Fast Build time
• High accuracy
Advantages of LOM Process
54. • Applications of LOM objects:
– LOM objects are durable, multilayered structures which can
be machined, sanded, polished, coated and painted.
– Used as precise patterns for secondary tooling processes such
as rubber moulding, sand casting and direct investment
casting.
– Medical sector for making instruments.
Laminated Object Manufacture
