Virtual prototyping has the potential to provide benefits but is not widely adopted in industry. This research aims to address this by developing an expanded framework called Intermediate Virtual Prototyping (IVP) that better integrates virtual prototyping into new product development processes. The research uses an industrial case study to investigate how IVP can capture value by challenging existing practices and integrating more stakeholders early in development. The framework is intended to provide both conceptual and practical contributions regarding how virtual prototyping can be implemented to create business value for low volume manufacturing companies.

1. 02/06/2015 1
Virtuaaliprototypoinnin vaikuttavuuden
arvioinnin laajennettu viitekehys
Lähestymistapa virtuaaliympäristöjä hyödyntävään virtuaaliprototypointiin
uustuotekehityksessä matalan volyymin tuotannossa
Reframing the value of virtual prototyping
Intermediary virtual prototyping - the evolving approach of virtual environments
based virtual prototyping in the context of new product development and low
volume production
Thesis for the degree of Doctor of Technology to be presented with
due permission for public examination and criticism in
Konetalo Building, Auditorium K1702, at Tampere University of Technology,
on the 22nd of May 2014 at 12 noon.
Lectio Praecursoria
Simo-Pekka Leino

2. 02/06/2015 2
The thesis is available at:
https://dspace.cc.tut.fi/dpub/handle/123456789/22994
©Simo-Pekka Leino

3. My lecture aims to:
• intorduce the practical industrial context
• define the practical and scientific problems that this research
aims to solve
• explain the high level research process
• summarize the key results and conclusions
I begin the lecture by explaining the key terms and concepts of
the title of my thesis
• The main title referst to the theoretical contribution of the
research
• The subtitle reveals the practical context of the research
©Simo-Pekka Leino

4. Motivation for the research
• In literature virtual prototyping is mainly treated very technically. On the
other hand its benefits are claimed without solid evidence and justification
from the business perspective
• This research does not treat virtual prototyping just as a technology, but
rather its applications as a methodology within product development and
business
• In this research context the therm ”virtual” means opposite to physical, e.g. a
physical prototype
• ”Value” is a key concept of the thesis. It is given a wide meaning; use value /
exchange value, social value, strategic business value, internal and external
customers
• The slides following explain the context more from the perspectives of
products, product development and product lifecycle
©Simo-Pekka Leino

5. 02/06/2015 5
©Simo-Pekka Leino

6. 02/06/2015 6
This slide introduces the industrial context of this research
The photo shows the Metso Minerals factory area in Tampere.
It aims to highlight how my research and this thesis is closely connected with manufacturing
industry and its long tradition in Tampere and in Finland.
Nature of Finnish heavy manufacturing industry
Products are partially configurable often including customization.
Almost every product individual is different.
Manual work (manufacture, assembly, etc.) intensive production.
Low volume variant production, short series; compared e.g. to automotive industry.
This research included case studies within the Metso Minerals product development and
product lifecycle management.
©Simo-Pekka Leino

7. 02/06/2015 7
©Simo-Pekka Leino

8. 02/06/2015 8
Industrial history and continuum
In the same area and partly in same factory buildings operated
Lokomo factory which is the predecessor of Metso Minerals.
The Lokomo factory first manufactured locomotives, then ship
propellers, forest machines, submarines, cannons, etc.
Today, May 22, happens to be the day when Metso Minerals
Tampere factory is celebrating 100 years anniversary.
My research aims to contribute to the future succes of Metso
Minerals and more generally to the Finnish manufacturing
industry.
©Simo-Pekka Leino

9. 02/06/2015 9
©Simo-Pekka Leino

10. 02/06/2015 10
Today’s products of Metso Minerals
The photo shows a typical product of Metso Minerals
Tampere factory today.
The main products are mobile rock crushing and
screening machines for mining and construction
business.
They are large and heavy, complicated products in
which lot of automation and high technology is
packed to small space because they are transferred
on truck trailers in highways.
The machines process large rocks smaller, and assort
them.
Finnish manufacturing industry
Production volumes in heavy manufacturing are
relatively low (10-200/year).
The products are partially configurable often
including engineering to order. In practice almost
every machine individual is different.
This is very different context compared e.g. to
passenger car manufacturing models in literature
©Simo-Pekka Leino

11. 02/06/2015 11
Product functionality perspective
The product may be often seen mainly the
perspective of its functionality – what is does, e.g.
efficient rock crushing.
This is naturally the most important feature of the
product from the customer perspective.
The concept of ”product” means two things:
Product type; product specifications and
descriptions – outcome of engineering design. The
virtual product.
Product individuals; product configurations –
outcome of manufacture. The physical product.
©Simo-Pekka Leino

12. 02/06/2015 12
©Simo-Pekka Leino

13. 02/06/2015 13
Product lifecycle perspective
Besides the product functionality, product delivery time,
product reliability and maintainability are important for the
customer as well.
Additionally, product manufacturability and maintainability
are important capabilities for the product manufacturing
company as well, especially when service business model is
increasingly important.
Produc lifecycle management (PLM)
A business stretegy where the product lifecycle and the
related information, processes, organisation, technologies,
and management are in at the center.
In colloquial language PLM abbreaviation often refers mainly
to the information management systems which manage
product items and documents.
The information management systems enable effective
product lifecycle management and business model. Anyway,
the product processes and procedures are more essential for
the successful business. ©Simo-Pekka Leino

14. 02/06/2015 14
This research proposes how product
development, engineering design and
PLM should be changed in
manufacturing companies, such as
Metso Minerals.
Furthermore, this research proposes how
so called ”virtual environments based
virtual prototyping” can add value to
new product development and product
lifecycle management as part of PLM-
concept.
©Simo-Pekka Leino

15. 02/06/2015 15
Toimittajat
Suunnittelu
Tuotteistus
Huolto
Markkinointi,
tuotehallinta Hankinta
Vakio
tuotanto
Asiakas
konsepti
layout
detalji
VIRTUAALINEN FYYSINEN
©Simo-Pekka Leino

16. 02/06/2015 16
Toimittajat
Suunnittelu
Tuotteistus
Huolto
Markkinointi,
tuotehallinta Hankinta
Vakio
tuotanto
Asiakas
konsepti
layout
detalji
VIRTUAALINEN FYYSINEN
Product development, new product development
The process from an idea to a commercial product.
Is described in literature and e.g. in companies’ quality manuals as process models
such as in the figure.
New product development (NPD) may have different drivers, thus different kind of
NPD exist. e.g:
• New product functions and properties valued by customers, e.g. crushing power
• Legislation and directives, e.g. noise, pollution, emissions, dust (case study)
• Manufacturability, maintainability (case study)
NPD is typically managed as projects with several decision gates, such in the figure.
Product development is a wider concept than engineering design. However these
concepts are often mixed in practice
©Simo-Pekka Leino

17. 02/06/2015 17
Toimittajat
Suunnittelu
Tuotteistus
Huolto
Markkinointi,
tuotehallinta Hankinta
Vakio
tuotanto
Asiakas
konsepti
layout
detalji
VIRTUAALINEN FYYSINEN
Engineering design
The process which produces product specifications and documentation including
manufacturing and assembly specifications, instructions, etc. starting from fuzzy
demands of users, customers, and other stakeholders.
Starts from a product concept which is a rough description about how the demands
are met with the new product.
First intangible and virtual, conventionally becomes physical in prototyping phase, i.e.
building the first machines in order to test and validate certain functions and
properties of the product.
In my research, I emphasize the importance of human and social dimension in design.
It is challenging, because demands, opinions and knowledge about the product
lifecycle are subjective, and difficult to be transformed into explicit design
documentation – the difference between internal and external product properties.
(concepts of engineering design theory of Hubka&Eder).
Therefore, also engineering design should be seen as a wider concept than it is usually
– involving the many product stakeholders.
©Simo-Pekka Leino

18. 02/06/2015 18
Toimittajat
Suunnittelu
Tuotteistus
Huolto
Markkinointi,
tuotehallinta Hankinta
Vakio
tuotanto
Asiakas
konsepti
layout
detalji
VIRTUAALINEN FYYSINEN
Challenges
Product development and engineering design should be seen as
processes where all stakeholders are involved – not just design
engineers.
The NPD should be frontloaded with early feedback from the
stakeholders. This is proposed as a major contribution of virtual
prototyping in this research.
How different stekeholders can be involved in NPD early enough?

19. 02/06/2015 19

20. 02/06/2015 20
Virtual environments (VE) based virtual prototyping (VP)
Engineering design is mainly done in 3D today (see the bottommost picture of a
Lokotrack). However, 3D is utilised mostly in producing 2D manufacturing drawings
Virtual prototype is a 3D-based digital computer model of a product. Aim is to substitute
at least partly a physical machine (prototype) in early NPD phase for analysing certain
product functions and properties from different perspectives, e.g. assembly and
maintainability
VE is an advanced user interface to the virtual prototype computer model.
It is more interactive and immersive (e.g. perspective) than a conventional 3D CAD
However, VE is often seen purely as piece of technology, when the business advantages
remain unclear.
Design review meeting is a typical application for utilising VE based virtual prototyping
during a new product developent. Product properties are analysed, information is shared
between stakeholders (e.g. engineering designers, project managers, product managers,
assembly workers, service workers, occupational health care, etc.
Virtual prototyping is typically combined with design methods such as participatory
design
This research proposes to describe virtual prototyping as a social and
managerial framework

21. 02/06/2015 21
Research motivation
Virtual prototyping paradox: Often claimed advantages
(literature, software providers) versus relatively slow
adoption in industry
Practical research problem: loose concept, unclear
terminology, lack of knowledge about real benefits and
business value
Scientific problem: gap in literature, gap between
concepts of VP and design theory
From technology demonstrations towards real
implementation and utilisation in industry

22. 02/06/2015 22
Toimittajat
Suunnittelu
Tuotteistus
Huolto
Markkinointi,
tuotehallinta Hankinta
Vakio
tuotanto
Asiakas
konsepti
layout
detalji
NYKYHETKI
Virtual Prototyping
VIRTUAALINEN VIRTUAALINEN
©Simo-Pekka Leino

23. 02/06/2015 23
Toimittajat
Suunnittelu
Tuotteistus
Huolto
Markkinointi,
tuotehallinta Hankinta
Vakio
tuotanto
Asiakas
konsepti
layout
detalji
NYKYHETKI
Virtual Prototyping
VIRTUAALINEN VIRTUAALINEN
VE based virtual prototyping integrates many stakeholders, processes and perspectives in early NPD
phase before building a physical prototype. For instance, in the phase of new product preparation for
production, the perspectives of suppliers, sourcing, standard production, service and end customers can
be assessed simultaneously with the virtual product model.
Engineering designers produce virtual product models, which other stakeholders can analyse.
The required engineering changes can be made before building a physical prototype.
However, there is a common problem where this research aims to contribute to solve.
Today virtual prototyping is not integrated in the NPD process.
This research aims to show whether virtual prototyping creates value to NPD and business.
On the other hand, this research reveals what kind of changes should be done to processes, oransisation,
management, leadership and technology in order to capture the potential value of virtual prototyping –
how the VP could be integrated.
©Simo-Pekka Leino

24. 02/06/2015 24
Reframing the value of virtual prototyping
IVP - the evolving approach of virtual environments based virtual prototyping in the context of new product development and low volume production
LUO LISÄARVOA
HAASTAA
ihmiset
tekniikka prosessit
ihmiset
tekniikka prosessit
LIIKETOIMINTA
 Expanded theory frame –
conceptual innovation IVP
 Integrates virtual prototyping within
design theory and product
development
 Knowledge about practical benefits
and impacts of virtual prototyping
 IVP as a wide concept that integrates
the stakeholders of manufacturing
companies
 New perspective to the societal
discussion about digitalisation,
Finnish competitivity, and change of
work
 Initiates a new design research
orientation
 Laajennettu teoriakehys -
käsiteinnovaatio IVP
 Kytkee virtuaaliprototypoinnin
suunnitteluteoriaan ja käytännön
tuotekehityksen prosessiin
 Tietoa IVP:n käytännön hyödyistä
ja vaikutuksista
 IVP teknistä välinettä laajempana
metodina ja investointina, joka
integroi yrityksen toimintaa
 Uutta näkökulmaa yhteiskunnassa
käytävään keskusteluun
digitalisaatiosta, Suomen
kilpailukyvystä ja työn
muuttumisesta
 Avaa uutta tutkimussuuntaa
suunnittelututkimukseen
 Teollinen laadullinen tapaustutkimus
 Poikkitieteellinen
 Abduktiivinen ja konstruktiivinen
 Inhimillisen näkökulman
korostaminen
 Industrial qualitative case study
 Multi-disciplinary
 Abductive and constructive
 Emphasis of social factors
IVP
IVP
©Simo-Pekka Leino