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Concurrent Engineering
Eng. K.C Wickramasinghe
BSc(Hon’s), AMIESL
Dept. of Mechanical & Manufacturing
Engineering,
Faculty of Engineering,
University of Ruhuna.
Lecture Session 01
01
Production and Operations
Management
“You can’t achieve world class
manufacturing without first
having a world class product
design”
Jack M. Walker
An approach used in product development in which the functions of
design engineering, manufacturing engineering and other functions
are integrated to reduce the elapsed time required to bring a new
product to market.
Concurrent Engineering
02
Development of a product - Traditional
03
Plan
Do
Check
Act(Adjust)
Plan : Plan the product
Do : Produce the product
Check: Check products to
make sure it was
produced in
accordance with
plan
Act : Market the product
Analyze how the
product is received
the marketplace in
terms of quality,
costs, and other
criteria
Traditional vs. Concurrent Engineering
04
Design changes as a function of time
05
Traditional Engineering
Concurrent Engineering
Concurrent Engineering
06
Concurrent engineering is a business strategy which replaces the
traditional product development process with one in which tasks
are done in parallel and there is an early consideration for every
aspect of a product's development process.
This strategy focuses on the optimization and distribution of a
firm's resources in the design and development process to ensure
effective and efficient product development process.
The Concept of Concurrent Engineering
07
The Concept of Concurrent Engineering
The design moves from the designer out to the experts
have the mission to conceptualize the product and optimize it until a consensus agreement is reached on the functionality, product ability, and cost constraints.
The design is then passed back to the designer, who resolves conflicts in the suggested changes, modifies the design, and sends it out again for evaluation.
08
Need for Concurrent Engineering
React to the rapid market change effectively and responsively
– Reduce their time to market
– Adapt changing environments
– Decisions must be made quickly
– Cannot wait time for repeating tasks
– Bringing rapid solutions to product design and development process.
In order to be competitive
– Must alter their product and process development cycle
– Able to complete diverse tasks concurrently
09
Case Study 02
10
Goals of CE
11
Minimize the product life cycle
Decrease production cost-Avoiding component features that are
unnecessarily expensive to produce e.g.. Specification of
surfaces smoother than necessary, wide variations in wall
thickness of an injection-molded component
Maximize production quality
Team work
Combined list of goals for Concurrent
Design
12
From the start, include all domains of expertise as active
participants in the design effort.
Resist making irreversible decisions before they must be made.
Perform continuous optimization of product and process.
Identify product concepts that are inherently easy to manufacture.
Focus on component design for manufacturing and assembly.
Integrate the manufacturing process design and product design
that best match needs and requirements.
13
Combined list of goals for Concurrent Design
Convert concept to manufacturable, salable, usable design by stating
all constraints.
Anticipate fabrication and assembly methods and problems.
Reduce number of parts.
Increase interchangeability between models.
Standardize fastener types and sizes
Identify difficult process steps for which costs and process times
cannot be predicted.
Use existing processes and facilities so that product yield is high.
Adjust tolerances to eliminate failures during assembly.
Combined list of goals for Concurrent Design
14
Identify testable areas.
Make assembly easier by minimizing setups and reorientations.
Carry out design for product ability and usability study
Design fabrication and assembly process.
Design assembly sequence.
Integrate quality control strategy with assembly.
Design each part so that tolerances are compatible with
assembly method and fabrication
Costs are compatible with cost goals.
Product Stages
in CE
15
Important factors in CE
16
Organizational Factors
– Cross functional teams (team composed of experts in engineering,
production, marketing, etc)
– Liaison personnel (fulltime job in coordinating separate functions)
– Job rotation (temporarily or permanently)
Some helpful rule base methods
– Product design methods (DFM, DFA, Design for quality, Design for
Life Cycle, etc)
– Axiomatic Design, Failure Mode and Effect Analysis (FMEA)
– Integrated computer analysis (products are interrelated and can be
modeled effectively using computers)
In addition to facilitate CE..
17
Technologies like rapid prototyping, virtual prototyping and organizational changes are required.
Rapid prototyping- is a new group of
technologies for
converting designs
from computer
representations directly into
solid objects
without human
intervention.
In addition to facilitate CE..
18
Virtual prototyping is a method in the process of product
development. It involves using CAD and computer-aided
engineering (CAE) software to validate a design before committing to
making a physical prototype. This is done by creating (usually 3D)
computer generated geometrical shapes (parts) and either combining
them into an "assembly" and testing different mechanical motions, fit
and function. The assembly or individual parts could be opened in
CAE software to simulate the behavior of the product in the real
world.