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Production and Operations

Management

Production and Operations Management Concurrent Engineering Lecture Session 01 “ You can’t achieve world class manufacturing

Concurrent Engineering

Lecture Session 01

You can’t achieve world class manufacturing without first

having a world class product

design”

Jack M. Walker

Eng. K.C Wickramasinghe

Production and Operations Management Concurrent Engineering Lecture Session 01 “ You can’t achieve world class manufacturing

BSc(Hon’s), AMIESL

Dept. of Mechanical & Manufacturing Engineering,

Faculty of Engineering,

University of Ruhuna.

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Concurrent Engineering

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 An approach used in product development in which the functions of design engineering, manufacturing

Development of a product - Traditional

Plan

: Plan the product

Do

: Produce the product

Check: Check products to make sure it was

Act

produced in accordance with plan : Market the product Analyze how the

product is received the marketplace in

terms of quality,

costs, and other criteria

Development of a product - Traditional Plan : Plan the product Do : Produce the product

Plan

Act(Adjust)

Development of a product - Traditional Plan : Plan the product Do : Produce the product

Check

Development of a product - Traditional Plan : Plan the product Do : Produce the product

Do

Development of a product - Traditional Plan : Plan the product Do : Produce the product

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Traditional vs. Concurrent Engineering

Traditional vs. Concurrent Engineering Design changes as a function of time 04

Design changes as a function of time

Traditional Engineering

Concurrent Engineering

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Concurrent Engineering

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

The Concept of Concurrent Engineering 07

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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.

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

Case Study 02

Case Study 02 10

Goals of CE

  • 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

  • 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.

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

  • 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

Important factors in CE

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 ..

Technologies like rapid prototyping, virtual prototyping and organizational

changes are required.

Rapid prototyping- is a new group of technologies for

In addition to facilitate CE .. Technologies like rapid prototyping, virtual prototyping and organizational changes are

converting designs

from computer

representations

directly into

solid objects without human intervention.

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In addition to facilitate CE ..

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.