MODULE DESIGN BASED ON INTERFACE INTEGRATION TO MAXIMIZE PRODUCT VARIETY AND MINIMIZE FAMILY COST

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1 INTERNATIONAL CONFERENCE ON ENGINEERING DESIGN, ICED AUGUST 2007, CITE DES SCIENCES ET DE L'INDUSTRIE, PARIS, FRANCE MODULE DESIGN BASED ON INTERFACE INTEGRATION TO MAIMIZE PRODUCT VARIETY AND MINIMIZE FAMILY COST Tsuyosh Koga and Kazuhro Aoyama Department of Envronmental and Ocean Engneerng, The Unversty of Tokyo ABSTRACT Ths paper proposes a desgn method for platform modules by consderng the varety of the product famly and the desgn and producton cost. Computatonal and graphcal models of the product famly archtecture are proposed as the summaton of all lne-up products. Based on the product famly model, the desgn problem of nterface ntegraton s formalzed as the generaton of a varety of products. The platform module desgn s represented as the generalzed module archtecture desgn that s commonly used n all products n the product famly. A decson makng system s developed consderng the value of the product famly, varety of lne-up products, cost reducton effect of the platform modules, and cost of desgn change. The proposed desgn method addresses: (1) how to computatonally formalze the product famly and platform modules; (2) how to evaluate the dffculty of desgn change, advantages and cost of the platform module, and the varety of the lne-up; and (3) how to desgn the platform module consderng the product famly strategy. Keywords: Platformzaton, common archtecture, product famly model, module, cut-set matrx 1 INTRODUCTION 1.1 Background Varous products are requred to satsfy varous customer needs n nche market and manstream markets. It s dffcult to acheve a good balance between product varety and cost, snce manufacturng a varety of products necesstates desgn and producton costs. Modularzaton and platformzaton consderng a product famly contrbutes to mprovements n both varety and cost. The use of common modules and platforms n a product famly reduces desgn and producton cost. An nterface ntegraton generates the product varety, because generalzed nterface creates new combnaton of modules. For example, the vehcle platform strategy s one of the mportant strateges for motor companes, snce t determnes the characterstc and a proft rato of the company. The producton and mantenance of press des for the body and chasss s expensve. The use of a common platform for producng both the body and chasss reduces the number of press des requred. Presently, the cost competton s so ntensve that manufacturers that have several dozens of products actually use only a few platforms n ther lneups. Therefore, the approprate desgn of platforms s hghly desred. Ths study defnes a module and a platform module as follows: Module: A group of components ntegrated from a certan vewpont. Platform module: A group of modules commonly used n a product famly. Platform desgn s one of the mportant decsons, because t determnes the common archtecture of products n the product famly. Not only the varety and cost of products but also the evoluton of technology and the organzatonal archtecture are sgnfcantly dependent on the common archtecture. Organzatons am to maxmze ther profts and the value of the product famly, as well as to acheve an effcent dvson of labour by desgnng an approprate common structure by the platform desgn. Determnng the approprate platform s very dffcult because the platform module s sgnfcantly dependent on the topologcal structure of the products n the product famly. Computatonal desgn support contrbutes to the logcal platform desgn. Hence, ths study proposes a desgn method that enables the desgner to desgn the platform modules by consderng the varety and cost of products ICED 07/372 1

2 based on the computatonal representaton model of the products n the product famly, modules and product structure. 1.2 Recent Works on Product Famly Desgn Presently, several methodologes have been developed for desgnng product famles and platform modules. Neson proposed the multcrtera optmzaton method for the product platform, ths method amed to realze benefts through reducton of nventory, prolferaton of dfferent parts, and desgn lead-n tme for a product [1]. For the purpose of the topologcal archtecture desgn, t s necessary to ntroduce a product and platform model that can represent the product structure. Smpson developed an nteractve web-based platform customzaton framework as an extenson for the product famly desgn and presented a prototype system [2]. Our study attempts to propose the meta-model of platforms and product famly based on ther framework. Raghothama proposed a topologcal framework for a parts famly [3]. They addressed the ssues of how to generate members of a parts famly and determne whch parts famly a gven object belongs to. Ther method s effectvely used n the detaled desgn stage, and ts applcaton to the early and strategc desgn stages s desred. The desgn method for the combnatons and attrbutes of modules by usng the optmzaton method s proposed by Fujta, Akund et al. [4] [5]. Ths study manly focuses on the desgn of the topologcal structure of the platform through the products based on ther attrbute optmzatons. Shddque presented a reasonng method for the product famly archtecture by consderng the product famly archtecture and manufacturng process [6]. Based on ther defnton of a product module model, representaton of product optons, and producton process model, we propose a product famly model to dscuss the nterface ntegraton and parts generalzaton. Jonathan proposed the evoluton model of products n the product famly [7]. Ths study represents Jonathon s product famly evoluton model as a result of desgner-based computaton and vrtual tral and error steps based on the proposton of the product famly and platform model. 1.3 Purpose of ths research The reducton n cost and ncrease n product varety are both necessary to ncrease the value of the product famly. To explan the ncrease n the value, ths study proposes a model of product varety ncrease based on the nterface ntegraton. Ths study formalzes the desgn of the platform modules by takng nto consderaton the product famly based on the common archtecture model and nterface ntegraton. Furthermore, we propose a formalzaton-based platform desgn method for ncreasng and maxmzng the value of the entre product famly. In order to mantan a good balance between varety and cost, t s necessary to estmate and consder (1) devsng optons by unfyng the parts and nterfaces, and (2) reducng the desgn and producton costs by usng the common platform modules. The desgn of the platform module s one of the chance dscovery ssues by defnng many constrants and searchng vast space of solutons. Hence, a system desgn method that models all the desgn objects and constrants [A] as one system and estmates varous factors [B] s requred for the development of an approprate platform module desgn. [A] Desgn objects and platformzaton constrants Product structure, common archtecture, unfed parts, unfed nterfaces, optons, unfed modules, and platforms [B] Factors contrbutng to the value of the product famly Varety of products, desgn change cost, and reducton n producton cost The exstng methodologes proposed n earler studes are ncomplete. There exsts no platform desgn method that can consder all the objects and factors gven n [A] and [B]. Generally, the common archtecture that sgnfcantly depends on the product structure has a longer lfespan than a sngle product. The product famly evoluton must be consdered at the platform desgn stage. Hence, the purpose of ths research s stated as follows: Research purpose: To propose a platformzaton method that can support the desgn of approprate platform modules based on the tral and error of the objects and constrants [A] by usng the evaluaton results of the product famly factors [B], takng nto consderaton the product famly evoluton Based on the Sddque s product opton model and producton model [6], ths study proposes the opton generaton model by addng the unfcaton model for parts and nterfaces. An assemblng ICED 07/372 2

3 process calculaton method usng a cut-set of the product representaton graph proposed by Mantrpragada s expanded as the method for calculatng the unfcaton and the platformzaton processes [8]. Ths study expands the proposed systematc modularzaton method by employng mult-stage decomposton proposed by the authors [9] from the early desgn stage to the detaled desgn stage. 2 PLATFORM DESIGN METHOD 2.1 Product Famly Model The product famly conssts of lne-up products. The product famly model that represents both of the product structures and the relatonshps between the products s requred for desgnng the platform module. The product famly model used n ths study s shown n Fgure 1. A sngle product s modelled from the entty model, attrbutes, and ther relatonshps. Ths product comprses components, parts and sub-systems. These are represented by the entty E. Ths entty s represented by the attrbutes A, e.g., ts shape, materal, and cost. A sngle product comprses a set of enttes. The structural connectons between these enttes are represented as the lnk F between them. The sngle product model s represented as a graph whose nodes and lnks represent enttes and structural connectons respectvely. There exst strong relatonshps between the products n the product famly. The exstence of these relatonshps mples that the commonly used parts and nterfaces can potentally be unfed. In order to descrbe the possblty of unfyng the parts and nterfaces, a unfcaton lnk U s ntroduced n the product famly model. The unfcaton lnk connects the enttes of dfferent products and represents the possblty of the ntegraton of the enttes at both ends. The ntegraton cost of the enttes s descrbed at the unfcaton lnk. A functonal module that s commonly used across the dfferent products n the product famly s defned as a platform module P. P s represented as a subgraph of the product famly model that comprses the enttes and connecton lnks. The entre product famly s represented as the summaton of the graphs of the products on a common archtecture element C. The common archtecture comprses the common archtecture element c, and represents the common structure of the products n the product famly. The entty represents the product element that s not ncluded wthn the common archtecture element. Product Famly Graph G c 1 c 2 famy e1 1 u 1 f 1 f 3 e 2 nl e 1 2 f 2 e 2 1 p 1 Defntons of Symbols Common Archtecture Element C Entty E Attrbute A Connecton lnk F Unfcaton Lnk U Platform Module P exst { f } F { c } C { e j, e nl} E { } U u { p } P Fgure 1. Product Famly Model 2.2 Formulaton of Product Famly Model Based on the defnton of the product famly model n Fgure 1, a formulaton of the product famly s proposed as a seres of formulas (1)-(6). The product famly graph G famly comprses the product graphs G product, and s represented n terms of C, E, A, P, F, and U as follows: famy product ( 1 product2 product G G, G,, G n ) = { C, E, A, P; F, U} (1) C comprses the enttes that belong to dfferent products. Each entty must belong to one common archtecture element: { n c = e 1, e 2,, e n }, E = E (2) = 1 All connecton lnks are defned between enttes that belong to dfferent common archtecture element: j F E E, j (3) The unfcaton lnk must be defned between enttes that belong to the same common archtecture element: ICED 07/372 3

4 U E E (4) The entty contans the connecton lnks, unfcaton lnks and attrbutes: e j = { F j, U j, A j} F j F, U j U, A j A (5) A platform s defned as the set of enttes that belongs to the dfferent common archtecture elements: p { e s e t e u = l, m,, n}, s t u (6) The product famly s formulated from the graph representaton n Fgure 1 and the nformaton structure and relatonshps shown n the formulas (1) - (6). 2.3 Formulaton of Interface Integraton and Parts Unfcaton Ths secton formulates the operatons of the nterface ntegraton and parts unfcaton. Ths study defnes the nterface as a component between parts or modules, and descrbes both the part and nterface as an entty. Hence, both nterface ntegraton and parts unfcaton are represented by the ntegraton of enttes. The unfed enttes must belong to dfferent lne-up products and same common archtecture element. The unfcaton operaton requres a unfcaton lnk to be present between the enttes to be ntegrated. The new entty that s generated by the ntegraton nherts the connecton lnks, the unfcaton lnks, and attrbutes that the ntegrated enttes possess by the and nhertance rule. The operaton of the parts and nterfaces unfcaton s formulated as gven n (7): s t For every two enttes e and e j that belong to the same common archtecture ( s = t ) and that have a unfcaton lnk between them ( s t s, U U j φ ), there exsts a unfcaton operaton h t, j s that generates the unfed entty e, j : s, h t, j : ( e s, e t j ) a e s, j where: s s t t F e, F j e j, F s F t j = F s, j e s, j (7) The operaton of the platform module desgn (referred to as platformzaton) s represented by the combnatons of the operaton of the nterface ntegraton and parts unfcaton. 2.5 Overvew of Platform Module Desgn Method An overvew of the platform desgn for the varety and cost of the product famly s shown n Fgure 2. Detaled procedures of ths method are descrbed n secton 3 through a case study, and a support prototype s ntroduced n secton 4. The man flowchart conssts of the followng steps: nput the current products <A>, the common archtecture desgn and the generaton of a product famly model <B>, nterface ntegraton and parts unfcaton <C>, platform module desgn <D>, evaluaton of the lne-up <E>, and an evaluaton of the product famly <F>. The desgn and evaluaton steps <A> to <F> are performed teratvely; ths mples that the evoluton spral of the product famly s desgned based on the computatonal models of the product famly and the platform modules. The detaled nformaton regardng each procedure s provded below: Desgn step <A> Input current products The desgner nputs the current products based on the exstng lne-up or the result of the teratve desgn loop. The enttes, attrbutes, and connectons of each product are fed as nputs to the computer. Based on the current products, the varety, costs, and proft rato of the current product famly are estmated. Fgure 2 <A> shows examples: sedan, van and compact. Desgn step <B> Product famly model calculaton The desgner ntroduces the common archtecture based on the summatons of the current product graphs. The product famly model s generated based on ths common archtecture by the detecton and defnton of the unfcaton lnks or the connecton lnks. Desgn step <C> Parts and nterfaces unfcaton The desgn system automatcally calculates the entre space of the unfcaton plans of the parts and nterfaces as a unfcaton tree. The desgner selects the unfcaton plan and the unfcaton scenaro. Furthermore, the ntegrated parts and nterfaces are desgned. Desgn step <D> Platform module desgn The desgn system automatcally calculates the entre space of the platformzaton plans as a platformzaton tree. The desgner selects the platformzaton plan. The platform modules are desgned by selectng the platformzaton plan. Desgn step <E> Lne-up Evaluaton The desgn system automatcally calculates the lne-up products, and the sharng rato of the platform modules. Fgure 2 <E> shows that the lne-ups of Famly Plan A and B comprses eght ICED 07/372 4

5 and three products, respectvely. The platform module A-1 that desgned n step <D> s commonly used n four products n the lne-up, therefore the sharng rato of module A-1 s 50%. Smlarly, the sharng rato of A-2, B-1, and B-2 s 50%, 66%, and 33%, respectvely. <E>Lneup Evaluaton Famly Plan A <A> Input Current Products Varety Product 1 (Sedan) <B> Product Famly Model Calculaton Current Products Platform A-2 Sharng Rato 50% Product 2 (Ban) Proft Rato 5% Product 3 (Compact) <D> Platform Module Desgn Platformzaton Tree Common Archtecture Product Famly Model Platform A-1 Sharng Rato 50% 66% Platform B-1 Famly Plan B A-1 A-2 Famly Plan A B-2 B-1 Famly Plan B <C> Parts and Interfaces Unfcaton Root Famly Plan Unfcaton Entty Tree Integraton Platform B-2 33% Product Famly Evoluton Spral Famly Plan A Famly Plan B Famly Plan A (Varety focused Strategy) Lneup (8 Products) Varety Proft Rato 20% Cost Varety <F> Product Famly Evaluaton Varety of Product Famly Value Constant Lne Cost of Product Famly Famly Plan B (Cost focused Strategy) Lneup (3 Products) Varety Proft Rato 8% Cost Varety Fgure 2. Overvew of the Platformzaton Method Desgn step <F> Product famly evaluaton In ths step, the product famly plans are evaluated and compared based on the desgn system, and selected by the desgner. The desgned unfed parts and nterfaces, and platform modules n the product famly plan determne the feasble products n the lne-up and the desgn change, and producton costs. Based on the evaluaton result of the feasble products, the varety of product famly s calculated. The ntegraton costs and the number of modules determne the desgn and producton costs. The graph n Fgure 2 <F> shows the value of the product famly plans. The ponts n the graph represent product famly plans ndvdually. The vertcal axs represents the evaluaton results of the product famly varety. The horzontal axs represents the total cost of the product famly, whch s calculated by addng the summaton of the desgn change cost and the reducton n the producton cost. The plans of upper area of the value constant lne have a hgher value than the current product famly plan. The proposed platform desgn method enables the desgner to compare and select the famly plan more approprately based on the strategy of the product famly. ICED 07/372 5

6 3 INFORMATION PROCESSING PROCEDURES Ths secton ntroduces nformaton processng procedures for the platform module desgn based on the example of the car platform desgn. 3.1 Generaton of Product Famly Model The product famly model comprses of the lne-up products. Fgure 3 shows the nformaton processng procedures for the generaton of the product famly model, these procedures accept three current products as nput and output the product famly graph. The detaled procedures are as follows: [1] Current Products Product 1 (Sedan) Product 2 (Ban) Product 3 (Compact) Underbody Underbody Underbody Chasss for Gasolne Sedan Chasss for Desel Ban Chasss for Compact Compact A2 Engne Engne Engne Trunk Gasolne Engne Desel Engne Hatch L Gasolne Engne Hatch S [1] Current Products A2 Product 1 Product 2 Product 3 [2] Common Archtecture Underbody Chasss for Gasolne a 3 a 1 Chasss a for Desel 2 A2 [4] Product Famly Model Sedan b Chasss 3 for Compact b 1 Ban b2 Compact [3] Relatonshps across products A2 Engne Trunk [4] Product Famly Model A2 Desel Engne Gasolne Engne d 1 Hatch L d 2 d 3 Hatch S Fgure 3. Generaton of Product Famly Model STEP [1] Input current product Based on three types of current products (Product 1, Product 2, and Product 3), the desgner nputs three product graphs n the desgn system (Product1: -, Product2: A2---, and Product3: ---). STEP [2] Set common archtecture The desgner ntroduces the common archtecture that compromses, Underbody, Engne and. The desgn system calculates one graph by ntegratng the product graphs. ICED 07/372 6

7 STEP [3] Add relatonshps across products The desgner adds the relatonshps across products. The desgner evaluates the possblty of the unfcaton of enttes n same common archtecture element and defnes the unfcaton lnks, e.g. the unfcaton lnks between -, -A2, and A2-. The addtonal connecton lnks are defned between enttes that can connect wthout desgn changes, e.g., the connecton lnk between and. STEP [4] Generate product famly The product famly model s generated as the ntegratons of three product graphs, nne unfcaton lnks and one connecton lnk. 3.2 Unfcaton of Parts and Interfaces The unfcaton operaton s performed by applyng formula (7) to the product famly model shown n Fgure 3. Fgure 4 shows an example of the unfcaton operaton. Two bodes and are ntegrated by the unfcaton operaton. The new ntegrated body nherts the connecton and unfcaton lnks. The nformaton processng procedure s descrbed n detal: STEP [1]: Integraton of the enttes The new ntegrated body 2 s generated by the unfcaton of enttes and. STEP [2]: Inhertance of the connecton lnks 2 nherts three connecton lnks from (-, -, and -) and three connecton lnks from (-, -, and -). Hence, sx connecton lnks are defned n 2. STEP [3]: Inhertance of the unfcaton lnks 2 nherts two unfcaton lnks from (b 1 and b 3 ) and two unfcaton lnks from (b 1 and b 3 ). Hence, one unfcaton lnk b 23 s defned n 2. The nherted connecton and unfcaton lnks ndcate the specfcatons of the new ntegrated entty. Underbody Underbody a 3 a 1 a 2 A2 Engne b 1 b 2 b 3 d 3 Unfcaton a 3 a 1 a 2 A2 Engne [2] [1] [3] 2 b23 d 3 d 1 d 2 d 1 d 2 2 Fgure 4. Unfcaton 3.3 Unfcaton Tree The determnaton of the unfcaton plan s a very dffcult desgn problem snce there exsts a huge number of canddates. The proposed desgn method automatcally calculates the space of the unfcaton plans by the unfcaton lnks. Fgure 5 shows the unfcaton tree that ncludes all the unfcaton plans and unfcaton scenaros. The unfcaton tree s defned as a graph whose node s one unfcaton plan (a unfcaton plan node) and ts sequence of unfcaton operatons. The unfcaton tree can be generated from the cut-set of the unfcaton lnks n the product famly graph. The unfcaton plan node s defned as the matrx of the unfcaton lnks. The product famly model shown n Fgure 3 has nne unfcaton lnks (d 1, d 2, d 3, b 1, b 2, b 3, a 1, a 2, and a 3 ), therefore one unfcaton plan node s represented by the nne cells n the matrx. A cell n the matrx represents a unfcaton lnk. A black cell represents that the unfcaton lnk s unfed. A lnk between unfcaton plans represents a unfcaton operaton. The desgner can desgn a unfcaton plan by selectng a unfcaton plan node and a unfcaton scenaro by selectng a path from the root node to the unfcaton plan node. Fgure 5 shows the desgn of the unfcaton plan by selectng two plans - ICED 07/372 7

8 Famly Plan A and Famly Plan B - and the unfcaton scenaro by selectng the paths: root-f1a-f1b- F1c and root-f2a-f2b-f2c. [F1a] [F1c] [ROOT] [F2a] [F1b] [F2b] [F2c] d 1 d 3 d 2 a 1 a 2 a 3 Famly Plan A [F2d] Famly Plan B Fgure 5. Unfcaton Tree 3.4 Unfcaton Process of Famly Plan A Based on the selected unfcaton scenaro, the parts and nterfaces are ntegrated. The unfcaton process changes the product famly varety. Fgure 6 shows the unfcaton scenaro of Famly Plan A shown n Fgure 5. The nformaton processng procedure s descrbed n detal as follows: STEP [1]: Integraton based on the unfcaton lnk b 1 The unfed entty 2 s desgned by the ntegraton of enttes and, based on the unfcaton lnk b 1. Ths ntegraton ncreases the number of products (sx products). STEP [2]: Integraton based on the unfcaton lnk a 1 The unfed entty 2 s desgned by the ntegraton of enttes and A2, based on the unfcaton lnk a 1. Ths ntegraton does not ncrease the number of products. STEP [3]: Integraton based on the unfcaton lnk a 2 a 3 The unfed entty 23 s desgned by the ntegraton of enttes 2 and, based on the unfcaton lnk a 2 a 3. Ths ntegraton ncreases the number of products (eght products). 3.5 Unfcaton Process of Famly Plan B As n the case of Famly Plan A, the result of the unfcaton scenaro of the Product Famly B s shown n Fgure 7. The number of products ncreases and decreases (fve, three, three, and two products), by the ntegraton based on the unfcaton lnks (b 3, a 3, d 2, and d 1 d 3 ). [ROOT] b 1 [F1a] Sedan Ban 2 6 products L-class a 1 [F1b] Chasss for Chasss for Gasolne A2 Desel 2 6 products Chasss for L-class a 2 a 3 Chasss for Chasss for 2 Compact L-class 23 Unversal Chasss [F1c] 8 products Famly Plan A Fgure 6. Unfcaton Process (Famly Plan A) ICED 07/372 8

9 3.6 Platformzaton The desgner desgns the [ROOT] platform module by the modularzaton of the enttes that are commonly used n the b 3 Sedan Compact Unversal 3 product famly. The module comprses enttes that belong [F2a] 5 products to dfferent element n common archtecture. Fgure Chasss for Chasss for Unversal Gasolne Compact Chasss 8 shows the platformzaton a 3 3 result of Famly Plans A and B (Fgure 8 [3]) by selectng a platformzaton plan n the [F2b] 3 products Hatch L Hatch S Hatch automatcally calculated result d of the platformzaton tree 2 3 (Fgure 8 [2]) based on the [F2c] 3 products structure of the common archtecture (Fgure 8 [1]). Famly Plan B Hatch Trunk Compartment The nformaton processng Hatch d 1 d procedures s descrbed n [F2d] 2 products detal as follows: STEP [1]: Input structure of the common archtecture The desgn system calculates the structure of Fgure 7. Unfcaton Process (Famly Plan B) the common archtecture (Fgure 8 [1]). The archtecture nterfaces (f 1, f 2, f 3, and f 4 ) that connect the common archtecture elements are defned based on the connecton lnks between the enttes. STEP [2]: Calculaton of the platformzaton graph The desgn system automatcally generates a platformzaton tree (Fgure 8 [2]). ths platformzaton tree represents the space of the platformzaton plans. It can be generated based on the cut-set of the common archtecture graph (Fgure 8 [1]). Ths tree conssts of the platformzaton plan nodes and platformzaton lnks. A platformzaton plan node s defned as a matrx that comprsng archtecture nterfaces. A black panted cell n the platformzaton matrx represents an archtecture nterface that has been elmnated by the platformzaton operaton. STEP [3]: Platformzaton based on the platformzaton plan node The platform module desgn s realzed by selectng one platformzaton plan node n the platformzaton tree. Fgure 8 [3] shows the platformzaton result of Famly Plans A and B. In Famly Plan A, the platform that ntegrates the body and underbody s obtaned. Platform A-1 for the compact car s desgned by ntegratng the body for compact car and the unversal chasss. Smlarly, platform A-2 for the L-class car s desgned by the ntegratng the body for the L-class car and the unversal chasss. [1] Common Archtecture Under- body f 4 f 1 f 2 f 3 Engne f : archtecture nterface [2] Platformzaton Tree [ROOT] f 1 f 2 f 3 f 4 [P2a] [P1a] Platform of Famly [P2b] Plan A Platform of Famly Plan B [3] Platformzaton based on Platformzaton plan node Platform of Famly Plan A [ROOT] [P1a] 2 23 Platform A-1 Compact Platform A-2 Platform Platform A-1 & Unversal L-class Compact L-class Chasss Platform Platform 23 2 A-2 Platform of Famly Plan B [ROOT] [P2a] [P2b] Platform B-1 Platform B-2 2 Fgure 8. Platformzaton ICED 07/372 9

10 A gudelne for platformzaton s shown n Fgure 9. The desgn system calculates the modularzaton (Fgure 9 [3]) and platformzaton (Fgure 9 [4]) ponts as the platformzaton gudelne. Hgh modularzaton and platformzaton ponts defned n the connecton lnks represent the recommended lnk for the modularzaton and platformzaton by the desgn system. The wde lnes n Fgure 9 [3] and [4] represent the connecton lnks wth hgh ponts. The modularzaton pont s calculated by addng the modularty of each module (Fgure 9 [2]). The modularty ndcates the concdence of lfespans and functonal ndependency. All modules can be automatcally calculated by the desgn system from the cut-set of the product graph. The platformzaton ponts are defned as the summaton of all modularzaton ponts n the product famly model. [1] Calculaton of Module Tree Cut Set Tree [2] Evaluaton of All Modules Module Modularty [3] Modularzaton pont [4] Platformzaton pont Fgure 9. Platformzaton and Modularzaton Gudelne 3.7 Evaluaton The desgn system evaluates the product famly plans. Each product famly plan s evaluated based on the followng three aspects: (1) varety of product famly, (2) desgn change cost, and (3) producton cost. The platformzaton value depends on mpact of the change n the product famly value. The change n the product famly value can be expressed by the followng equaton: Platformzaton value = Varety of product famly / (Desgn change cost + Producton cost) ( ) Evaluaton [1]: Varety of product famly The varety of the product famly s calculated by estmatng the postonng of each product n the market. For example, Famly Plan A has eght products (Fgure 6). Each product has the cover area n the market as one of ts attrbutes. The varety of Famly Plan A s evaluated by the postonng of these eght products. Evaluaton 2: Desgn change cost The cost of desgn changes s estmated based on the unfcaton operatons. New product components and parts are requred for the ntegraton of the enttes. Hence, new costs for the development of the ntegrated enttes are estmated. For example, Famly Plan A has four ntegrated unfcaton lnks (a 1, a 2, a 3, and b 1 ) and two ntegrated enttes (2 and 23). The cost of desgn change s estmated to be the summaton of the ntegraton cost of the four lnks and the desgn cost of the two enttes. Evaluaton 3: Producton cost The producton cost s estmated based on the number of modules. Unfcaton and platformzaton reduces the number of modules n the product famly. The number of modules s estmated to be the number of enttes n the platformzed product famly model. The enttes nclude parts, ntegrated parts and platforms. For example, the platformzaton plan [P1a] n Fgure 8 [3] has seven nodes, therefore the number of the modules s seven. Smlarly, the platformzaton plan [P2b] n Fgure 8 [3] has four modules. The producton cost can be reduced by the mass effects based on the reducton n the number of modules. Hence, the proposed method estmates the producton costs based on the sze of modules. ICED 07/372 10

11 4 PROTOTYPE SYSTEM AND DESIGN EAMPLE 4.1 Prototype System Implementaton Based on the explanatons n the prevous sectons, we developed a prototype desgn system usng the object-orented language VsualWorks Release 7.3 (CINCOM Smalltalk). Fgure 10 shows the overvew of the prototype desgn system. The prototype system conssts of four desgn tools: [1] product famly modellng tool, [2] parts and nterfaces unfcaton tool, [3] platform module desgn tool, and [4] product famly evaluaton tool. Each wndow dsplays the desgn results of the platformzaton of the car famly. The detaled functons of each tool are as follows: [1] Product famly modellng tool: Ths tool supports the desgn of the product famly model by addng product graphs, defnng a common archtecture and connectng unfcaton lnks. [2] Parts and nterfaces unfcaton tool: Ths tool supports the unfcaton of parts and nterfaces. The unfcaton tree s calculated automatcally generated from the product famly model. The product famly model and the lne-up on each unfcaton plan are provded by ths wndow. [3] Platform module desgn tool: Ths tool supports the modularzaton and [1] Product Famly Modelng Tool [2] Parts and Interfaces Unfcaton Tool platformzaton. The platformzaton tree s generated and the lst of all Unfcaton Tree modules s provded by ths wndow. [4] Product famly evaluaton tool: Ths Selected Product Famly tool supports the vsualzaton of the Product Famly Model evaluaton result of the product famly plans. Each product famly plan s [3] Platform Module Desgn Tool [4] Product Famly Evaluaton Tool evaluated based on ts varety and cost. Lneup Lst The desgner can select an approprate product famly plan that matches the Lst of product famly strategy on ths All Modules Module Structure wndow. 4.2 Result and Dscusson Both of the Famly Plans A and B n Fgures 5,6,7, and 8 have hgher famly values than current famly. However, they have sgnfcantly dfferent strategc drectons. The bggest advantage of Famly Plan A s the varety of ts products. The cover area of the market s very large because of the number of the products n the lne-up (eght products, Fgure 6 [F1c]). However, the reducton n the number of the modules (seven) s not as much as that n Famly Plan B (Fgure 6 [3] [P1a]). Hence, Famly Plan A has a hgh varety of products, but ts producton cost s also hgh. To the contrary, the bggest advantage of Famly Plan B s the reducton n the producton cost. The number of the modules n Famly Plan B s only four as shown n Fgure 8 [P2b]. However, the Famly Plan B has only three products n ts lne-up (Fgure 7 [F2c]). Hence, Famly Plan B reduces the producton cost sgnfcantly, but ts varety of products s not very hgh. The comparson between Famly Plan A and B s shown n Table 1. Table 1 ndcates that the desgner can desgn an approprate product famly plan that reflects the product famly strategy, by comparng wth the alternatve canddates from the vewponts of the varety of products and the total cost of the product famly. Hence, the platform module desgn method proposed n ths research can defntely mprove the product famly value by balancng of the varety and cost. Lneup products Modules Table 1. Comparson between Famly Plan A and B Product Famly Current Famly Plan A Famly Plan B 3 12 Platformzaton Tree Fgure 10. Prototype System and Example 8 < > A2 > Platform A-1 > Platform B-1 Platform A-2 Platform B-2 ICED 07/372 11

12 5 CLOSING REMARKS Conclusons In ths paper, we propose a desgn method of the platform module takng nto consderaton the varety and cost of the product famly. The desgn system can assst the desgner n comparng the platformzaton plans by automatc calculaton of the soluton space of the product famly, and by estmatng the varety of products and the desgn and producton costs. The to-be desgn method of platform module desgn s proposed by comparng the platformzaton plans whle consderng varous constrants and the growth of the entre product famly. The ntegraton of nterfaces and the ntroducton of the use of common archtectures are effectve n the automoble and computer ndustres. In the near future, the proposed platform desgn method wll be effectvely used to desgn a to-be model of a common archtecture and a drecton of the nterface ntegraton n the software development ndustres, servce ndustres, and lfecycle systems ndustres. Future Studes As future studes, an ntroducton of a mult-phased platform desgn method and an expanson for a product lfe cycle desgn method are requred to nvestgate. REFERENCES [1] Neson S., Parknson M. and Papalambros P. Multcrtera Optmzaton n Product Platform Desgn. ASME Journal of Mechancal Desgn, 2001, Vol. 123, [2] Smpson T. et al. Development of a Framework for Web-based Product Platform Customzaton. ASME Journal of Computng and Informaton Scence n Engneerng, 2003, Vol. 3, [3] Raghothama S. and Shaprro V. Topologcal Framework for Part Famles. ASME Journal of Computng and Informaton Scence n Engneerng, 2003, Vol. 2, [4] Fujta K. and Yoshda Y. PRODUCT VARIETY OPTIMIZATION: SIMULTANEOUS OPTIMIZATION OF MODULE COMBINATION AND MODULE ATTRIBUTES. In Proceedngs of the ASME Desgn Engneerng Techncal Conference and Computers and Informaton n Engneerng Conference, DET (CD-ROM). [5] Akund S., Smpson T. and Reed P. MULTI-OBJECTIVE DESIGN OPTIMIZATION FOR PRODUCT PLATFORM AND PRODUCT FAMILY DESIGN USING GENETIC ALGORITHMS. Proceedngs of ASME 2005 Internatonal Desgn Engneerng Techncal Conferences & Computers and Informaton n Engneerng Conference, DET [6] Sddque Z. and Adupala R. PRODUCT FAMILY ARCHITECTURE REASONING. Proceedngs of ASME 2005 Internatonal Desgn Engneerng Techncal Conferences & Computers and Informaton n Engneerng Conference, Long Beach, CA, USA, DET (CD-ROM). [7] Maer J. and Fadel G. STRATEGIC DECISIONS IN THE EARLY STAGES OF PRODUCT FAMILY DESIGN. Proceedngs of the ASME Desgn Engneerng Techncal Conference and Computers and Informaton n Engneerng Conference, DET (CD-ROM). [8] Mantrpragada, R., "Assembly Orented Desgn: Concepts, Algorthms and Computatonal Tools", Ph.D. thess, Massachusetts Insttute of Technology, USA. [9] Aoyama K. and Koga T. Step-by-Step Modular Desgn and Management of Modular Interface. Proceedngs of the Desgn Engneerng Workshop 2005, Contact: T.Koga The Unversty of Tokyo Department of Envronmental and Ocean Engneerng Hongo, Bunkyo-ku , Tokyo Japan Phone: Fax: e-mal: tsuyosh-koga@msel.t.u-tokyo.ac.jp ICED 07/372 12

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