Product Architecture/ Design for Manufacturing

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1 Product Architecture/ Design for Manufacturing Architectura Engineering System Design May 20 th, 2009 Moonseo Park Associate Professor, PhD 39 동 433 Phone , Fax E-mai: Department of Architecture Coege of Engineering Seou Nationa University

2 Product Architecture

3 Product Design and Deveopment 2nd edition, Irwin McGraw-Hi, Chapter Tabe of Contents 1. Introduction 2. Deveopment Processes and Organizations 3. Product Panning 4. Identifying Customer Needs 5. Product Specifications 6. Concept Generation 7. Concept Seection 8. Concept Testing 9. Product Architecture 10. Industria Design 11. Design for Manufacturing 12. Prototyping 13. Product Deveopment Economics 14. Managing Projects

4 Product Architecture The arrangement of functiona eements into physica chunks which become the buiding bocks for the product or famiy of products. modue modue Product modue modue modue modue modue modue

5 What is this?

6 Nai Cippers?

7 Moduar Product Architectures Chunks impement one or a few functions entirey. Interactions between chunks are we defined. Moduar architecture has advantages in simpicity and reusabiity for a product famiy or patform. Swiss Army Knife Sony Wakman

8 Patform Architecture of the Sony Wakman

9 Integra Product Architectures Functiona eements are impemented by mutipe chunks, or a chunk may impement many functions. Interactions between chunks are poory defined. Integra architecture generay increases performance and reduces costs for any specific product mode. Compact Camera

10 Traier Exampe: Moduar Architecture box hitch fairing bed springs whees protect cargo from weather connect to vehice minimize air drag support cargo oads suspend traier structure transfer oads to road

11 Traier Exampe: Integra Architecture upper haf ower haf nose piece cargo hanging straps spring sot covers whees protect cargo from weather connect to vehice minimize air drag support cargo oads suspend traier structure transfer oads to road

12 Choosing the Product Architecture Architecture decisions (e.g., how to divide into chunks, how much moduarity to impose) reate to product panning and concept deveopment decisions.

13 Product Change Upgrade (e.g., process board in printer) Add-ons (e.g., USB memories) Adaptation (e.g., gasoine engine to propane engine) Wear (e.g., razors, tires) Consumption (e.g., copier toner) Fexibiity in use (e.g., camera enses) Reuse (e.g., minor change of consumer eectronics)

14 Product Variety (computers, automobies) Standardization (movement for Swatch, motors, bearings, fasteners) Performance (racing bikes, fighter panes) Manufacturing Cost (disk drives, razors) Project Management (team capacity, skis) System Engineering (decomposition, integration)

15 Ford Taurus Integrated Contro Pane

16 The concepts of integra and moduar appy at severa eves: system sub-system component

17 Product Architecture = Decomposition + Interactions Interactions within chunks Interactions across chunks

18 Estabishing the Architecture To estabish a moduar architecture, create a schematic of the product, and custer the eements of the schematic to achieve the types of product variety desired. A schematic is a diagram representing the team s understanding of the constituent eements of the product

19 DeskJet Printer Schematic Encose Printer Print Cartridge Provide Structura Support Position Cartridge In X-Axis Accept User Inputs Dispay Status Store Output Store Bank Paper Position Paper In Y-Axis Pick Paper Contro Printer Suppy DC Power Functiona or Physica Eements Fow of forces or energy Fow of materia Fow of signas or data Communicate with Host Connect to Host Command Printer

20 Custer Eements into Chunks Encosure Encose Printer Provide Structura Support Chassis Print Cartridge Position Cartridge In X-Axis User Interface Board Accept User Inputs Dispay Status Store Output Position Paper In Y-Axis Contro Printer Power Cord and Brick Store Bank Paper Pick Paper Suppy DC Power Paper Tray Print Mechanism Communicate with Host Command Printer Functiona or Physica Eements Chunks Connect to Host Host Driver Software Logic Board

21 Geometric Layout ogic board user interface board print mechanism print cartridge paper tray chassis encosure height ogic board print cartridge roer paper chassis paper tray

22 Incidenta Interactions Encosure User Interface Board Stying Paper Tray Vibration Print Mechanism Therma Distortion Logic Board Host Driver Software Therma Distortion RF Shieding RF Interference Chassis Power Cord and Brick

23 System Team Assignment Based on Product Architecture F G E D I A C B1K1 J P N Q R B2K2 O L M H S T U V Crankshaft F F Fywhee G G Team 1 Connecting Rods E E Pistons D D Lubrication I I Team 2 Engine Bock A A Camshaft/Vave Train C C Cyinder Heads B1 B1 Intake Manifod K1 K1 Team 3 Water Pump/Cooing J J Fue System P P Air Ceaner N N Throtte Body Q Q EVAP R R Team 4 Cyinder Heads B2 B2 Intake Manifod K2 Integration K2 A.I.R. O Team O Exhaust L L E.G.R. M M Accessory Drive H H Ignition S S E.C.M. T T Eectrica System U U Engine Assemby V V Frequency of PDT Interactions Daiy Weeky Monthy From Innovation at the Speed of Information, S. Eppinger, HBR, January 2001.

24 Product Mode Lifetime Fract ion Surviving Average Ot hers 1.18 yr Life Sony 1.97 yr Sony AIWA Toshiba Panasonic From Sanderson and Uzumeri, The Innovation Imperative, Irwin Surviva Time (years)

25 LF Speaker Audio System Exercise: Where are the Chunks? RF Speaker Ceuar Antenna AM/FM Antenna Antenna Motor Ceuar Phone Tuner Cassette Front Contros Dispay FM Microphone Power Ampifier CD Changer Rear Contros Rear Headphones LR Speaker RR Speaker

26 Fundamenta Decisions Integra vs. moduar architecture? What type of moduarity? How to assign functions to chunks? How to assign chunks to teams? Which chunks to outsource?

27 Practica Concerns Panning is essentia to achieve the desired variety and product change capabiity. Coordination is difficut, particuary across teams, companies, or great distances. Specia attention must be paid to hande compex interactions between chunks (system engineering methods).

28 Product Architecture: Concusions Architecture choices define the sub-systems and modues of the product patform or famiy. Architecture determines: ease of production variety feasibiity of customer modification system-eve production costs Key Concepts: moduar vs. integra architecture custering into chunks panning product famiies

29 Design for Manufacturing

30 Product Design and Deveopment 2nd edition, Irwin McGraw-Hi, Chapter Tabe of Contents 1. Introduction 2. Deveopment Processes and Organizations 3. Product Panning 4. Identifying Customer Needs 5. Product Specifications 6. Concept Generation 7. Concept Seection 8. Concept Testing 9. Product Architecture 10. Industria Design 11. Design for Manufacturing 12. Prototyping 13. Product Deveopment Economics 14. Managing Projects

31 Product Deveopment Process Panning Panning Concept Concept Deveopment Deveopment System-Leve System-Leve Design Design Detai Detai Design Design Testing Testing and and Refinement Refinement Production Production Ramp-Up Ramp-Up How can we emphasize manufacturing issues throughout the deveopment process?

32 Design for Manufacturing Exampe: GM 3.8-iter V6 Engine

33 Understanding Manufacturing Costs Manufacturing Cost Components Assemby Overhead Standard Custom Labor Equipment and Tooing Support Indirect Aocation Raw Materia Processing Tooing

34 Definition Design for manufacturing (DFM) is a deveopment practice emphasizing manufacturing issues throughout the product deveopment process. Successfu DFM resuts in ower production cost without sacrificing product quaity.

35 Three Methods to Impement DFM 1. Organization: Cross-Functiona Teams 2. Design Rues: Speciaized by Firm 3. CAD Toos: Boothroyd-Dewhurst Software

36 Design for Assemby Rues Exampe set of DFA guideines from a computer manufacturer. 1. Minimize parts count. 2. Encourage moduar assemby. 3. Stack assembies. 4. Eiminate adjustments. 5. Eiminate cabes. 6. Use sef-fastening parts. 7. Use sef-ocating parts. 8. Eiminate reorientation. 9. Faciitate parts handing. 10. Specify standard parts.

37 Design for Assemby Key ideas of DFA: Minimize parts count Maximize the ease of handing parts Maximize the ease of inserting parts Benefits of DFA Lower abor costs Other indirect benefits Popuar software deveoped by Boothroyd and Dewhurst.

38 To Compute Assemby Time Handing Time + Insertion Time Assemby Time

39 Method for Part Integration Ask of each part in a candidate design: 1.Does the part need to move reative to the rest of the device? 2.Does it need to be of a different materia because of fundamenta physica properties? 3.Does it need to be separated from the rest of the device to aow for assemby, access, or repair? If not, combine the part with another part in the device.

40 Videocassette DFM Exercise 2 biion wordwide annua voume 7 major producers of 1/2 cassette shes JVC icenses the VHS standard dimensions, interfaces, ight path, etc VHS cassette shes cost ~$0.25 each What is a $0.01 cost reduction worth?

41 DFM Strategy is Contingent Corporate Strategy Product Strategy Production Strategy DFM Strategy

Product Design & Development

Product Design & Development Product Design & Deveopment Product Architecture 1 2 1 What is Product Architecture? Product architecture is the assignment of the product's functions to physica buiding bocks or "chunks". Product modue