1. Automation (21-541) Sharif University of Technology Session # 5
Advanced Manufacturing Laboratory
Department of Industrial Engineering
Sharif University of Technology
Session # 5

2. Automation (21541), Session # 5
Session Schedule
‎‎‎Product lifecycle management (PLM) from automation and CIM perspective
Automation & CIM role in Product development
Product development cycle
Concurrent engineering and automation & CIM considerations
Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology
Automation (21541), Session # 5 2

3. Automation (21541), Session # 5
Introduction to manufacturing automation and CIM (Computer Integrated Manufacturing)
Automation:
Set of all measures aiming at replacing human work through machines (e.g. automation is applied science)
the technology used for this purpose (e.g. this company has an automation department)
Replacement of human work through machines (e.g. the automatisation of the textile factory caused uproar of the workers)
Replacement of conscious activity by reflexes (e.g. drill of the sailors allows the automatisation of ship handling)
The use of computers and machines instead of people to do a job
Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology
Automation (21541), Session # 5 3

4. Product lifecycle management (PLM)
Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology
Automation (21541), Session # 5 4

5. Product lifecycle management (PLM)
Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology
Automation (21541), Session # 5 5

6. Product lifecycle management (PLM)
Sequential Engineering:
The traditional product development process at the prototype development stage is sequential.
It includes
Product design,
Development of manufacturing process and
Supporting quality and testing activities
Which are all carried out one after another.
Often the need for engineering
changes is discovered during planning or manufacturing or assembly. Design department
in a typical sequential product development process finalizes the design without
consulting the manufacturing, quality or purchase departments.
Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology
Automation (21541), Session # 5 6

7. Product lifecycle management (PLM)
Sequential Engineering is often called “across the wall”:
Sequential Engineering is often called “across the wall” method. Figure 2.5 illustrates
the insulated way each department may function in sequential approach. Each segment
of the product development team (Design, Planning, Manufacturing etc.) completes its
task in isolation and passes over the documents to the next segment. There is no interaction
among the groups before the design is finalized. If a serious mistake in the product is
detected during testing, the revision process has to start from design, resulting in materials
wastage and loss of time. In the context of extensive outsourcing, there is also need for
intensive consultation between vendors and manufacturers.
Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology
Automation (21541), Session # 5 7

8. Product lifecycle management (PLM)
Sequential Engineering discussions:
Changes in design may be called for when the manufacturing department is unable to meet design specifications or there are problems in assembly.
This will lead to inevitable conflicts, each department sticking to their own decisions and may often require intervention of senior management to resolve conflicts or differences in opinion.
Time taken to product development is usually more than what is anticipated and correspondingly the response to the market requirements will be slow compared to a competing company.
Design department
in a typical sequential product development process finalizes the design without
consulting the manufacturing, quality or purchase departments. Planning might feel it
necessary to request design changes based on a number of reasons like the procurement
or facility limitations. Changes in design may be called for when the manufacturing
department is unable to meet design specifications or there are problems in assembly.
These changes are however to be incorporated in design. The design documents are
therefore sent back to the design department for incorporating the changes. The design/
redesign path is shown in Fig The design documents are passed on back and forth
to incorporate design changes as illustrated. This will lead to inevitable conflicts, each
department sticking to their own decisions and may often require intervention of senior
management to resolve conflicts or differences in opinion. Design changes will involve
both material and time wastages. In such a situation, time taken to product development
is usually more than what is anticipated and correspondingly the response to the market
requirements will be slow compared to a competing company which can create an error
free design at the first instance.
Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology
Automation (21541), Session # 5 8

9. Product lifecycle management (PLM)
Sequential Engineering discussions:
Even after the prototype development stage is over, the need for design change may
arise during service. Such changes are usually few in number, but are very costly.
Thus in the traditional manufacturing, the design documents move sequentially through
the various departments of the organization. The R & D group completes the design task
and passes the data to planning, which in turn passes the information to manufacturing
and so on. If any downstream department wants to introduce any change, the process has
to backtrack and this often involves additional expenditure as well as inevitable delay in
realizing the product.
Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology
Automation (21541), Session # 5 9

10. Product lifecycle management (PLM)
Concurrent Engineering:
Concurrent engineering or Simultaneous Engineering is a methodology of restructuring the product development activity in a manufacturing organization
This is accomplished through using a cross functional team approach and is a technique adopted to improve the efficiency of product design and reduce the product development cycle time.
Concurrent engineering is also sometimes referred to as Parallel Engineering.
Concurrent Engineering brings together a wide spectrum of people from several functional areas in the design and manufacture of a product.
Concurrent engineering or Simultaneous Engineering is a methodology of restructuring
the product development activity in a manufacturing organization using a cross
functional team approach and is a technique adopted to improve the efficiency of
product design and reduce the product development cycle time. This is also sometimes
referred to as Parallel Engineering. Concurrent Engineering brings together a wide
spectrum of people from several functional areas in the design and manufacture of a
product. Representatives from R & D, engineering, manufacturing, materials
management, quality assurance, marketing etc. develop the product as a team. Everyone
interacts with each other from the start, and they perform their tasks in parallel. The
team reviews the design from the point of view of marketing, process, tool design and
procurement, operation, facility and capacity planning, design for manufacturability,
assembly, testing and maintenance, standardization, procurement of components and
sub-assemblies, quality assurance etc as the design is evolved. Even the vendor
development department is associated with the prototype development. Any possible
bottleneck in the development process is thoroughly studied and rectified. All the
departments get a chance to review the design and identify delays and difficulties.
The departments can start their own processes simultaneously. For example, the tool
design, procurement of material and machinery and recruitment and training of
manpower which contributes to considerable delay can be taken up simultaneously as
the design development is in progress. Issues are debated thoroughly and conflicts are
resolved amicably.
Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology
Automation (21541), Session # 5 10

11. Product lifecycle management (PLM)
Concurrent Engineering:
In CE everyone interacts with each other from the start, and they perform their tasks in parallel.
The team reviews the design from the point of view of marketing, process, tool design and procurement, operation, facility and capacity planning, design for manufacturability, assembly, testing and maintenance, standardization, procurement of components and sub-assemblies, quality assurance, … .
Any possible bottleneck in the development process is thoroughly studied and rectified.
Concurrent engineering or Simultaneous Engineering is a methodology of restructuring
the product development activity in a manufacturing organization using a cross
functional team approach and is a technique adopted to improve the efficiency of
product design and reduce the product development cycle time. This is also sometimes
referred to as Parallel Engineering. Concurrent Engineering brings together a wide
spectrum of people from several functional areas in the design and manufacture of a
product. Representatives from R & D, engineering, manufacturing, materials
management, quality assurance, marketing etc. develop the product as a team. Everyone
interacts with each other from the start, and they perform their tasks in parallel. The
team reviews the design from the point of view of marketing, process, tool design and
procurement, operation, facility and capacity planning, design for manufacturability,
assembly, testing and maintenance, standardization, procurement of components and
sub-assemblies, quality assurance etc as the design is evolved. Even the vendor
development department is associated with the prototype development. Any possible
bottleneck in the development process is thoroughly studied and rectified. All the
departments get a chance to review the design and identify delays and difficulties.
The departments can start their own processes simultaneously. For example, the tool
design, procurement of material and machinery and recruitment and training of
manpower which contributes to considerable delay can be taken up simultaneously as
the design development is in progress. Issues are debated thoroughly and conflicts are
resolved amicably.
Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology
Automation (21541), Session # 5 11

12. Product lifecycle management (PLM)
Concurrent Engineering:
CE gives marketing and other groups the opportunity to review the design during the modeling, prototyping and soft tooling phases of development.
CAD systems especially 3D modelers can play an important role in early product development phases.
CE enables the co-operation between various specialists and systematic application of special methods such as QFD (Quality Function Deployment), DFMA (Design for Manufacture and Assembly) and FMEA (Failure Mode and Effect Analysis) ensures quick optimization of design and early detection of possible faults in product and production planning.
Intensive teamwork between product development, production planning and
manufacturing is essential for satisfactory implementation of concurrent engineering.
The teamwork also brings additional advantages ; the co-operation between various
specialists and systematic application of special methods such as QFD (Quality Function
Deployment), DFMA (Design for Manufacture and Assembly) and FMEA (Failure Mode
and Effect Analysis) ensures quick optimization of design and early detection of possible
faults in product and production planning. This additionally leads to reduction in lead
time which reduces cost of production and guarantees better quality.
Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology
Automation (21541), Session # 5 12

13. Product lifecycle management (PLM)
Concurrent Engineering:
A comparison of concurrent and sequential engineering based on cost is attempted in
this section. The distribution of the product development cost during the product
development cycle is shown in Fig This figure shows that though only about 15%
of the budget is spent at the time of design completion, whereas the remaining 85% is
already committed. The decisions taken during the design stage have an important
bearing on the cost of the development of the product. Therefore the development cost
and product cost can be reduced by proper and careful design. CE facilitates this. The
significantly large number of nonconformities detected in the later stages of product
development cycle in sequential engineering results in large time and cost overrun.
Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology
Automation (21541), Session # 5 13

14. Product lifecycle management (PLM)
Concurrent Engineering merits:
Reduction in the number of design changes
Cost of changes in design
Holistic approach to product development
Robust products
Reduction in lead time for product development
Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology
Automation (21541), Session # 5 14

15. Product lifecycle management (PLM)
Concurrent Engineering merits:
Reduction in the number of design changes
The advantage of concurrent engineering over the traditional sequential (SE) and
concurrent engineering (CE) is that a large number of design changes are identified and
implemented at the beginning or in the early phase of product development cycle. In the
case of CE this number goes on decreasing for the remaining period, whereas many
changes are now and then incorporated at every stage of development in the case of
traditional sequential approach. This is due to the fact that most of the design changes
needed are detected early in design. The reduction in design change requests with CE is
substantially less at the later stages of the product development process. Compared to
this, defects are detected often during the sequential engineering process. This is shown
graphically
Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology
Automation (21541), Session # 5 15

16. Product lifecycle management (PLM)
Concurrent Engineering merits:
Cost of changes in design
The cost of introducing a design change in a product progressively increases as the
development proceeds through design and manufacturing. This can be elaborated with a
simple example. If a change in the conceptual 3D CAD model costs Rs.50, 000. The same
change during the planning stage would cost Rs.1, 50,000. By the time the product moves
to prototyping and testing, the change may cost Rs.2, 50,000. The cost goes up to Rs.25,00,000
if the product is in the manufacturing stage and Rs.50,00,000 or more after the company
releases the product to sales and marketing. Figure 2.8 illustrates this. While these numbers
differ greatly from company to company and from product to product, they give a feel of
the importance of feedback early in the design cycle.
Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology
Automation (21541), Session # 5 16

17. Product lifecycle management (PLM)
Concurrent Engineering merits:
Holistic approach to product development
In CE, no longer product development is considered the exclusive activity of the design department.
Participation of
Planning,
Manufacturing,
Quality,
Service,
Vendor development and
Marketing personnel
in the development process enables the cross functional team to view the development as a total responsibility and this results in better communication among the various departments.
Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology
Automation (21541), Session # 5 17

18. Product lifecycle management (PLM)
Concurrent Engineering merits:
Robust products
Concurrent approach to product design results in products with fewer errors
It avoids the loss of goodwill of the customers due to poorly engineered products
The entire product development team looks at each and every aspect of products – cost, specifications, aesthetics, ergonomics, performance and maintainability.
The resulting product will naturally satisfy the customer.
Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology
Automation (21541), Session # 5 18

19. Product lifecycle management (PLM)
Concurrent Engineering merits:
Reduction in lead time for product development
Time compression in product development is an important issue today.
Concurrent engineering reduces the product development time significantly as the preparatory work in all downstream functions can take place concurrently with design.
Elimination of the errors in design appreciably reduces the possibility of time overrun, enabling the development schedule to be maintained.
Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology
Automation (21541), Session # 5 19

20. Product lifecycle management (PLM)
Concurrent Engineering implementation via CIM:
Concurrent (Simultaneous) Engineering is an orthogonal concept that defines how concurrent and simultaneous work flows are organized and the information flow, storage, retrieval and decision making can be supported and controlled.
Information Technology(IT) is the backbone of CE.
Software tools are available today to perform all the manufacturing related activities.
CIM tries to permit almost seamless transfer of data from one application to another.
The challenge to engineering information systems today is to have the ability to handle
very large amount of data and information which the engineering organizations have to
cope with. Design changes, status reviews, releases and their effects on cost, delivery and
quality have to be managed. It has to be made sure that the workplace of each engineer,
planner and manager is not overloaded so as to make the work ineffective.
Concurrent or simultaneous engineering is an orthogonal concept that defines how
concurrent and simultaneous work flows are organized and the information flow, storage,
retrieval and decision making can be supported and controlled. In particular the principles
and methods of concurrent or simultaneous engineering integrate these activities through
the information technology (IT). Hence IT is the backbone of this approach. Software tools
are available today to perform all the manufacturing related activities. These tools today
permit almost seamless transfer of data from one application to another. The possibilities
of extensive reuse of data are another welcome feature. Naturally IT assures productivity
increase and shorter overall cycle times with improved quality.
The product design is currently carried out using a wide range of related and reasonably
well integrated design support tools. A number of tools exist in the market which addresses
the specific requirements of certain design activities. The manufacturing engineers have a
wide choice today to manage product development through product life cycle management
(PLM) software. However, there exists no coherent view yet as to how the design activity
should be structured to provide rapid throughput of satisfactorily validated designs. The
approach therefore will be to identify the necessary tools required for the design of products
and include all of them in some kind of integrated platform. Concurrent engineering
together with CIM aims to achieve this objective. Thus concurrent engineering helps to
create an environment in which teams of product engineers can develop products from
initial concept to prototype and to final product with the integration of manufacturing
engineering and design of production facilities.
Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology
Automation (21541), Session # 5 20

21. Product lifecycle management (PLM)
Concurrent Engineering implementation via CIM:
In every phase of the product development, from concept to final design, sufficient information has to be provided to the product development team
The members of the team need to take the right decisions with respect to
production,
production planning and
product support.
Special attention has to be given to the adoption of new production technologies and to take make or buy decisions including the early integration of the suppliers into the development process.
The pressure to be the first in the market with a new product requires the design to be
right from the beginning. Therefore in every phase of the product development, from
concept to final design, sufficient information has to be provided to the product
development team based on which the members of the team take the right decisions with
respect to production, production planning and product support. Special attention has to
be given to the adoption of new production technologies and to take make or buy decisions
including the early integration of the suppliers into the development process.
As a result of these requirements, information systems have to be developed which
integrate the different engineering disciplines and their support tools, promoting and
pushing a conversion of the currently practiced sequential work flow into a more
concurrent work flow with a higher degree of parallelism to shorten the product
development lead-time.
Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology
Automation (21541), Session # 5 21

22. Product lifecycle management (PLM)
Concurrent Engineering implementation via CIM:
Through CIM concept, information systems have to be developed which integrate the different engineering disciplines
CIM moreover integrates the various engineering support tools, promoting and pushing a conversion of the currently practiced sequential work flow into a more concurrent work flow
with a higher degree of parallelism to shorten the product development lead-time.
As a result of these requirements, information systems have to be developed which
integrate the different engineering disciplines and their support tools, promoting and
pushing a conversion of the currently practiced sequential work flow into a more
concurrent work flow with a higher degree of parallelism to shorten the product
development lead-time.
Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology
Automation (21541), Session # 5 22