1. Manufacturing Systems
Concurrent Engineering

2. Concurrent Engineering
Is a strategy where all the tasks involved in product development are done in parallel.
Collaboration between all individuals, groups and departments within a company.
Customer research
Designers
Marketing
Accounting
Engineering

3. Concurrent Engineering
Form Design
Functional Design
Production Design
Revising and testing prototypes
Manufacturing Specifications
Design
Specifications
Feasibility
Study
Idea
Generation
Suppliers
R&D
Customers
Marketing
Competitors
Product or Service concept
Performance Specifications
Pilot run and final tests
Final Design and process plans
Product Launch
Preliminary Design
Commercial Design Process
Linear Process

4. Concurrent Engineering
Techniques:
Perceptual mapping
Benchmarking
Reverse Engineering

5. Concurrent Engineering
Perceptual Mapping
Low Nutrition
Good Taste
Bad Taste
High Nutrition
Coco Pops
Rice Krispies
Cheerios
Shredded Wheat
Compares customers perception of available products
Identifies gap in market

6. Concurrent Engineering
Benchmarking
Get the best product available
Base performance specifications for new product on it
Reverse Engineering
Dismantle and inspect competitors product(s)
Select features to incorporate into new product

7. Concurrent Engineering
Demand for the proposed product?
Cost of developing and producing the product?
Does company have manufacturing capability?
Skilled personnel?

8. Concurrent Engineering
Form Design: Physical appearance of the product
Functional Design: Performance of the product
Production Design: How to manufacture product

9. Concurrent Engineering
Prototype produced
Adjustments made
Final specification agreed

10. Concurrent Engineering
Manufacturing process commences
Product is marketed to buying public

11. Concurrent Engineering
Traditional Process = Linear Vs
Concurrent Engineering = Team collaboration

12. Concurrent Engineering
Why Concurrent Engineering?
Pace of market change has increased
Companies must keep pace with changing markets
Decisions made sooner rather than later
Reduces/eliminates repetition of tasks
Reduces waste and reworking of design
Product quicker to market
Maximises company profit
Company operates more efficiently

13. Concurrent Engineering
To make decisions concurrently:
Team knows the design goals/objectives
Team is aware of the interrelationships between all aspects of the design process
Superior communication between all sections of the company
Method:
Quality Function Deployment (QFD)

14. Concurrent Engineering
Quality Function Deployment (QFD)
Collection of matrices that converts the needs of the customer into technical specifications at all stages of the design and manufacture process.
Product Planning (most popular)
House of Quality

15. Concurrent Engineering
House of Quality
Customer requirements prioritised (scale or %)
Competitive product evaluation
Engineering characteristics
Interrelationships of 1 & 3
Relations between engineering characteristics
Targets for new product 5 3 1 4 2 6

16. Concurrent Engineering
Example: Water-pond Alarm
1. Identify customer requirement and prioritise them (scale or %)

17. Competitive Assessment
Concurrent Engineering
2. Compare product to competitors
Competitive Assessment
Attribute 1 2 3 4 5
Sensitive to water level 25 A X
Durable 15 B
Makes a loud noise 10
Inexpensive
Small
Looks Good
weighting B

18. Concurrent Engineering
3.Identify engineering characteristics
Attribute
Sensitive to water level 25 ++ +
Durable 15
Makes a loud noise 10 -
Inexpensive --
Small
Looks Good
Complexity of circuit
Energy Efficiency
Material for casing
Cost of Sensor
Weighting

19. Concurrent Engineering
4. Identify strength of interrelationships between customer requirements and the engineering characteristics.
Weighting
Complexity of circuit
Energy Efficiency
Material for casing
Cost of Sensor
Legend:
Positive correlation +
Strong positive correlation ++
None
Negative correlation -
Strong Negative correlation - -
Attribute
Sensitive to water level 25 ++ +
Durable 15
Makes a loud noise 10 -
Inexpensive --
Small
Looks Good

20. Concurrent Engineering
Interpreting the matrix
Sensitivity to water level is likely to be very dependent on complexity of circuit
Weighting
Complexity of circuit
Energy Efficiency
Material for casing
Cost of Sensor
Attribute
Sensitive to water level 25 ++ +
Durable 15
Makes a loud noise 10 -
Inexpensive --
Small
Looks Good
Increasing the noise level could reduce the energy efficiency

21. Concurrent Engineering
A complex circuit and quality sensor could increase cost of product
Weighting
Complexity of circuit
Energy Efficiency
Material for casing
Cost of Sensor
Attribute
Sensitive to water level 25 ++ +
Durable 15
Makes a loud noise 10 -
Inexpensive --
Small
Looks Good
The choice of material will affect the durability of the product

22. Concurrent Engineering
5. Identify correlation between engineering characteristics.
A good quality sensor could improve energy efficiency
Increasing complexity of circuit could require a more costly sensor
Complex circuit (more parts) could reduce energy efficiency

23. Concurrent Engineering
6. Identify targets for new product
120
Target
120
<30

24. Concurrent Engineering
© 2002 DRM Associates

25. Concurrent Engineering
Role of CAD in Design & Manufacture
Model part or assembly being designed
Part visualised and manipulated on screen
Realistic
Function tested
Textures & lighting effects can be applied
Photorealistic effects
Manufacturing drawings generated automatically
Modelled part and its manufacturing requirements shared with the entire design and manufacturing team

26. Concurrent Engineering
Role of CAD in Design & Manufacture
Geometry from CAD system used to produce part on CAM system
CAD model used by marketing to create images for packaging
Simulate behaviour of product under stresses and forces using CAE system
Model data used by rapid prototyping machine

27. Concurrent Engineering
Role of CAD in Design & Manufacture
Advantages:
All above can be done concurrently
Manufacturing problems identified early
Changes in design can be seen immediately
Speeds up design and prototyping processes

28. Concurrent Engineering
Design for the Environment
There are three major elements of design for the environment:
Design for environmental manufacturing
Design for environmental packaging
Design for disposal and recyclability.

29. Concurrent Engineering
Design for Environmental Manufacturing:
Non-toxic processes & production materials
Minimum energy utilization
Minimize emissions
Minimize waste, scrap & by-products

30. Concurrent Engineering
Design for Environmental Packaging:
Minimum of packaging materials
Reusable pallets and packaging 
Recyclable packaging materials
Bio-degradable packaging materials

31. Concurrent Engineering
Design for Disposal & Recycling:
Re-use/refurbishment of components & assemblies
Material selection to enable re-use (e.g., thermoset plastics vs. thermoplastics) and minimize toxicity
Avoids filler material in plastics such as fibreglass and graphite
Minimum number of materials/colours to facilitate separating materials and re-use
Design for serviceability to minimize disposal of non-working products

32. Concurrent Engineering
Design for Disposal & Recycling:
Material identification to facilitate re-use
Design to enable materials to be easily separated
Design for disassembly (e.g., fracture points, fastening vs. bonding)
Avoid use of adhesives
Limit contaminants - additives, coatings, metal plating of plastics, etc.
Maximize use of recycled or ground material with virgin material

33. Concurrent Engineering
Impact of Product Life Cycle on the Environment
Product life cycle = design, manufacture, use & disposal stages of product
Minimise a products negative impact on the environment
Incorporate DfE considerations into design process of a new product

34. Concurrent Engineering
Case study 1: Desktop computer
Design Stage:
The design could specify the following
Reusable components e.g. monitor, keyboard
Recycled materials where possible
Minimise toxic materials used
Manufacture:
Use ethical work practices and sources for raw materials
Use ‘clean’ manufacturing processes
Minimise transport of components and materials
Implement quality procedures to minimise waste etc.
Use:
Low power consumption
Serviceable items rather than replaceable e.g. disk drive, peripherals etc.
Disposal:
Design for disassembly – use easily dismantled fixings etc.
Identify materials used for recycling
Minimise mixed materials to facilitate separation later

35. Concurrent Engineering
Role of Testing in Product Design
Cannot predict with absolute certainty how product will perform
Need test product before mass production
Mass production very costly to setup
Changes cannot be made easily
Speeds up design and prototyping processes

36. Concurrent Engineering
Role of Testing in Product Design
Possible tests:
Product meets performance specifications
Expected life of product
Likely cause of failure
Accelerated testing

37. Concurrent Engineering
Performance test: Pond Alarm
Test
Procedure
Minimum performance
Result
Casing Seal
Submerge in water for 8 hours
Remove, Dry, disassemble and inspect
No evidence of water ingress
Sensitivity of sensor
Submerge probes to 8mm in sample of pond water
Retract
Alarm should trigger before 8mm is reached
Alarm should reset within 1 min
Battery life
Trigger alarm and measure time until battery depletes.
Alarm should sound for 1 hour minimum
Ability to withstand extreme weather
Place in freezer at -15°C and in oven at 50°C for 1 hour
No damage should be apparent to casing or function
Alarm Volume
Trigger in an unobstructed area then move away until alarm is no longer audible
Should be audible up to 30m

38. Qualitative or Quantitative
Concurrent Engineering
Role of Accelerated Testing
Used when expected life is long to capture life data
Life data is needed to estimate the reliability of a product
Tests are conducted on a sample or prototype
Tests cause product to fail in same manner as normal use
Test time is greatly reduced
Product is quicker to market
Low development and warranty costs
Qualitative or Quantitative

39. Concurrent Engineering
Qualitative Accelerated Tests
To reveal probable failure modes
Good tests quickly reveal failure modes
Improve design product
Performed on small number of samples
Product subjected to one severe level of stress
e.g. Stress cycling or hot to cold
Product intact – pass
Failure - action taken to eliminate cause of failure
Only tests conditions encountered in real use
Cannot be used to quantify life of product

40. Concurrent Engineering
Quantitative Accelerated Life Tests
Quantify the life of the product
Controlled application of accelerated stress conditions to simulate product failure
Reduces the time-to-failure for a product
Data used to estimate reliability of product

41. Concurrent Engineering
Example:
A washing machine to last for ten years in normal use.
Expected typical household use: three times a week for a wash cycle that will last for 2 hours on average.
What type of test should be used?
How long must the machine survive during the test?
Total hours life required for the machine is:
2 hours/wash x 3 washes/week x 52 weeks/year x 10 years = 3120 hours
Use a quantitative accelerated test. Run the machine constantly for 3120 hours

42. Concurrent Engineering
Sample Paper: HL
Explain why accelerated testing is used on some products.
Some products have a long life – need to test reliability
– quantify life of product - warranty
A washing machine will be used for two hours per day, three days per week in normal use. What type of accelerated testing will determine the lifetime of the washing machine?
Quantitative test – data is used to determine expected normal life time of product
During testing, the washing machine ran for 3000 operating hours before failing. Recommend a suitable guarantee period for the washing machine and give reasons for your recommendation.
2hrs/day x 3days/week = 6hrs/week
3000/6 = weeks
566.67/52 =
Guarantee period = 10 years.