1. 1 Rev: 3/29/07 MSE-415: B. Hawrylo Chapter 9 Product Architecture MSE-415: Product Design Lecture #9

2. 2 Rev: 3/29/07 MSE-415: B. Hawrylo Lecture Objectives: Discuss midterm result Discuss presentation results Lecture on Product Architecture Lecture on Design for Manufacturing

3. 3 Rev: 3/29/07 MSE-415: B. Hawrylo Product Architecture Product architecture is the assignment of the functional elements of a product to the physical building blocks of the product.

4. 4 Rev: 3/29/07 MSE-415: B. Hawrylo Product Architecture The way the functions of the product are implemented through the use of chunks defines its architecture. Modular Architecture Chunks implement one or a few function elements Interactions between chunks are well defined and fundamental to the primary functions of the product. A D C B Process Design changes are relatively easy.

5. 5 Rev: 3/29/07 MSE-415: B. Hawrylo Product Architecture The way the functions of the product are implemented through the use of chunks defines its architecture. Integral Architecture Functional elements are implemented using more than one chunk. Single Chunk implements several functions. Interactions between chunks are ill defined and may be incidental to the primary functions of the product. Process A – B C D Design changes are more complex.

6. 6 Rev: 3/29/07 MSE-415: B. Hawrylo Example: Coffee Maker Mix Coffee and Water Heat Coffee Heat Water Store Water Electricity Water Ground Coffee Brew Coffee Overall Function Supporting Sub-Functions Auxiliary Functions Shut-off Heater Coffee Beans Grind Beans Store Grounds Store Coffee

7. 7 Rev: 3/29/07 MSE-415: B. Hawrylo How to Create a Function Structure 1.Formulate the overall product function 2.Split up overall function into sub-functions 3.Determine simplified functions structure 4.Identify material, energy, and information/signal flows 5.Add secondary/auxiliary functions and flows

8. 8 Rev: 3/29/07 MSE-415: B. Hawrylo Morphological Matrix Search for solution principles to fulfill sub- functions  Identify as many solutions for each sub-function and auxiliary functions as possible Combine solutions to embody physical concepts  Use morphological matrix to identify combinations of solutions  Each combination of solutions will fulfill overall function Use expertise and heuristics to eliminate infeasible solution combinations

9. 9 Rev: 3/29/07 MSE-415: B. Hawrylo Morphological Matrix for Coffee Maker Heat Coffee Heat Water Store Water Store Grounds Mix Coffee and Water Store Coffee Brew Coffee S11S12  S1jS1m  Si1Si2  SijSim  Sn1Sn2  SnjSnm           FilterOsmosisDissolveIonize  Stir

10. 10 Rev: 3/29/07 MSE-415: B. Hawrylo Modularity Defined After we brainstorm solutions for each sub- function, we combine them to create the product architecture. As part of this process, we seek to identify modules. Modularity is defined as: 1. a one-to-one correspondence between functional elements and physical structures 2. unintended interactions between modules are minimized (i.e., component interfaces are de-coupled). The opposite of modularity is referred to as integral.

11. 11 Rev: 3/29/07 MSE-415: B. Hawrylo Product Architecture Definition Recall that a product architecture is:  the arrangement of functional elements  the mapping of functional elements to physical components  the specification of the interfaces among physical components A modular architecture is:  One physical component per function; de-coupled interfaces An integral architecture is:  Coupled interfaces; multiple functions per physical component

12. 12 Rev: 3/29/07 MSE-415: B. Hawrylo Types of Modularity: Slot In a slot architecture, each module has a different interface with the overall system. Why different interfaces?  So that various components cannot be interchanged Examples:  SCSI, Ethernet, and parallel ports on laptop 

13. 13 Rev: 3/29/07 MSE-415: B. Hawrylo Types of Modularity: Bus In a bus architecture, there is a common bus to which modules connect via the same interface. What are the advantages of this type of modularity? Examples:  Modem and Internet cards on laptop; CD and disk drive 

14. 14 Rev: 3/29/07 MSE-415: B. Hawrylo Types of Modularity: Sectional In a sectional architecture, all interfaces are the same type but there is no single element to which modules attach. What are advantages and disadvantages of a sectional approach? Examples:  Legos  Using a sectional architecture, the assembly is built up by connecting the modules to each other via identical interfaces.

15. 15 Rev: 3/29/07 MSE-415: B. Hawrylo Selecting Architecture Decisions about how to divide the product into chunks and about how much modularity to impose on the architecture are tightly linked to several issues of importance: Product Change Product Variety Component Standardization Product Performance Manufacturability Product Development Management

16. 16 Rev: 3/29/07 MSE-415: B. Hawrylo Selecting Architecture Product Change Architecture defines how the product can be changed. Modular = changes to be made to few isolated functional elements Integral = changes may influence many functional elements Reasons for Change: UpgradeAdd-onsAdaptation WearConsumptionFlexibility of Use Reuse

17. 17 Rev: 3/29/07 MSE-415: B. Hawrylo C Selecting Architecture Product Variety Variety refers to the range of product models the firm can produce within a particular time period in response to market demand. Modular = Easier variation without adding tremendous complexity to the manufacturing system. Integral = Variation of product can add complexity to the manufacturing system. A B1 D A – B – C - D B2

18. 18 Rev: 3/29/07 MSE-415: B. Hawrylo Selecting Architecture Component Standardization Component standardization is the use of the same component or chunk in multiple products. Modular = Chunks can be manufactured in higher volumes saving the organization money. Integral = Chunks are specialized resulting in lower manufacturing volumes.

19. 19 Rev: 3/29/07 MSE-415: B. Hawrylo Selecting Architecture Product Performance Product performance is how well a product implements its intended functions such as: Speed – Efficiency – Life – Accuracy - Noise Integral Architecture facilitates optimization of characteristics driven by size, shape, and mass of a product such as: Acceleration – Energy Consumption – Aerodynamics Drag Redundancy can be eliminated

20. 20 Rev: 3/29/07 MSE-415: B. Hawrylo Selecting Architecture Manufacturability Involves Design for Manufacturing (DFM). One important concept of DFM involves minimization of the number of parts in the design. Discussed in more detail in Chapter 11.

21. 21 Rev: 3/29/07 MSE-415: B. Hawrylo Selecting Architecture Product Development Management Detail design of each chunk is usually assigned to a relatively small group within a firm or to an outside supplier. Modular – The group assigned to design a chunk deals with known, and relatively limited, functional interactions with other chunks. Integral – Detail design will require close coordination with other groups.

22. 22 Rev: 3/29/07 MSE-415: B. Hawrylo Establishing the Architecture 4-Step Structured Method 1.Create a schematic of the product. 2.Cluster the elements of the schematic. 3.Create a rough geometric layout. 4.Identify the fundamental and incidental interactions.

23. 23 Rev: 3/29/07 MSE-415: B. Hawrylo Creating a Module-Based Product Family 1.Decompose products into their representative functions 2.Develop modules with one-to-one (or many-to-one) correspondence with functions 3.Group common functional modules into a common product platform Common Functions Specific Function 1 Specific Function 2 Specific Function k Derivative Product 1 Derivative Product 2 Derivative Product k 4.Standardize interfaces to facilitate addition, removal, and substitution of modules Product Family { Product Platform }

24. 24 Rev: 3/29/07 MSE-415: B. Hawrylo Example: Braun Family of Coffee Makers KF130 Basic Model KF180 Auto Shut- off, Clock KF185 Adjustable Heater KF190 Frothing Attachment KF170 Thermos Karafe KF145 Water Filter Common Function Brew Coffee Electricity Water Ground Coffee Mix Coffee and Water Heat Coffee Store Water Store Grounds Store Coffee Heat Water

25. 25 Rev: 3/29/07 MSE-415: B. Hawrylo Developing Modular Architectures What are some rules of thumb you, might follow to develop a modular product architecture? 

26. 26 Rev: 3/29/07 MSE-415: B. Hawrylo Establishing the Architecture Cluster the Elements of the Schematic 1.Geometric integration/precision Elements that must be close together are logically grouped in one chunk. 2.Function sharing When a single physical component can implement several functional elements of the product the elements should be clustered together. 3.Capabilities of vendors The elements that a vendor has capability in should be grouped together. 4.Similarity of design or production technology When two or more functional elements are likely to be implemented using the same design/production technology, then incorporating these into the same chunk may allow for more economical design.

27. 27 Rev: 3/29/07 MSE-415: B. Hawrylo Establishing the Architecture Cluster the Elements of the Schematic 5.Localization of Change When you anticipate a lot of change in some element it makes sense to isolate the element in one chunk. 6.Accommodating Variety Elements should be grouped together to enable the firm to vary the product in ways that will have value for the customers. 7.Enabling Standardization If a set of elements will be useful in other products, they should be clustered together into a single chunk. 8.Portability of interfaces Functions that must be close to one another to work properly should be clustered into one chunk.

28. 28 Rev: 3/29/07 MSE-415: B. Hawrylo Establishing the Architecture Cluster the Elements of the Schematic Enclose Printer Structural Support Store Output Connect to Host Command Printer Supply DC Power Display Status Comm. With Host Control Printer Accept User Inputs “Pick” Paper Position Cartridge In Y-axis Position Cartridge In X-axis Print Cartridge Store Blank Paper Flow of forces/energy Flow of material Flow of signals/data Enclosure Chassis Paper Tray Print Mechanism User Interface Logic Board Driver Software Power Cord

29. 29 Rev: 3/29/07 MSE-415: B. Hawrylo Establishing the Architecture Create a Rough Geometric Layout Creating a geometric layout forces the team to consider whether the geometric interfaces among the chunks are feasible. Paper Tray Print Mechanism Print Cartridge User Interface Logic Board

30. 30 Rev: 3/29/07 MSE-415: B. Hawrylo Establishing the Architecture Identify the Fundamental and Incidental Interactions Fundamental: Identified in the schematic. Incidental: Shown in an incidental interaction graph. Enclosure Paper Tray Power Cord Brick Logic Board Chassis User Interface Board Print Mechanism Host Driver Software Thermal Distortion RF Interface Thermal Distortion RF Shielding Vibration Styling

31. 31 Rev: 3/29/07 MSE-415: B. Hawrylo Delayed Differentiation Postponing the differentiation of a product until late in the supply chain is called ‘delayed differentiation’ or simply ‘postponement’ and may offer substantial reductions in the costs of operating the supply chain, primarily through reductions in inventory requirements. Two design principles are necessary conditions for postponement. 1. The differentiating elements of the product must be concentrated in one or few chunks. 2. The product and production process must be designed so that the differentiating chunk(s) can be added to the product near the end of the supply chain.

32. 32 Rev: 3/29/07 MSE-415: B. Hawrylo Platform Planning The collection of assets shared by various products to meet various markets is called the product platform. There are market advantages to have several distinct versions of a product. There are design/manufacturing advantages to have when versions share many components. But how do you determine the trade-off?

33. 33 Rev: 3/29/07 MSE-415: B. Hawrylo Platform Planning Differentiation Plan Commonality Plan

34. 34 Rev: 3/29/07 MSE-415: B. Hawrylo Platform Planning Differentiation Plan Explicitly represents the ways in which multiple versions of a product will be different from the perspective of the customer and the market. Differentiating AttributesFamilyStudentSOHO Black print quality"Near laser" qualityLaser quality Color print quality"Near photo" qualityEquivalent to DJ 600 Print Speed6 pages/minute8 pages/minute10 pages/minute Footprint360mm x 400mm340mm x 360mm400mm x 450mm Paper storage100 sheets 150 sheets StyleConsumerYouth consumerCommercial Connectivity to ComputerUSB/ParallelUSB Operating System CapabilityMac/Windows Windows

35. 35 Rev: 3/29/07 MSE-415: B. Hawrylo Platform Planning Commonality Plan Explicitly represents the ways in which multiple versions of a product will be the same physically. Chunks Number of TypesFamilyStudentSOHO Print Cartridge2Manet CartridgePicasso Cartridge Print Mechanism2Aurora Series Narrow Aurora Series“Aurora” Series Paper Tray2Front-in/Front-out Tall Front-in/out Logic board2 Next gen board with parallel portNext gen board Enclosure3Home StyleYouth StyleSoft office style Driver Software5 Version A-PC Version A-Mac Version B-PC Version B-MacVersion C

36. 36 Rev: 3/29/07 MSE-415: B. Hawrylo Platform Planning Managing the Trade-off Platform planning decisions should be informed by quantitative estimates of cost and revenue implications. Iteration is beneficial. The product architecture dictates the nature of the trade-off between differentiation and commonality.

37. 37 Rev: 3/29/07 MSE-415: B. Hawrylo MSE-415: Product Design Lecture #10 Chapter 11 Design for Manufacturing

38. 38 Rev: 3/29/07 MSE-415: B. Hawrylo Lecture Objectives: Overview of the DFM process  Estimate manufacturing cost  Reduce cost of components  Reduce cost of assembly  Reduce cost of supporting production  Consider impact of DFM decisions on other factors

39. 39 Rev: 3/29/07 MSE-415: B. Hawrylo Gathering DFM Information Sketches, drawings, product specifications, and design alternatives. A detailed understanding of production and assembly processes Estimates of manufacturing costs, production volumes, and ramp-up timing.

40. 40 Rev: 3/29/07 MSE-415: B. Hawrylo DFM Method

41. 41 Rev: 3/29/07 MSE-415: B. Hawrylo 1. Estimate the Manufacturing Costs

42. 42 Rev: 3/29/07 MSE-415: B. Hawrylo Manufacturing Costs Defined Sum of all the expenditures for the inputs of the system (i.e. purchased components, energy, raw materials, etc.) and for disposal of the wastes produced by the system

43. 43 Rev: 3/29/07 MSE-415: B. Hawrylo Elements of the Manufacturing Cost of a Product

44. 44 Rev: 3/29/07 MSE-415: B. Hawrylo Manufacturing Cost of a Product Component Costs (parts of the product)  Parts purchased from supplier  Custom parts made in the manufacturer’s own plant or by suppliers according to the manufacturer’s design specifications Assembly Costs (labor, equipment, & tooling) Overhead Costs (all other costs)  Support Costs (material handling, quality assurance, purchasing, shipping, receiving, facilities, etc.)  Indirect Allocations (not directly linked to a particular product but must be paid for to be in business)

45. 45 Rev: 3/29/07 MSE-415: B. Hawrylo Fixed Costs vs. Variable Costs Fixed Costs – incurred in a predetermined amount, regardless of number of units produced (i.e. setting up the factory work area or cost of an injection mold) Variable Costs – incurred in direct proportion to the number of units produced (i.e. cost of raw materials) Fixed Variable N $

46. 46 Rev: 3/29/07 MSE-415: B. Hawrylo 2. Reduce the Cost of Components Understand the Process Constraints and Cost Drivers Redesign Components to Eliminate Processing Steps Choose the Appropriate Economic Scale for the Part Process Standardize Components and Processes Adhere to “Black Box” Component Procurement

47. 47 Rev: 3/29/07 MSE-415: B. Hawrylo Redesign costly parts with the same performance while avoiding high manufacturing costs. Work closely with design engineers—raise awareness of difficult operations and high costs. Understand the Process Constraints and Cost Drivers

48. 48 Rev: 3/29/07 MSE-415: B. Hawrylo Redesign Components to Eliminate Processing Steps Reduce the number of steps of the production process  Will usually result in reduce costs Eliminate unnecessary steps. Use substitution steps, where applicable. Analysis Tool – Process Flow Chart and Value Stream Mapping

49. 49 Rev: 3/29/07 MSE-415: B. Hawrylo Choose Appropriate Economics of Scale Economies of Scale – As production volume increases, manufacturing costs usually decrease. Fixed costs divided among more units. Variable costs are lower since the firm can use more efficient processes and equipment. LRAC – Long Run Average Cost/Unit

50. 50 Rev: 3/29/07 MSE-415: B. Hawrylo Standardize Components and Processes Economies of Scale – The unit cost of a component decreases as the production volume increases. Standard Components—common to more than one product Analysis tools – group technology and mass customization

51. 51 Rev: 3/29/07 MSE-415: B. Hawrylo Adhere to “Black Box” Component Procurement Black box—only give a description of what the component has to do, not how to achieve it Successful black box design requires clear definitions of the functions, interfaces, and interactions of each component. What

52. 52 Rev: 3/29/07 MSE-415: B. Hawrylo 3. Reduce the Costs of Assembly Design for Assembly (DFA) index  Design for assembly (DFA) is a subset of DFM which involves minimizing the cost of assembly. Integrated Parts (Advantages and Disadvantages) Maximize Ease of Assembly Consider Customer Assembly

53. 53 Rev: 3/29/07 MSE-415: B. Hawrylo Advantages of Integrated Parts Do not have to be assembled Often less expensive to fabricate rather than the sum of each individual part Allows critical geometric features to be controlled by the part fabrication process versus a similar assembly process Disadvantages of Integrated Parts Conflict with other sound approaches to minimize costs Not always a wise strategy

54. 54 Rev: 3/29/07 MSE-415: B. Hawrylo Minimize Ease of Assembly Part is inserted from the top of the assembly Part is self-aligning Part does not need to be oriented Part requires only one hand for assembly Part requires no tools Part is assembled in a single, linear motion Part is secured immediately upon insertion

55. 55 Rev: 3/29/07 MSE-415: B. Hawrylo Consider Customer Assembly Customers will tolerate some assembly Design product so that customers can easily and assemble correctly Customers will likely ignore directions

56. 56 Rev: 3/29/07 MSE-415: B. Hawrylo 4. Reduce the Costs of Supporting Production Minimize Systemic Complexity (inputs, outputs, and transforming processes)  Use smart design decisions Error Proofing (Poka Yoke)  Anticipate possible failure modes  Take appropriate corrective actions in the early stages  Use color coding to easily identify similar looking, but different parts

57. 57 Rev: 3/29/07 MSE-415: B. Hawrylo 5. Consider the Impact of DFM Decisions on Other Factors Development Time Development Cost Product Quality External Factors  Component reuse  Life cycle costs

58. 58 Rev: 3/29/07 MSE-415: B. Hawrylo Next Week – November 14, 2007 (Lecture #11) Homework #7 - Handout Read Chapter 12 – Prototyping Read Chapter 13 – Robust Design Prepare for a potential quiz on:  Chapters 9, 11, 12, 13  Lectures #9, #10  Additional reading handout