1. PENN S TATE © T. W. S IMPSON PENN S TATE Timothy W. Simpson Professor of Mechanical & Industrial Engineering and Engineering Design The Pennsylvania State University University Park, PA 16802 phone: (814) 863-7136 email: tws8@psu.edu http://www.mne.psu.edu/simpson/courses/me546 Design Structure Matrix ME 546 - Designing Product Families - IE 546 © T. W. S IMPSON

2. PENN S TATE © T. W. S IMPSON Overview of Lecture Design Structure Matrix DSMWeb.org Coupling Index Tasked-based DSMs

3. PENN S TATE © T. W. S IMPSON Design Structure Matrix (DSM) A DSM = matrix representation of connections between components, modules, and/or sub-systems in a product  Each row and column lists a component (or sub-system)  Connections are noted with a ‘1’ in that cell

4. PENN S TATE © T. W. S IMPSON DSM Clustering A DSM can then be “clustered” to identify modules or “chunks” within the architecture – or to define teams Source: Thomas A. Roemer and Prof. Steve Eppinger, MIT Sloan

5. PENN S TATE © T. W. S IMPSON DSM Example Noting Multiple Types of Connections Hydrogen-Enhanced Internal Combustion Engine Ref: Smaling, Rudy, “System Architecture Selection under Uncertainty”, Engineering Systems Division, June 2005, Ph.D. Thesis Slide adapted from O. de Weck & T. Simpson, MIT ESD 39s

6. PENN S TATE © T. W. S IMPSON www.DSMWeb.org There are a variety of clustering algorithms available  Many are available online at: http://www.DSMWeb.org How else is a DSM useful? 

7. PENN S TATE © T. W. S IMPSON Component Coupling DSM can be used to identify the strength of coupling between components/modules in the architecture Consider water cooler example: Source:Martin, M. V. and Ishii, K., 2002, "Design for Variety: Developing Standardized and Modularized Product Platform Architectures," Research in Engineering Design, 13(4), pp. 213-235. Water bottle Insulation TECTEC Heat sink Fan Power supply Reservoir

8. PENN S TATE © T. W. S IMPSON Coupling Index Compute the coupling based on sensitivity to changes  Coupling Index-Receiving (CI-R): – indicates the strength (or impact) of the specifications that a component receives from other components  Coupling Index-Supplying (CI-S): – indicates the strength (or impact) of the specifications that a component supplies to other components Source:(Martin and Ishii, 2002)

9. PENN S TATE © T. W. S IMPSON Design for Variety (DfV) Method With this information, Martin & Ishii propose DfV as:  Step 1: Generate GVI and CI for the design  Step 2: Order the components  Step 3: Determine where to focus efforts (i.e., where to standardize and/or modularize  Step 4: Develop product platform architecture Source:(Martin and Ishii, 2002)

10. PENN S TATE © T. W. S IMPSON Ranking Components GVI & CI indicate the drivers of change for each component: Combining this with development costs (NRE) helps us focus our platforming efforts Source:(Martin and Ishii, 2002)

11. PENN S TATE © T. W. S IMPSON Guidelines for Standardization and Modularization Standardized (GVI and CI-R related)  Fully standardized: – component will not change across generations (GVI and CI-R are close or equal to zero)  Partially standardized: – component is expected to require minor changes across generations; the higher the GVI and CI–R, the less it can be standardized Modularized (CI-S related)  Fully modularized: – geometry, energy, material, or signal (GEMS) of the component can be changed to meet expected customer requirements without requiring other components to change (CI-S of the component is zero or low)  Partially modularized: – changes in the GEMS of the component may require changes in other components; the higher the CI–S, the more changes expected, and thus the component is considered less modular Source:Martin, M. V. and Ishii, K., 2002, "Design for Variety: Developing Standardized and Modularized Product Platform Architectures," Research in Engineering Design, 13(4), pp. 213-235.

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14. PENN S TATE © T. W. S IMPSON Other Uses of DSMs How else can we use DSMs? 

15. PENN S TATE © T. W. S IMPSON Task-based Design Structure Matrix Task Sequence C D A B G H E F K L I J CDABGHEFKLIJ Sequential Parallel Coupled DSM can also be used to show task dependencies  Sequential, parallel, and coupled tasks are easily identified  Matrix partitioning/sequencing can expedite the product development process and facilitate integration and testing Slide adapted from O. de Weck & T. Simpson, MIT ESD 39s

16. PENN S TATE © T. W. S IMPSON Engine Evaporator Heater Core Blower Motor AccumulatorCompressor Blower Controls Evaporator Case Radiator Condenser Fan Oncoming Air Interior Air Heater Hoses A/C Hoses Source: Prof. Steve Eppinger, CIPD, MIT Example: Engine Climate Control System Slide adapted from O. de Weck & T. Simpson, MIT ESD 39s

17. PENN S TATE © T. W. S IMPSON Engine Compartment Chunk Vehicle Interior Chunk Engine Evaporator Heater Core Blower Motor AccumulatorCompressor Blower Controls Evaporator Case Radiator Condenser Fan Oncoming Air Interior Air Heater Hoses A/C Hoses Decomposition by Physical Collocation Source: Prof. Steve Eppinger, CIPD, MIT Slide adapted from O. de Weck & T. Simpson, MIT ESD 39s

18. PENN S TATE © T. W. S IMPSON Front End Air Heating Loop Air Conditioning Loop Engine Evaporator Heater Core Blower Motor AccumulatorCompressor Blower Controls Evaporator Case Radiator Condenser Fan Oncoming Air Interior Air Heater Hoses A/C Hoses Decomposition by Functional Flows Source: Prof. Steve Eppinger, CIPD, MIT Slide adapted from O. de Weck & T. Simpson, MIT ESD 39s

19. PENN S TATE © T. W. S IMPSON Front End Air Air Conditioning Interior Air Controls and Connections DSM View of Climate Control System potential module boundaries Source: Prof. Steve Eppinger, CIPD, MIT Slide adapted from O. de Weck & T. Simpson, MIT ESD 39s

20. PENN S TATE © T. W. S IMPSON Radiator Engine Fan Condenser Accumulator Compressor Evaporator Core Evaporator Case Heater Core Blower Motor Blower Controller Actuators EATC Control Refrigeration Control Heater Hoses Command Distribution Sensors Front End Air Team A/C Team Interior Air Team Controls/Connections Team Integrated Product Team (IPT) Assignments Source: Prof. Steve Eppinger, CIPD, MIT Slide adapted from O. de Weck & T. Simpson, MIT ESD 39s

21. PENN S TATE © T. W. S IMPSON DSM for Team Formation Team 1 Integration Team Team 2 Team 4 Team 3 Flywheel Connecting Rods Crankshaft Cylinder Heads Intake Manifold E.V.A.P. Fuel System Air Cleaner Throttle Body Electronic Control Module Pistons Engine Block Lubrication Water Pump/ Cooling Camshaft/ Valve Train Exhaust E.G.R. A.I.R. Electrical System Ignition Engine Assembly Accessory Drive Engine Development Team Map IPT team structure to DSM via frequency of interaction - daily, weekly, monthly Source: Prof. Steve Eppinger, CIPD, MIT Slide adapted from O. de Weck & T. Simpson, MIT ESD 39s