A Comprehensive Review of Concurrent Engineering in

Manufacturing Systems
Mohammed Imran Hossain – MH24171

Modern Design Theory- Professor Xu Jing

Abstract

Introduction
The main aim of concurrent engineering is to reduce significantly the time from design to
manufacture by applying a simultaneous rather than sequential approach to the various product
and process design activities. The full realization of concurrent engineering is a challenging task
that requires an in-depth understanding of the designer’s decision-making logic and
comprehensive models describing the information flow between concurrent activities in product
and process design. The task involves choosing a design representation scheme capable of
capturing the designer’s intents and of being used for various downstream applications[1, 2]
Implementation of concurrent engineering also entails the provision of intelligent system support
to the designer. This requires the identification of the information needed for supporting the
different design activities and the determination of adequate techniques for information selection
and presentation. The designer is, through his or her decisions, responsible for 70 to 80 per cent
of the product cost[3], but during the design process there is usually no access to existing
knowledge about the manufacturing environment which could facilitate and direct decision-
making activities.
The decision logic employed in concurrent design is primarily based on simultaneously matching
the functional requirements of a product to the technological requirements of each component
and the technological requirements to the capabilities of a given manufacturing system.[2, 4, 5]
Product designs have been a significant aspect of mass manufacturing since the early days, with
a division of intellectual work between the designer and producer. This gap between design and
production has led to increased competition, new manufacturing techniques, and reduced
development. Engineering authors argue for the reduction of these obstacles and the importance
of interaction between the design department and production.

The rising degree of competition is justified by the need for more collaboration in product
creation. As new manufacturing techniques come into service, information about these processes
must be made accessible to the product designer, enabling designers to adapt to the limits of new
processes. Design engineers often collaborate closely with production engineers when new
manufacturing techniques are deployed.[6]
A concurrent engineering method aims to reduce the development cycle and offer a competitive
edge by tackling all parts of the design challenge concurrently, resulting in reduced development
time. Cross-functional interaction is necessary for achieving this integration, and organizational
approaches include demanding consent from other departments, creating a liaison department,
assembling all interested parties into one cross-functional team, and employing job rotation to
ensure functional cross-pollination.

Liaison people coordinate the operations of design and production, solving challenges that
traverse organizational boundaries. High-level interdepartmental meetings, such as the
establishment of a Design Committee, can help overcome coordination concerns. Cross-
functional design teams, created in the 1940s-1960s, are crucial organizational strategies for
concurrent engineering, ensuring close coordination between engineering and manufacturing for
optimal production efficiency.[6]
Various Approaches of Concurrent Engineering

Concurrent engineering strategies include information systems, software engineering, artificial

intelligence, computer-aided design and manufacturing integration, life cycle engineering, Design for
Manufacturability and Design for Assembly, and organizational and cultural transformations, which aim
to streamline processes and improve efficiency.

The methodologies of concurrent engineering stem from personal preferences and backgrounds. The
overarching structure of these methodologies is examined in greater detail. [7]

2.1 Information Systems, Software Design, and Artificial Intelligence

The methodology states that concurrent engineering depends on prompt, precise, and pertinent
information, enabled by databases, software, expert systems, and an information network serving as an
integrative link across functions.

Fig. 1 shows a system approach to design and development of an integrated manufacturing information
system. In Fig. 1, the inner layer represents the manufacturing functions; the innermost layer represents
commercial functions; and the outer layer represents the logistical functions. Each of the functional
needs can be employed in a modular format with substantial hierarchical structure.
Design of complex items demands a vast deal of data during the design process. To employ successfully
the information system for design of mechanical systems, two pieces of data are required. The first
collection of data, referred known as design data, consists of:

Design database: This consists of the data that can be communicated among the design and
manufacturing tools in the design environment. The data should be capable of being represented in
numerous forms in an evolving format. Design databases should allow for concurrent access and change
by many users. A data control system should be added to ensure the data integrity and provide for limits
for unauthorized users.

Configuration management: This relates to identification and documenting of functional,

behavioral, and physical attributes of a configured device.
Design release :This comprises information concerning design documentation, product testing,
design validation, design reviews, and product reliability tools and records.

The second collection of data, referred known as performance data, is acquired from multiple
sources once the design is placed in service. These data provide feedback to design teams as to
the operation and performance of a product in an actual operational environment. The
performance data can be categorized into three time-phased stages:

Preliminary performance statistics: These apply to the data initially accessible when a product
is placed in service. These performance statistics assist the designers in detecting any faults or
malfunctions that are integrated in the design.
Intermediate performance data: These refer to a considerable period of the useful life of the
product. These metrics represent the overall performance of the product.
Final performance data: These refer to the short duration of the life of the product before its
disposal. These data consist of dependability and maintainability information.
After one design cycle is completed, the performance data gathered will be used to refine and modify
the design process. The effectiveness of this procedure is defined by the availability of timely, relevant,
and correct information.

The current software and technologies lack comprehensiveness and good communication with existing
systems. High development costs and cycle time, performance concerns, inflexibility, and obsolescence
lead to functionality problems. More effort is needed to improve these characteristics.

Although this method to concurrent engineering still requires further research, various tools and
technologies have arisen that fulfill the information requirements of a concurrent engineering
environment.
1. Mechanical computer-aided engineering (MCAE) software assists engineers in conceptual design
development, drafting, analysis, testing, documentation, communication, and information retrieval,
while also functioning as a communication medium.[8]
2. Computer-aided simultaneous engineering (CASE) is a technique that facilitates human-computer
interaction in fragmented and disassembled mechanical systems. [9]
3. An advanced knowledge-based system capable of efficiently resolving design optimization challenges
and evaluating the resultant outputs.[10-13]
4. Maher.[14] has developed a program named HI-RISE which is capable of giving configurational design
of three-dimensional high-rise buildings. The program often generates multiple structural configurations
consisting on standard structural subsystems
5. Mittal et al. [15] created PRIDE, PRIDE is a knowledge-based computer software designed for
designing paper transport systems in copiers, enabling the development, assessment, and redesign of
setups.

2.2 Integration of CAD and CAM

Concurrent engineering is the integration of computer-aided design (CAD) and computer-aided

manufacturing (CAM) technologies into a manufacturing system to develop both products and processes
simultaneously. However, existing CAD systems lack comprehensive data management facilities, leading
to a lack of effective connection with CAM systems and trouble handling huge volumes of information
for process planning tasks. Various ways have been developed to accomplish CAD/CAM integration, with
feature-based design being the most promising. However, the largest challenge is the compatibility of
design features. Part features can be considered as a common ground for integrating design and
manufacturing operations, but the feature-based design method has limitations in its generality due to
the varied features of different manufacturing processes.

The suggested framework for CAD/CAM integration involves determining design requirements,
manufacturing process planning, design and manufacturing features, and building a knowledge base
management system (KBMS) based on these features.[7]

Application Of Concurrent Engineering

Concurrent engineering has acquired substantial use in different areas, with the military industry
being one of its early adopters. Aerospace corporations like Boeing employed this strategy,
known as concurrent product development, to design and manufacture the 777 series of
airplanes.[16]
In the following sections, i present a quick overview of the usage of concurrent engineering in
several domains. The presentation is not exhaustive nor complete. Rather, the objective is to
demonstrate how pervasive the usage of concurrent engineering has become over the last several
years.
• Concurrent engineering in defence and aerospace
Since 1988, major US aerospace corporations including Boeing, General Dynamics, Lockheed
Martin, and Northrop-Grumman have been adopting concurrent engineering, with cross-
functional teams institutionalized. The US Department of Defense requirement has pushed its
usage, with the CALS effort responsible for quick implementation. Success in military and
aerospace has hastened its transfer to civilian commercial industries.[17]
• Concurrent engineering in the automotive industry
The automobile sector has been a pioneer in concurrent engineering, with major Japanese car
manufacturers including Honda, Mazda, Nissan, and Toyota embracing methods like just in time,
quality function deployment, and product development teams. Honda's SED system has helped
them acquire and maintain market share in numerous nations, including the US. In the US,
General Motors, Ford, and Chrysler started adopting concurrent engineering in 1984, with
Chrysler extending their process since the Liberty team's formation. General Motors optimized
the vehicle development process utilizing a concurrent engineering method, resulting in a 70%
decrease in product development cycle time and over $1 billion in savings. This led to a lean and
integrated design approach across the supply chain.[17-22]
• Concurrent engineering in process science and technology
Process science and technology are vital for chemical manufacturing facilities development,
scale-up, and design. However, present applications are scattered and generally driven by short-
term commercial demands. A concurrent engineering strategy, incorporating multi-disciplinary
teams and early integration of key disciplines, technologies, and processes, may considerably
enhance the applications of these technologies. Large chemical businesses like Dow Chemical
are using this technique.[22]
• Use of concurrent engineering in education
Educational institutions are leveraging concurrent engineering concepts to give hands-on design
and project experience to students. The SEEHIGHS program in Canada puts high school students
to the engineering profession via a group project, engaging industry partners. The program has
proved that concurrent engineering can be employed in academic contexts, resulting in superior
designers. The Concurrent Engineering Group of the Center for Educational Technology of
Parana in Brazil also utilizes this method.[22, 23]
• Concurrent engineering in the electronics industry
Electronics corporations including Intel, Motorola, Mentor Graphics, and Texas Instruments are
employing concurrent product development methodologies to minimize cycle time, time-to-
market, and unit cost while preserving quality. Kaiser Electronics has adopted a concurrent
engineering approach, integrating integrated teams from several divisions, to shorten product
development time by 50%. Telia Research also employs concurrent engineering for an
interactive TV interface.[22, 24, 25]
• Concurrent engineering applied to medical devices
Concurrent engineering may be used to medical device manufacture, concentrating on cost
reduction, time-to-market efficiency, and device dependability. Smaller enterprises confront
competitive obstacles, with examples including catheter and guide wire design and infusion
pump design.[22]
Concurrent Engineering in the Construction Industry
The construction business is a multifaceted sector that includes power plant construction,
residential and commercial building projects, road construction, infrastructure development, and
service installations. It constitutes a substantial portion of the economy, representing 60% of
total spending[26]. The construction sector in an industrialized country accounts for more than
12 percent of the GDP[27]. The construction sector's substantial employment rate, representing
over 7% of Australia's overall workforce, highlights its significance in the labor market[28].
The construction sector is battling with low productivity and poor performance. To solve this, the
Concurrent Engineering (CE) technique has been implemented to enhance manufacturing and
construction processes. This strategy comprises concurrent building, integrating people into a
single development process, and addressing all downstream components of the design and
construction process. This strategy attempts to boost product quality, decrease costs, and
optimize the whole system, including design, manufacturing, production, and marketing. The
construction industry, a diversified sector, comprises power plant construction, residential and
non-residential building construction, and services installation. The public sector is the largest
customer, accounting for 60% of total spending on new and repair works.[26]
The construction industry's productivity has fallen owing to problems including fragmentation,
poor communication, quality variations, and non-productive time. A re-engineering concept,
Concurrent Construction (CC), is recommended to overcome these challenges. CC includes
integrated design and production of goods, considering all life cycle factors. It incorporates a
multi-disciplinary team, computer assistance, and planning tools. Construction Engineering (CE)
is critical for improving project performance by addressing all downstream stages, including
construction operation and maintenance, throughout the design process[26] .
Advantages
Concurrent Engineering Approaches and Quality Improvement
• Concurrent engineering can enhance quality, reduce costs, and shorten development cycles.
• Companies often use this approach to enhance competitiveness.
• Japanese quality approach leads to cost savings, decreased scrap and rework, and enhanced
production efficiency.
• Quality improvements include Aerojet Ordnance's salvage of pyrotechnic pellets, AT&T's
decrease in variability, and Deere's reduction in inspectors.[29]
• Cost savings include lower bids, reduced design process, fabrication, production, and assembly
costs, parts reduction, and inventory management.
• Interactions with concurrent engineering can lead to improvements in quality, cost, and
schedule[29]
Pitfalls of Concurrent Engineering

• The advantages of concurrent engineering are promising but frequently unappreciated owing to
the control of bigger systems by top management.
• Most divisions concentrate too much on methods of concurrent engineering without addressing
the key management philosophy behind their use.
• The customer's acquisition strategy might sometimes delay the deployment of concurrent
engineering.
• A contracting process that separates engineering from production may restrict cost reduction,
enhance quality, and decrease scrap.
• Engineering modifications are typically created by rival engineering companies, inhibiting
continual improvement and disconnecting manufacturing from design.
• The expectation of rapid success might lead to higher initial project expenditures and delay in
the execution of early design activities.[29, 30]
Challenges
Concurrency planning on the basis of forward and backward effects : In sequential
manufacturing processes, each process's findings are passed to the next, producing a lack of
systematic attention to subsequent phases. Concurrency planning can be based on forward
effects, backward effects, or combination forward and backward effects. Forward effect (FE)
believes each process effects solely its previous ones, whereas backward effect (BE) includes
each process impacting its preceding ones. Analyzing BE is crucial for scheduling operations and
increasing concurrency. In parallel work, both FE and BE (FBE) should be considered for
scheduling activities, building up interdisciplinary teams, and defining focus points. Thorough
concurrency planning needs both forward and backward chaining.[31]

Future aspects
The theory of connections is a promising technique for mathematical modeling of
complex systems, providing quantitative study of constituents and system
towlogy. Knowledge Processing Technology (KPT) is another potential topic for
Concurrent Engineering, concentrating on group productivity. Current tools are
built for individual productivity, but future ones should facilitate group interaction
of engineering teams with various technical backgrounds and geographical
locations. These technologies need to manage group problem-solving exercises,
collaborate across conflicting disciplines, communicate upstream and
downstream, and include complementary technical skills.[32, 33]
Further developments: networks
Concurrent Engineering in the extended enterprise: In the future, firms will need
to work more with suppliers, consumers, and other stakeholders, leading to
changes in organizational structure. Improved communication methods will
increase distance between sites, and the corporation will become a factory with a
flat organization. The plant manager will concentrate on assisting the organization
get its task done, while suppliers will become partners and build strategic
connections. Communication between suppliers and the firm will increase,
enabling suppliers to engage in product development early. Customers will
become designers of future, and corporations must build up modules for them to
customize their own goods. For example, a Japanese company employs a
technology to let consumers to create their own outfits by dressing up a
computer-based 3-D picture, which will control automated fabric cutters and
sewing machines at an experimental plant.[34]
Agile manufacturing
Japanese corporations have promoted inter-firm collaboration to combine skills
and capabilities in response to fast technological advances. This has led to the
establishment of extended businesses where each stakeholder is accountable for
a subset of Product Development operations. Ensuring information sharing
without jeopardizing each participating firm's position is a significant challenge in
Product Development. This tendency may evolve to Agile Manufacturing, where
each chain activity can be done by various partners for each project. Knowledge
centers are also significant. Environmental concerns are generating increasing
cooperation between manufacturers and recycling firms. Product disposal has
become relevant in Product Development owing to increased prices and the
necessity to address reuse of components or basic materials. Companies that
swiftly create their essential network have the greatest chance of becoming a
successful firm.[34]

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