Mod 1 Lecture_PDC.pdf
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The document discusses the product life cycle and concurrent engineering. It provides the following key points: 1. A product goes through two main processes - design and manufacturing. The design process involves synthesis and analysis to conceptualize and model the product. The manufacturing process begins with planning and ends with the finished product. 2. Concurrent engineering brings together cross-functional teams from different departments to work in parallel from the beginning of product development. This reduces costs and time to market compared to traditional sequential engineering. 3. Product life cycle management (PLM) views the entire lifespan of a product as a process that can be managed, measured, and modified for continuous improvement. PLM helps collaboration both internally and with partners
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Mod 1 Lecture_PDC.pdf
- 1. UNIT 1 Lecture 1 Product Life Cycle
- 2. 2 The Product Cycle and CAD/CAM A study of a typical product cycle is necessary • to establish the scope and definition of CAD/CAM in an engineering environment • to identify existing and future related tools
- 3. 3 The Manufacturing Process The Design Process Synthesis Analysis The CAD Process The CAM Process Design needs Design definitions, specifications, and requirements Collecting relevant design information and feasibility study Design conceptualization Design modeling and simulation Design analysis Design optimization Design evaluation Design documentation and communication Process planning Order materials Design and procurement of new tools Production planning NC, CNC, DNC programming Production Quality control Packaging Marketing Shipping Typical Product Life Cycle
- 4. 4 • The product begins with a need which is identified based on customers' and markets' demands. • The product goes through two main processes from the idea conceptualization to the finished product: 1. The design process. 2. The manufacturing process. The main sub-processes that constitute the design process are: 1. Synthesis. 2. Analysis.
- 5. Product goes through two main processes from inception to a finished product : - the design and manufacturing process Design process involves Synthesis and analysis # Synthesis determines the philosophy, functionality and uniqueness of the product # Analysis answers the question ‘What if’, evaluates the concept design in the engineering perspective, helps in performance evaluation and in evaluating multiple designs Manufacturing process begins with process planning and ends with actual product
- 6. Product Development Cycle -Industries have to design and re-design their products to stay put in the market -Upon Initial introduction to market, customers define the survival of a product based on satisfying customers need and their perception - Elaborate network is enabled to service customer problems with regard to the problems -Inspite of being successful in case of deficiencies, today’s market demands product recall Successful Product… #1 The sales volume will pick up gradually and peak after some time. The product will continue to sell for some time. #2 The sales will then start gradually declining owing to availability of better products in the market. It is time for the company to introduce a new and improved product in the market as well as to retire the old product. #3 The companies will usually advice the customers that the old product will be further supported by the sales and service department only for a limited period of time.
- 7. The cycle through which a product goes through from development to retirement is called the product life cycle. Variation of sales volume through the life of a product
- 8. Product Life Cycle Time Product Develop- ment Introduction Profits Sales Growth Maturity Decline Losses/ Investments ($) Sales and Profits ($)
- 9. The product development Cycle is a spiral The idea of a product may come from a - patent - suggestion of the customers - feedback of the sales and service department - market research carried out by the marketing or from the R&D department The next stage is the conceptualization of the product -The cost at which the product could be sold in the market - the overall design in terms of shape, functional specifications, ergonomics, aesthetics etc are considered in detail and finalized
- 10. Design Stage • design department who carefully designs each assembly and each component of the assembly. • Detailed design analysis and optimization is carried out at this stage. A design may have several variants. • The design department creates these designs through a top down approach or a bottom up approach. – In top down approach, the entire assembly is designed first and individual designs are done latter. In bottom up approach, the component design is done first and the product is realized by assembling the components suitably. • Engineering the product consists of process planning, tool design, facility design, capacity planning, quality assurance activities, procurement, assembly planning, etc. Marketing Stage • have the responsibility of carrying out appropriate product launch activities as well as planning the sales and service network, advertising and training of sales and service personnel.
- 11. Product Development Spiral The design development process is an iterative process Instance from the Ford 1920s model to the current model the amount of design iteration that has taken place
- 12. Product Sustainability – Life Cycle @ Ford
- 13. Traditional or 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, all carried out one after another. This situation assumes that there is no interaction among the major departments involved in product manufacturing during the initial development process. Design department in a typical sequential product development process finalizes the design without consulting the manufacturing, quality or purchase departments. Any Change may require starting from the first sequence • Design changes will involve both material and time wastages. • response to the market requirements will be slow compared to a competing company which can create an error free design at the first instance.
- 14. Design and Re-design path Across the wall approach in a traditional design
- 15. Concurrent Engineering Concurrent engineering/ Simultaneous Engineering / Parallel Engineeing is a methodology of restructuring the product development activity in a manufacturing organization using a cross functional team approach is a technique adopted to improve the efficiency of product design and reduce the product development cycle time. • 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, vendor development etc. develop the product as a team. – Everyone interacts with each other from the start, and they perform their tasks in parallel. 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.
- 16. CE can be defined as… “Integrated approach to product-design that takes into account all stages of a product’s life cycle from design to disposal – including costs, quality, testing, user needs, customer support, and logistics”
- 17. Product R&D Design & Engineering Planning & Purchase Sales & Service QC & QA Manufacturing May also include Finance, Outsourcing
- 18. The activities necessary to complete a particular task within a specific engineering discipline have to emerge wherever possible from their sequential flow into a concurrent workflow with a high degree of parallelism Total quality management is thus closely related to concurrent engineering.
- 19. An example of various activities done in parallel
- 20. Typical Characteristics of concurrent engineering • Integration of product and process development and logistics support • Closer attention to the needs of customers • Adoption of new technologies • Continuous review of design and development process • Rapid and automated information exchange • Cross functional teams • Rapid prototyping
- 21. The CE Approach • Focuses on optimizing and distributing resources within a company or unit during design and development • Collaboration is required • Involves implementation, appraisal, and continuous improvement initiatives • Must be applied throughout a system to be successful (requires strong leadership)
- 22. Success/advantage of CE depends on • Get a strong commitment from senior management. • Establish unified project goals and a clear business mission. • Develop a detailed plan early in the process. • Continually review your progress and revise your plan. • Develop project leaders that have an overall vision of the project and goals. • Analyze your market and know your customers. • Suppress individualism and foster a team concept. • Establish and cultivate cross-functional integration and collaboration. • Transfer technology between individuals and departments. • Break project into its natural phases. • Develop metrics. • Set milestones throughout the development process. • Collectively work on all parts of project. • Reduce costs and time to market. • Complete tasks in parallel.
- 23. How can the data be managed • Design changes, status reviews, releases and their effects on cost, delivery and quality have to be managed. • How work flows and the information flow, storage,retrieval and decision making can be supported and controlled. information systems have to be developed which integrate the different engineering disciplines and their support tools
- 24. Product life cycle management (PLM) This tool views the entire life cycle of a product as a process that can be managed, measured, monitored modified to achieve continuous improvement. PLM helps manufacturers acquire the capability to collaborate internally (within the organization) and externally (outsourcing partners or vendors) collaborate on product development, manufacture, market and service till the retirement of the product, consistently maintaining the highest possible efficiency throughout the value chain. Product Life Cycle Management is a total production system that tracks a product from inception to disposal
- 25. The Scope of PLM Product Lifecycle Plus the engineering business systems to make the process work with the rest of the company
- 26. Components of PLM Engineering Design Design management - Design, validation using CAE Engineering process - CAD drawing realase, CAM Change management- Design changes,process changes, roles changes Design colloboration from multi sites Knowledge management and process automation Design iterative data documentation versions control product structure and configuration management archiving and creating a knowlege respositary Product visualisation visualization and collaboration capabilities enable team members to view the digital mock up or exchange their representations Aesthetics and ergonomics - concept team to design and sales service involvement Real time collaboration Secure,adoptive and user friendly real time collaborative enables rapidness in all functional areas
- 27. Project Management Assessing and capturing customer requirements Supply Chain management • PLM integrates the procurement/outsourcing related processes with the rest of the engineering • The product development teams can assess through various functionalities the design content, cost efficiency, product quality and suppliers capabilities Manufacturing • Planning for assembly process, factory layout , robot programming, worker safety and ergonomic studies Servicing capability Common PLM softwares Siemens PLM Enovia of DS Winchill of PTC ARAS