IPD: Concurrent Engineering

1. Integrated Product Development
IPD - Concurrent engineering
Thomas J. Howard
https://sites.google.com/site/thomasjameshowardhomepage/
thow@mek.dtu.dk
Unless otherwise stated, this material is under a Creative
Commons 3.0 Attribution–Share-Alike licence and can be
freely modified, used and redistributed but only under the
same licence and if including the following statement:
“Original material by Thomas J. Howard for course 42629 – Innovation and Product Development
Department of Mechanical Engineering, The Technical University of Denmark”
Thanks to Thorkild Ahm, IPU for providing DfA samples

2. Concurrent Engineering
Designing the Product and
Production simultaneously
Market
Product Business
Production
2 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012
Department of Mechanical Engineering, The Technical University of Denmark

3. What are DFX methods?
DFX: Design For X
• where „X‟ is an important aspect related to the product lifecycle,
• and „Design For‟ means to design the product in order to improve
Important DFXs:
DFE – Design for the Environment
DFM – Design for Manufacturability
DFA – Design for Assembly
DFS – Design for Serviceability
DFC – Design for Changeover
DFD – Design for Disassembly
DFQ – Design for Quality (QFD method)
3 Original material by Tim C. McAloone adapted for course 42629 – Innovation and Product 2012
Development Department of Mechanical Engineering, The Technical University of Denmark

4. DfX and Life Cycle
Environment
Flexibility
Efficiency
Quality
Time
Cost
Risk
Design for …
Df – Cost
Df – Assembly
Df – Manufacturing
Df – Usability
Df – Quality
Df – Serviceability
Df – Environment
Platform development
…
[Score model from
Olesen, 1992]
4 Original material by Tim C. McAloone adapted for course 42629 – Innovation and Product 2012
Development Department of Mechanical Engineering, The Technical University of Denmark

5. Trade-offs
… require knowledge of all DFX-areas
Acceleration User-
ability 0-100km experienced Q
[s]
Petrol useage Weight [g]
[km/L]
[From McAloone,
Assembly speed Running costs
[kr] Inspired by Allen Ward]
[s]
Amount of Manufacturing costs
components [n] [kr]
5 Original material by Tim C. McAloone adapted for course 42629 – Innovation and Product 2012
Development Department of Mechanical Engineering, The Technical University of Denmark

6. Design for Serviceability (DFS)
“Don‟t make „em start all over”

7. DFS improvements...
Original Redesign
7 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012
Department of Mechanical Engineering, The Technical University of Denmark

8. Think about service in advance...
Headlamp bulb replacement example
This side up
[Case from Winston Knight, Rhode Island]
8 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012
Department of Mechanical Engineering, The Technical University of Denmark

9. Here’s what it takes...
Disassemble: Reassemble:
2 Screws (left side light) Headlamp bulb
Cover (left side light) Headlamp glass
Cable connector Headlamp trim
Housing (left side light) 4 Screws (headlamp trim)
2 Screws (right side light) Radiator panel
Cover (right side light) 14 Screws (radiator panel)
Cable connector Housing (right side light)
Housing (right side light) Cable connector
14 Screws (radiator panel) Cover (right side light)
Radiator panel 2 Screws (right side light)
4 Screws (headlamp trim) Housing (left side light)
Headlamp trim Cable connector
Headlamp glass Cover (left side light)
Headlamp bulb 2 Screws (left side light)
32 items 32 items
[Case from Winston Knight, Rhode Island]
9 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012
Department of Mechanical Engineering, The Technical University of Denmark

10. Design for Manufacture and
Assembly (DFMA)
“That‟s all well and good but how are we gonna make it?”

11. Boeing Helicopter
(formerly McDonnell Douglas Helicopter Systems)
Apache Longbow Helicopter
Redesign
Estimated savings
$1.3 billion over life of program
One aircraft per month
Increased to five per month
[Case from Winston Knight, Rhode Island]
11 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012
Department of Mechanical Engineering, The Technical University of Denmark

12. Anti-Flair Bracket Assembly for the
Boeing Longbow Apache Helicopter
Before After
1 high-speed machined part
5 sheet metal parts 2 hours manufacturing
19 rivets 10% less weight
20 tools needed 45% less cost
32 hours manufacturing Tooling cost virtually eliminated
Source: Alfredo Herrera,1998 International DFMA forum, Newport, RI
12 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012
Department of Mechanical Engineering, The Technical University of Denmark

13. Jump Seat for Extended Cab Pick-up
Base line analysis
105 separate parts
Total assembly time estimate
1440 s, excluding paint
application
Many tubular parts and small
tabs hand welded during
assembly
Many reorientations of product
during assembly
[Case from Winston Knight, Rhode Island]
13 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012
Department of Mechanical Engineering, The Technical University of Denmark

14. Jump Seat for Extended Cab Pick-up
Phase 1 Proposal
Objective to reduce parts and assembly time
while maintaining essential functions
Most welding steps eliminated
Cams and rolling components replaced by
slides guided in slots
Part count reduced to 19 , with 5 major
subassemblies
Assembly time estimate reduced to 258 s
A more radical Phase 2 proposal that loses
some functionality was also developed
[Case from Winston Knight, Rhode Island]
14 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012
Department of Mechanical Engineering, The Technical University of Denmark

15. DfMA – Housing corner piece
Lønstrup
[Andreasen, Kähler & Lund, 1988 – “Design for Assembly”]
15 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012
Department of Mechanical Engineering, The Technical University of Denmark

16. DfA – Water sprinkler
[Andreasen, Kähler & Lund, 1988 – “Design for Assembly”]
16 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012
Department of Mechanical Engineering, The Technical University of Denmark

17. DfA – ‘Stacking’
[Andreasen, Kähler & Lund, 1988 – “Design for Assembly”]
17 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012
Department of Mechanical Engineering, The Technical University of Denmark

18. GNT Automatic
[Andreasen, Kähler & Lund, 1988 – “Design for Assembly”]
18 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012
Department of Mechanical Engineering, The Technical University of Denmark

19. DfA – Plastic integration
19 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012
Department of Mechanical Engineering, The Technical University of Denmark

20. DFMA exercise 2 small screws
end plate -
sheet steel
bushing -
plastic
2 standoffs -
motor steel - machined
sensor
2 motor
screws
small screw
2 bushings -
base - machined
powder metal - brass
aluminum
cover - sheet
steel - welded 4 small
screws
[Case from Winston Knight, Rhode Island]
20 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012
Department of Mechanical Engineering, The Technical University of Denmark

21. DFA Analysis data sheet
[Case from Winston Knight, Rhode Island]
21 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012
Department of Mechanical Engineering, The Technical University of Denmark

22. Re-designed solution
cover -
injection
molding
motor
2 motor sensor
screws small screw
base - nylon
[Case from Winston Knight, Rhode Island]
22 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012
Department of Mechanical Engineering, The Technical University of Denmark

23. Questions
?
23 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012
Department of Mechanical Engineering, The Technical University of Denmark