CONCURRENT ENGINEERING

FUNDAMENTALS VOLUME II

Integrated Product Development

Biren Prasad PRENTICE HALL INTERNATIONAL SERIES

IN ~NDUSTRIAL AND SYSTEMS ENGINEERING

To join a Prentice Hall PTR internet mailing list, point to: http://www.prenhall.com/register

Prentice Hall PTR Upper Saddle River, New Jersey 07458

http://www.prenhall.com

Library of Congress Cataloging-in-Publication Data Prasad, Biren

Concurrent engineering fundamentals: integrated product development / Biren Prasad.

p. cm. - (Prentice-Hall international series in industrial and systems engineering)

Includes bibliographical references and index. ISBN &13-3969464 1. Production engineering. 2. Concurrent engineering. 3. Design,

Industrial. 1. Title. 11. Series. TS 176.P694 1996 670.4--dc20 95-43 132

CIP

Acquisitions editor: Bernard Goodwin Cover designer: Design Source Cover design director: Jerry Votta Manufacturing buyer: Alexis R. Heydt Compositor/Production services: Pine Tree Composition, Inc.

O 1997 by Prentice Hall PTR Prentice-Hall, Inc. A Simon & Schuster Company Upper Saddle River, New Jersey 07458

The publisher offers discounts on this book when ordered in bulk quantities. For more information contact:

Corporate Sales Department Prentice Hall PTR One Lake Street Upper Saddle River, New Jersey 07458

Phone: 80&382-3419 Fax: 201-236-7141 email: corpsales@prenhall.com

All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher.

Printed in the United States of America

ISBN: 0-33-3767q6-0

Prentice-Hall International (UK) Limited, London Prentice-Hall of Australia Pty. Limited, Sydney Prentice-Hall Canada, Inc., Toronto Prentice-Hall Hispanoamericana, S.A., Mexico Prentice-Hall of India Private Limited, New Delhi Prentice-Hall of Japan, Inc., Tokyo Simon & Schuster Asia Pte. Ltd., Singapore Editora Prentice-Hall do Brasil, Ltda., Rio de Janeiro

WHAT OUR READERSIREVIEWERS SAY ABOUT VOLUME I?

In the last few years, several books have been published in Concurrent Engineering. The book Concurrent Engineering Fundamentals is the first comprehensive text book, which balances cov- erage of fundamental concepts, original research results, industrial applications and practical expe- riences. It deals with all major issues involved in CE ranging from information technology to life cycle management. Concurrent Engineering Fundamentals is essential reading for engineers, man- agers and academics who are working in the field of concurrent engineering.

... It is an excellent text book for senior undergraduate students and graduate students in the field of manufacturing engineering, production engineering, industrial engineering and business schools.

Peihua Gu, Ph.D. and P.Eng. Professor and NSERC/AECL Chair Dept. of Mechanical Engineering University of Saskatchewan, Saskatoon, SK, Canada

I found Concurrent Engiyleering Fundamentals to be an easy-to-read introduction to an area that has intrigued me for several years. The book is rich in illustrations and tables, and this abundance of visual material helped me make sense of the concepts and jargon introduced in the book. Furthermore, I found that I could skip around the book to topics of particular interest without too much trouble. That I

is, the book permits the reader to select topics of interest without having to read it in its entirety. 1

. . .The Concurrent Engineering Fundamentals book will be eminently useful both to students taking a course in Concurrent Engineering and to engineers seeking to update their skills on their own.

Raphael (Raji) T. Haftka, Ph.D. Professor, University of Florida Department of Aerospace Engineering Mechanics and Engineering Science Gainesville, Florida

This book Concurrent Engineering Fundamentals-although it has Fundamentals in its title-is a book not only for the newcomers to the field, but also for the experts, too. What distinguishes this book from others is that it really embodies concurrent engineering in its writing. Concurrency is well main- tained throughout-among the concepts, methodologies including discussions of the social and techni- cal backgrounds. Further, these concepts and methodologies are so well illustrated that newcomers will not find any difficulty in understanding them. The well indexed technical terms help a great deal for the newcomers to understand. Experts will also find Concurrent Engineering Fundamentals very informative because there are so many descriptions and comparisons of different cultures. There are also many descriptions about Japan. Even to a Japanese like me, I found that the book contains many new findings about our Japanese industrial backgrounds that I did not know before.

. . . I would like to recommend Concurrent Engineering Fundamentals for all who have inter- ests in CE, newcomers and experts as well.

Shuichi Fukuda, Ph. D. Chair Professor and Deparment Chair Department of Production, Information and Systems Engineering Tokyo Metropolitan Institute of Technology Asahigaoka, Hino, Tokyo, JAPAN

A long needed book ... Concurrent Engineering Fundamentals is the first comprehensive text in the rapidly developing area of CE that covers the very fundamentals.. . .

Apart from its merits of high quality and timely content, the book is very well organized edi- torially. The book will appeal to both the engineering and management practitioner, as well as the academic community, where it can serve as a textbook.

Dr. Marek B. Zaremba Professor, Dept. of Computer Science University of Quebec, CANADA

The cost and time it takes to do product and process engineering has been escalating over the last few decades due to several reasons among them: increasing customer satisfaction, increasing gov- ernment regulations, and increasing design alternatives due to material and process innovations. Concurrent Engineering Fundamentals rightly sets forth the philosophy and methodology neces- sary to conduct a modem concurrent engineering process.

. ..Concurrent Engineering Fundamentals will be a very welcomed addition to the literature I in this important growing field.

Mounir M. Kamal, Ph.D. Executive Director (Retired) General Motors Research Laboratory

I Warren, Michigan

1 Concurrent Engineering Fundamentals is a very comprehensive, thorough, and visionary analysis of the concurrent engineering process. It serves a wide range of needs from an engineering text-

, book to a highly useful reference. In this day of exploding knowledge, intensifying global competi- tion, and more demanding customers, it is imperative to significantly improve the engineering process. No longer is an undisciplined and often ad hoc process good enough. The entire process must be managed following a very disciplined approach.

Concurrent Engineering Fundamentals is a book that brings both breadth and depth to the issue. It is a coherent work integrating the "alphabet soup" of current thidcing and new techniques re-

\ lated to the overall product development process and should help individuals, work teams, and com-

! panies improve their effectiveness. Key performance factors, including quality, time to market, and

I cost are given appropriate attention as is the important issue of continuous improvement and re- I engineering.

1 . . . I recommend Concurrent Engineering Fundamentals to all who are faced with challenges of improving the effectiveness and efficiency of their engineering process.

I David E. Cole, Ph.D. Director, Transportation Research Institute Ofice for the Study of Automotive Transportation The University of Michigan

I Ann Arbor, Michigan

Concurrent Engineering Fundamentals offers a lot of new information . . . new material and fo- cused. Frankly speaking, no book exits in the market to this-CE Fundamentals book.. . .

Nanua Singh, Ph.D. Professor, Department of Industrial and Manufacturing Engineering Wayne State University, Detroit, MI

To Pushpa, Rosalie, Gunjan, and Palak, for your patience and support

Trademarks (TM)

pro/EngineerTM: Parametric Technology Corp., Waltham, MA.

I-DEAS Master seriesTM: SDRC, Milford, OH.

CADDS 5TM: Computervision Corp., Bedford, MA.

Anvil 5 0 0 0 ~ : Manufacturing & Consulting Series, Scottsdale, AZ. catiaTM Solutions: Dassault Systems, North Hollywood, CA.

unigraphicsTM: EDS Unigraphics, Maryland Heights, MO.

HP ~ ~ l ~ o l i d ~ e s i ~ n e r ~ : Hewlett-Packard, Ft. Collins, CO.

lcADTM: Concentra Corporation, Burlington, MA.

I / E M S ~ : Intergraph Corp., Huntsville, AL.

Acronyms

Preface

Acknowledgments

1 Concurrent Function Deployment

Introduction 1 Components of QFD 2 Limitations in Deploying QFD 10 Concurrent Product Development 13 Concurrent Function Deployment 13 CFD Methodology 17 Applications of CFD 25 Formulation of CFD as an Optimization Problem 29 Horizontal Deployment 32 CFD Tier-based Vertical Deployment 41 Ihplementation Issues 47 References 49 Test Problems: Concurrent Function Deployment 50

2 CE Metrics and Measures

2.0 Introduction 52 2.1 Metrics of Measurements 56

xiii

xvi i

xxxvii

Contents

2.2 Establishing Life-cycle Measures 59 2.3 Value Characteristic Metrics (VCM) 61 2.4 Simulations and Analyses 65 2.5 Product Feasibility and Quality Assessment 70 2.6 "Design for X-ability" Assessment 77 2.7 Process Quality Assessment 91 2.8 VCM Management 106

References 106 Test Problems: CE Metrics and Measures 108

3 Total Vallie Management

Introduction 11 1 Total Quality Management 113 Total Value Management 123 Methodology for TVh4 124 Major Elements of TVM 128 TVh4 in the P~oduct Development Process 130 TVM Measures of Merits 135 Value Management Tools 144 Concurrent Process for TVM 152 TVM Measures 154 References 160 Test Problems: Total Value Management 161

4 Product Development Methodology

Introduction 164 IPD Process Invariant 167 Integrated Product Development Process 173 Steps in IPD Methodology 178 Product Requirements Planning and Management 18 1 Work Structuring and CE Team Deployment 182 Methodology Systemization 183 Product and Process Systemization 187 Problem Identification and Solving Methodologies 193 Integrated Problem Formulation 194 Collaboration and Cross-functional Problem Solving 198 Continuous Monitoring and Knowledge Upgrade 200 Concurrent IPD Methodology 20 1 References 203 Test Problems: Product Development Methodology 204

Contents

5 Frameworks and Architectures

Introduction 207 General Architecture 208 Distributed Computing 221 Work Group Computing 225 Product Information Management (PIM) 23 1 CE Architecture 239 CE Sub-architectures 245 CE Computational Architecture 248 Standards 254 References 258 Test Problems: Frameworks and Architectures 259

6 Capturing Life-cycle Intent

6.0 Introduction 261 6.1 Design Classification 263 6.2 Life-cycle Capture 267 6.3 Language for Life-cycle Capture 275 6.4 Capture Product Models 281 6.5 Creation of Smart or Intelligent Models 285 6.6 Smart or Intelligent Models 301

References 308 Test Problems: Capturing Life-cycle Intent 310

7 Decision Support Systems

7.0 Introduction 3 13 7.1 Basis of Decision Making 3 15 7.2 Typical Progressive Models 322 7.3 Intelligent Models 328 7.4 Smart Regenerative System 334 7.5 Life-cycle Values 338 7.6 Total Life-cycle Cost 346 7.7 Compatibility Analysis 350 7.8 Sensitivity Analysis 35 1 7.9 Life-cycle Ranking or Rating Scheme (LCRS) 351

References 353 Test Problems: Decision Support Systems 355

8 Intelligent Information System

8.0 Introduction 358 8.1 Enabling Elements 364

Contents

Major Bamers 367 Vision of the Future 374 Levels of Intelligence 379 Product Intelligence 384 Process Intelligence 385 Technical Memeory 392 Flexible Computer Integrated Manufacturing (FCIM) 396 Groupware 398 References 401 Test Problems: Intelligent Information System 401

9 Life-cycle Mechanization

Introduction 405 CE Mechanized Environment 409 Concurrent Product Development (CPD) 414 CE Network Tools and Services 415 IPD Automation Modules (Preprocessing) 419 IPD Automation Modules 423 Library of Parts 427 Synthesis Models 427 Decision Support Tools or Models 429 Knowledge-based Product and Process Models 432 Computer-based Training Tools 432 Cost and Risk Reduction Tools 433 IPD Automation Modules (Post-processing) 433 Unified or Single PPO Concept 440 References 443 Test Problems: Life-cycle Mechanization 444

10 IPD Deployment Methodology

10.0 Introduction 447 10.1 Strategic CE Ideals 447 10.2 Ten Commandments of IPD Deployment 452 10.3 CE Case Histories 472 10.4 Computation of Savings 474

References 478 Test Problems: IPD Deployment Methodology 478

Index

8Ws AFNOR AMICE ANSI API ATIS BOMs BSI C4 CA CAD CAE CALS CALS CAM

Policy, Practices, and Procedures Fourth Generation Language Models, Methods, Metrics, and Measures Six Resource Elements (Materials, Manpower, Methods, Management,

Money, and Machine)-(Figure 3.8Nolume I) Talents, Tasks, Teams, Techniques, Technology, Time, and Tools

(Figure 4.1Nolume I) Collaboration, Commitment, Communications, Compromise,

Consensus, Continuous Improvement, and Coordination Eight Waste Components (Figure 3.4Nolume I) French Association for Standardization European CIM Architecture-in reverse American National Standards Institute Application Programming Interface A Tools' Integration Standards Bill-of-materials British Standard Institution CADICAMICAEICIM Computational Architecture Computer-Aided Design Computer-aided Engineering Computer-aided Acquisition and Logistics Support (old) Computer-aided Acquisition and Life-cycle Support (new) Computer-aided Manufacturing

xiii

xiv Acronyms

CAPP CASA CASE

CEC CERA CFD CFI CIM CIMOSA COe CORBA

I CPU CWCe DARPA DBMS DDL DECnet DFM DFm DICE DIN DNS E-mail EAL EC ESPRINT

ED1 ESPRIT EWS FEA FEM FMEA GUI GKS ICAM IDL IEEE IGES 1 0 s IPPO IPD IPPD IPR

Computer-aided Process Planning Computer-aided Society of Manufacturing Engineers Computer-aided Process Engineering or

Computer-aided Simultaneous Engineering Commission of the European Communities Concurrent Engineering: Research and Applications Concurrent Function Deployment CAD Framework Initiative Computer-integrated Manufacturing Open System Architecture for CIM Consistent Office environment Common Object Request Broker Architecture Central Processing Unit Consistent Work group Computing environment Defense Agency for Research Projects Data Base Management Systems Dynamic Data Linking Digital Electronic Computer (DEC) Network Design for Manufacturability Distributed File management DARPA Initiative in Concurrent Engineering German Industrial Standards Institute Distributed Name Service Electronic-mail Engineering Analysis Language European Strategic Program for Research and Development in

Information Technology Electronic Data Interchange European Strategic Planning for Research in Information Technology Engineering Workstations Finite Element Analysis Finite Element Modeling Failure Mode and Effects Analysis Graphics User Interface Graphics Kernel System Integrated Computer-Aided Manufacturing ICAD Design Language Institute of Electricals and Electronics Engineers Initial Graphics Exchange Specification InputlOutput Sub-systems Integrated Product and Process Organization Integrated Product Development Integrated Product and Process Development Interactive Photorealistic Rendering

Acronyms

ISPE JISC LAN MAP MCAE MFLOPS MIS MRP NAS NC NCS NFS NIST NURBS OSF OSI/MAP PC P D ~ PDES PDES/Express PDMS PHIGS PIM PPO PsBS PtBS QC QFD RDBMS RISC RPC SARA SBU SLA SME SNA SPEC SQL SSD STEP TaskBroker

International Standard Organization International Standard OrganizationOnitial Graphics Exchange

Specification International Society for Productivity Enhancement Japanese Industrial Standards Committee Local Area Network Manufacturing Automation Protocol Mechanical Computer-aided Engineering Million Instructions Per Second Mainframe Information System Manufacturing Resource Planning Network Application Services Numerical Control Network Computing System Network File System National Institute of Standards and Technology Non-Uniform Rational B-Splines Open System Foundation Open System InstituteManufacturing Automation Protocol Personal Computer Product, Design, Development and Delivery Product Data Exchange using STEP A Language developed using PDES Product Database Management System Programmers' Hierarchical Interactive Graphic Standard Product Information Management Product, Process, and Organization Process Breakdown Structure Product Breakdown Structure Quality Control Quality Function Deployment Relational Data Base Management System Reduced Instruction Set Computing Remote Procedure Call Systems Automation: Research and Applications Strategic Business Unit Stereolithography Apparatus Society of Manufacturing Engineers Systems Network Architecture System Performance Evaluation Cooperative Structured Query Language Secondary Storage Device Standard for the Exchange of Product Model Data - (HP) TaskBroker program

xvi Acronyms

TCP/IP TQM TVM UI v-c WAN WBS WC

Transmission Control Protocol/Internet Protocol Total Quality Management Total Values Management User Interface Video-conferenceing Wide Area Network Work Breakdown Structure Work-group Computing