chap01-01a preamble - product development and manufacturing cycles.pdf

7/24/2019 Chap01-01a Preamble - Product Development and Manufacturing Cycles.pdf

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Preamble:

Product Development andManufacturing Cycles

K.P. Karunakaran

Indian Institute of Technology Bombay


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Preambles

Three Industrial Revolutions

Three Influencing Factors of This Era

Three Types of Businesses

Essentials of Good Product Development

Product Development and Manufacturing Cycles

Outline


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Three Industrial Revolutions

Ind.Rev.

Effect Enablers

I Mechanization

(1760-1840)

Water wheel and wind mill

Steam engine, IC engine

Electricity, pneumatics and hydraulics

II Automation

(1870-1914)

Hard automation

III Integration

(1950-till date)

NC, CNC, Robotics, PCs &

CAD/CAM/CAE/PLM/ERP systems

Network & Internet,

3D scanning and 3D Printing

Digital (ease of copying, modification and transmission), virtual (high speed; less

expensive and risky), mobile (anywhere, any time), personal (done by self goodcontrol, confidentiality).


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Three Influencing Factors of This Era3rd Ind. Revolution driven by Internet, AM, Bio, Nano, AM,

1. Information 2. Communication 3. TransportationThe most powerful

weapon today.

Data, knowledge,

inference, information,

intuition

Software tools help in

managing the vast

information (relational

databases Oracle; data

mining Google, Yahoo,

Wikipedia etc.). Therefore

IT is synonymous with

software that manage

these data.

Transfer of information.

One way: Radio, TV

Both ways: (sync/ async):

Post, telephone, fax,Intranet, Internet, Email

Transfer of physical things

By road, rail, water, air,

Speed is the bottleneck;

of late, with the risingterror attacks, safety too is

a concern.

Convertibility between information and

physical things (similar to mass and energy,currencies )?

(See the science fiction movie The Fly)

Manage with video conferences


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Three Types of Businesses

Type of Business Profit Remarks

Production Due to the higher profit margins, there isa tendency for producers to shift to

service and trading. However, these

three functions need to be balanced;

when this balance is disturbed, it leads to

economic recession. The other reasonfor recession is complacence. There are

external factors too such as rise in oil

price that have spiralling effect.

Service

Trading

Plastic spectacle frame Rs. 30 is the price manufacturer getswhereas it is sold at > Rs. 300 at the shop. There are many traders

between the producer and customer.

OptiLOM 50% for the trader, 25% each for the two developers.

Examples:


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Essentials for Good Product Development1. Design iterations

A design is rarely right first time. So no escape from iterations.

Number of design iterations is not necessarily a reflection of your

inability to look ahead.

Design iterations improve the quality of design (which is different

from the standard definition of quality which actually refers toquality of manufacture, viz., conformance to design).

Iterations cost in time and money too! So, use quicker and cheaper

tools such as sketches, virtual CAE tools etc.


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Essentials for Good Product Development2. Do lot of sketching

Ideas come at high speed (Vayu

vegam Mano vegam). Existing

CAD cannot capture all. So, grasp

them quickly through sketches.

(Analogy: Lord Ganesh helping VedVyas for recording Maha Bharat).

Your sketch need not be beautiful or neat; but when you look at

them, you will be able to recall most of the thinking of that time.

Therefore, the sketches make more sense to the designer whosketched them than to the others.


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Essentials for Good Product Development3. Do not evaluate ideas while generating them

This is one place where we favor serial activities.

Evaluating the idea as it is suggested will (i) block further flow of

ideas and (ii) inhibit the participant in the brainstorming session.


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Essentials for Good Product Development4. Do not fall in love with your ideas or its manifestations

This is too will inhibit further generation of ideas.


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Essentials for Good Product Development5. Do not be lazy to iterate

This is too will inhibit further generation of ideas.


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Essentials for Good Product Development6. Appropriate manpower

Manpower: Skilled & Dedicated & Passionate & Loyal & Team-spirited.

High attrition rate is the single most challenging problem today;

not funds or equipment any more.

Man behind the machine is important. Organizations excel notbecause of their infrastructure but because of their people.


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Essentials for Good Product DevelopmentIllustration: Design iterations of a drawing table

Constraints:

Conventional and

CAD design on the

same table.

Adjustable

inclination with

ease

Ease of shifting

between manualdrafting and CAD

Limited space[Courtesy:S

hrishailandParth

AlumniofVJTI]


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Survey of some tables available in the market.

[Courtesy:S

hrishailandParth

AlumniofVJTI]



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[Courtesy:S

hrishailandParth

AlumniofVJTI] Sketching new options

Importance of rough sketching in design process

Table layout options

Monitor mechanisms



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Design to meet the basic requirements

Frame and wedge design to achieve

variable angle for the drafting board

Board lifted and kept behind while

using monitor

Swivelling mechanism for monitor

[Courtesy:S

hrishailandParth

AlumniofVJTI]Base Design



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Board had to be lifted every time youhave to use the computer

Glass surface used

The base was removed to incorporate

new monitor mechanism

The base side of the frame made

circular for better support

Fillet provided at the base of the

wedges for a surface contact insteadof line contact

[Courtesy:S

hrishailandParth

AlumniofVJTI]Iteration 2:



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Angle cannot be reduced below 45degrees

The dimensions of the frame has to be

modified to improve the range

Frame made in two parts

Two bolts on each arm

Height of the frame is adjustable

Very low angles possible Angles below 30 degrees not possible

[Courtesy:S

hrishailandParth



f G


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The bolts must be adjusted every time

Design iterations for various possible

solutions

Clip mechanism introduced

Importance of sketching in the

configurational design stage

Design improved by providing wedges

on both the links

Entire frame can be removed

Even 0 degrees possible[Courtesy:S

hrishailandParth



E ti l f G d P d t D l t


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The bolts must be adjusted every time

Design iterations for various possible

solutions

Clip mechanism introduced

Importance of sketching in the

configurational design stage

Design improved by providing wedges

on both the links

Entire frame can be removed

Even 0 degrees possible[Courtesy:S

hrishailandParth





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All previous mechanisms give discretevariation in the angle

Use of a handle for continuous

variation

Use of bevel gears and stud to convertrotary motion to linear motion

Different iterations to determine the

best position of joints

Problem at lower angles

Cost increases

[Courtesy:S

hrishailandParth





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[Courtesy:S

hrishailandParth

AlumniofVJTI]

FINAL

DRAFTING AND

PROTOTYPING




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Essentials for Good Product DevelopmentIllustration: Design iterations of the rotor of a MAV


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Product Development and Manufacturing

Cycles

Product & Its classification

Product Cycle


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Product

A product is a commodity that serves certain functions.

It could be physical or virtual (say, a software). However,

we shall be mostly concerned with the physical ones.


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Product Cycle

The activities are actually arranged in a cycle.

All need not take constant and equal duration.

They have precedence relationships among them;parallelism and slack also exist.

They may occur at different geographic locations too.

These are handled by Marketing, Design and

Manufacturing departments.


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Product Cycle

Product Cycle


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i. Product Development Cycle

The phase from identifying the need for the product, conception of the product

through its development, proving through a series of prototypes till productionizing.

ii. Product Life Cycle

The phase from the manufacture of the product batch after batch, sales, service till

finally disposal of the product after it has finished its useful life.

Product CycleTwo phases of product cycle

Product Cycle


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i. Product Identification

ii. Designiii. Manufacture

iv. Sales & Service

Product CycleFour phases of product cycle

Product Cycle


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1. Recognition of need

2. Specification of the product

3. Synthesis

Product CycleShigleys Six stages of product development cycle

4. Analysis and Optimization

5. Evaluation

6. Presentation

Product Cycle


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- Market Survey

-Analysis of Customer Requirements & Feedback-Watch the competitor

Product CycleProduct identification

Product identification


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It starts with a need. Identification of this need is the responsibility of

the marketing department. Extensive market research (data

collection from customers, retailers etc. and analysis) will be required

to identify the need. Often watching the competitors is enough!

(industrial espionage! Reverse Engineering!!)

Product identificationNeed



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The need could be met by

products arising out of radically

new ideas or a modification of an

existing product.

Sometimes, a technology may

lead to innovative new productsfor which a market may not exist

readily. In such a case, marketing

department has to excite the

customers and generate interest

in it through advertising/ demos. Project types

Q: Identify the group for cell phone with camera and radio, European

car for India, an automotive company starting an IT division, annual

release

Product identificationProduct types



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Product identificationImportance of correct identification and undistorted communication

Marketing, Design and

Manufacturing are the

three main groups

responsible for the product

It is essential that they

communicate amongthemselves the need for

and specifications of the

product without distortion.

If the company

understands the needcorrectly and launches a

product in time that meets

this need, it flourishes.

D i


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Design is the creative activity of developing a new product that meetsthe needs. Design involves a series of decisions which form an

inverted tree. It is often an iterative process.

Design

Design


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1. Conceptual design

2. Configurational design

3. Detailed design

DesignThree stages of design

Design


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The 3 important phases of design are [Fisher]:

i. Conceptual design Generation of numerous ideas to meet the need

Evaluation of these ideas and choosing the best one

Arriving at an abstract design

ii. Configurational design Modularization Decide interface among the modules & design collaborations

iii. Detailed design The work is distributed to the functional groups are

distributed

Geometric modeling, Determination of material etc. Analysis, synthesis and optimization.

The possibilities of automation increases in these phases creative

to mundane!

DesignThree stages of design

Design


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- Product Definition, i.e., Specifications.

-Synthesis of Ideas (leading to the principle ofoperation of the product)

es gConceptual design

Design


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- Modularization

- Establishing Design Collaborations

gConfigurational design

Design


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Detailed Design: Modeling

- Geometric Modeling CAD

- Digitizing

- Drafting

gDetailed design : Modeling

Design


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Detailed Design: Engg Analysis & Synthesis

CAE (a misnomer)- Structural Analysis

- Heat & Fluid Flow Analysis

- Kinematic Analysis- Dynamic Analysis

- Design for Xability (DFX) Analysis

(X = Manufacture, Assembly, Disassembly, Repair, Eco-

Friendliness, Mass Customization etc.),

- Optimization

gDetailed design : Analysis, synthesis & optimization

Design


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- Mathematical Modeling

- Virtual Reality, Interference Check

- Virtual Testing

gDetailed design : Virtual Prototyping

Manufacture


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Manufacture

Manufacture is the physical realization of a design specification. Manufacturing strategies are different for prototypes and regular

product. Furthermore, it also depends on other factors such as

volume, quality of labor etc.

Manufacture


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Types of Manufacture

1. Prototype manufacture

2. Regular production

Types of Activities

1. Managerial activities

2. Shop floor activities

Types

Manufacture


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Physical Prototyping:

- Physical Models (scaled/full, actual/ Alternate material) by conventional manufacture or by Rapid

Prototyping

- Working Prototypes. One has to do manufacturing activities such as Process Planning, Tool Design,

NC Programming etc. specific to these prototypes

- Physical Testing

Physical Prototyping

Manufacture


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- Make/ Buy Decision

- Vendor Development- Resource Planning (facilities etc. : BPR or

MRP III)

- Selection of Site

- Scheduling

- Machine loading

- Line balancing

- Man power deployment- Salary

- Purchase

-Resource planning (MRP I & II)

-Supply Chain Management

-Product Lifecycle Management

- Product Design (Value Engineering,

Aesthetics and Ergonomics)

- Freezing Design and Release of Design

Documents- Process Planning

- Tool Design & Manufacture

- NC Programming

- Group Technology

- Plant Layout

- Regular manufacture (casting, forging, forming,

machining & Joining)- Assembly

- Inspection & QC

- Warehousing

- Shipping

Physical Prototyping

Sales & Service


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- Advertising

- Maintenance

Sales & service is the responsibility of Marketing Department. As this

department is directly in touch with the consumer, they are also responsible for

identifying the need for a product.

Sales & Service

Summary So Far


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Activities of the product form cycles. Each may have different and non-constant periods with

precedence relations. Hence parallelism and slacks are possible.

Mostly they are stochastic rather than deterministic.

Various classifications were presented.

Use of computers helps in better efficiency and integration.

Summary So Far

Thank You!


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Thank You!

K.P. Karunakaran

Professor

Department of Mechanical EngineeringIndian Institute of Technology Bombay

Powai, Mumbai-400076, INDIA

Tel.: 022-25767530/ [email protected]

www.me.iitb.ac.in/~karuna