cost estimation for low volume long life products in

Innovative Design & Manufacturing Research Centre, University of BathAerospace Manufacturing Research Centre, University of the West of England

“World-leading research in engineering design and manufacture.”

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Cost Estimation for Low Volume Long Life Products in Electronic

Defence SystemsPresenter: R. MarshResearchers : W.M. Cheung and R. MarshPrincipal Investigators: L.B. Newnes, A.R. Mileham and J.D. Lanham

Bath IdMRC UWE AMRC

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Introduction

Project BackgroundRecent work on Through Life Costing (TLC)Research Issues

TLC Terminologies, Boundary and ElementsCost Estimation Software EvaluationDefinition of TLC RequirementsProduct Exemplar and TLC Approach

Conclusions and Further Work

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Project Background …

Academic Collaborator

Industrial Collaborators

Funding Sponsors

Cost Estimating for Low Volume Long Life Products in Electronic Defence Systems

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Project Background -The Definitions

Whole Life Costing (WLC)

Whole Life Costing (WLC)Kishk et

al. [16] Kishk et al. [16] Through Life

Costing (TLC) Through Life

Costing (TLC)

Life Cycle Costing (LCC)

Life Cycle Costing (LCC)

Total Cost Total Cost

Total Life Costing Total Life Costing

Total Cost of Ownership Total Cost of Ownership

Costs in Use

Costs in Use

Ultimate Life Cost

Ultimate Life Cost

Definition of TLC, Ministry of Defence (MoD) at UK

Definition of TLC, Ministry of Defence (MoD) at UK

Definition of LCC, Cole et al. [10]

Definition of LCC, Cole et al. [10]

Definition of WLC, Bradley and Dawson [17]

Definition of WLC, Bradley and Dawson [17]

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Project Background - Rationale

Complex Defence Systems

Conventional approaches are unreliable

Aims and ObjectivesDevelop a method to perform TLC.

Provide a hybrid bottom-up, top-down approach.

To support a rough-cut cost estimate.

To accept greater detail to improve the accuracy of the cost estimate.

e.g. a standby display unit

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Product Lifecycle Standards

Common terminologies adopted for the TLC

research are based on :

ISO 15288 (System Lifecycle Process)

ISO 10303’s Application Protocols

AP 239 (Product Lifecycle Support)

AP 233(System Engineering Integration)

DES and GE-A

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TLC Terminologies

DevelopmentAssessmentAssessmentDesignDevelopment

DemonstrationDemonstration

Support

ConceptualiseConceptConceptConcept

ISO 15288

ISO 10303 AP233

ISO 10303 AP239

DES (UK MoD)

GE-A (UK)

ManufactureManufactureManufactureProduction

In-ServiceIn-ServiceIn-ServiceUtilisation

DisposalDisposalRepairRetirement

Maintenance

Operation

Production

Pre-Production

Concept

Development

Demonstration

Manufacture

In-Service

Disposal

Project Terminologies

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TLC Elements

Three types of costs (Davies

et al [22])

Three types of costs (Davies

et al [22])

Focus on Product

Producer’s Cost

Focus on Product

Producer’s Cost

Elements of Product

Producer’s Cost

Elements of Product

Producer’s Cost

ConceptConcept

DevelopmentDevelopment

DemonstrationDemonstration

ManufactureManufacture

In-ServiceIn-Service

DisposalDisposal



Boundaries to be covered in terms of Product Producer’s Cost Marketing, Research Concept, Obsolescence Management and Technology Insertion Product Details, Obsolescence Management and Technology Insertion -

Facilities, Process, Obsolescence Management and Technology Insertion, Tracking Counterfeit Components Warranty, Spares, Distribution and Obsolescence Management, Design Refreshment Recycling

Boundaries to be covered in terms of Product Producer’s Cost Marketing, Research Concept, Obsolescence Management and Technology Insertion Product Details, Obsolescence Management and Technology Insertion -

Facilities, Process, Obsolescence Management and Technology Insertion, Tracking Counterfeit Components Warranty, Spares, Distribution and Obsolescence Management, Design Refreshment Recycling

Validation and prototype

, EOF issues

Elements

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Cost Estimation Software Evaluation

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TLC Framework and Its Requirements

Top-Down approachElaborate an abstract designDesign reconfigurationRapid decision making

Covering Life Cycle

Bottom-Up approachUtilise existing informationmodular approach is needed.Detailed analysis from a BoM

SEER–H and SEER-DFM Relex LCC

Vanguard

OldConnectors1

Has been removed

WoundComponents1PCB 1 NewConnectors1 Other Components 1

Module 1Power Supply Parametric Model available

Module 2Display Parametric Model available

Module 3 … nDetail Models available

Electronic System ModelWhole-part Hierarchy

OldConnectors1

Has been removed

OldConnectors1

Has been removed

WoundComponents1PCB 1 NewConnectors1 Other Components 1

Module 1Power Supply Parametric Model available

Module 2Display Parametric Model available

Module 3 … nDetail Models available


Concept Manufacture

In-ServiceDisposal

Top Down Approach

Bottom Up Approach

Development Demonstration

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Product Exemplar – Modular Approach

WoundComponents1WoundComponents1WoundComponents1

OldConnectors1

Has been removed

OldConnectors1

Has been removed

PCB 1PCB 1 NewConnectors1 Other Components 1Other Components 1

Module 1

Power Supply Parametric Model available

Module 1


Module 2

Display Parametric Model available

Module 2


Module 3 … n

Detail Models available



Conceptual design

Detailed design

Upgrade, Replacement and Design refresh

Top Down

Bottom Up

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Example of Top-Down Approach

WoundComponents1WoundComponents1WoundComponents1

OldConnectors1

Has been removed

OldConnectors1

Has been removed

PCB 1PCB 1 NewConnectors1 Other Components 1Other Components 1

Module 1


Module 1


Module 2


Module 2


Module 3 … n

Detail Models available



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Example of SEER Implementation in Bottom-up Approach

The initial approach of testing the SEER environment

Using SEER to build sub- modules

BoM Module Detailed

Design Parameters

Cost Analysis

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Linking and Mapping Methods

The Electronics and Mechanical Modular-based Library (EMMbL)

The library allows users to select and reconfigure existing modules

Macro method will be written in Visual Basic for ‘class’

EMMbL

Excel Macro Method – Mapping in Server Mode

ConceptConcept

DetailedDetailed ManufactureManufacture In-ServiceIn-Service

Object-Oriented technique for building modular library

Excel format

Excel format

DisposalDisposal

Map the relationships

DemoDemo

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Conclusions and Further Work

A TLC method has been identified.

Terms, Boundary and Elements have been defined.

An exemplar involved the 1st-tier industrial collaborator has been selected.

The library of electronics and mechanical modules is under development.

Selection of a 2nd-tier industrial collaborator.

An initial validation in the concept, development and manufacturing stages.

Parametric, risk and uncertainty investigations on TLC for defence products

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IdMRC - http://www.bath.ac.uk/eimrc/AMRC - http://www.cems.uwe.ac.uk/amrc/IeMRC - http://www.lboro.ac.uk/research/iemrc/

Presenter: R. Marsh [email protected]

W.M. Cheung, L.B. Newnes, A.R. Mileham and J.D. Lanham

cost estimation for low volume long life products in

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