NAME: KISHORE PADIGIREDDY

EMAIL: kp399@njit.edu
IE655 CONCURRENT ENGINEERING
E-LEARNING PACK: IE655-FALL 2015-32-12
PROFESSOR: PAUL G RANKY
Statement of Work: The below assignment has been done solely by Kishore
Padigireddy.
Contents:

Introduction
Objective
Methodologies Applied
Part 0 Rework
Part 1
1. Innovative Green PLM Design
2. Product/Process Innovation, Introduction Methods and Processes.
3. Green Product Innovation Introduction (NPI & I)
4. CORA
5. PFRA
6. Rapid Prototyping
7. Further Work Proposed
Part 2
1. PLM/Digital Design, Digital Manufacturing & Sustainable Green Transition
Plan
2. Transition Plan CIMpgr
3. Implementation of Transition Plan
4. ROI Plan
Video Conferencing
Summary
Social Networking
References
Self Assessment

Introduction:
There are many aspects in this world that are yet to be discovered and researched upon.
Looking at the future there is going to be a great demand for many more new generation
machinery that can perform not only just programmed work but also be able to self
program them, that is, the machines got to be intelligent artificially. Yes, this is what
exactly our company ROBOFUSION Inc. is all about.
Our company aims to build extremely intelligent robotic system for the future. Looking
at the current perspective of this particular area there arent many companies who have

actually set foot into this business as it involves a great deal of research than business at
present. Robofusion Inc. aims at designing and manufacturing intelligent robots for
electronic, telecommunication and industrial sectors for high-speed picking and
packaging applications. The company operates under segments that include power
products, power systems, automation products, process automation and robotics.
Robofusion is the leading supplier of robots-also providing robotic software, peripheral
equipments, modular manufacturing cells and service for task as simple as welding to
complicated task such as handling, assembly, painting and finishing, picking, packing,
pelletizing and machine tending. Robofusion offers complete capability in robotic
solutions and supports its customers in manufacturing all over the world. The company
provides practical assistance in the implementation of automation projects
Objective:
The goal of this is task is to survey these routines using the E-Book sections and
electronic examination while attempting to give an arrangement to apply the strategies to
Robofusion. It is a multi-didactical advancement enterprise organization. Our goal is to
plan and make a mechanized Industrial robots for Industries which is less expensive,
energy effective and upgrade the execution of the organization
Our main goal is to work towards the green part of environment, plan and assembling
for our transmission framework.
Methodologies Applied:
The methodologies applied by Robofusion Inc. for gaining a better edge over the
Competitors in the market and to promote the company towards new goals and
milestones are:
1 To make use of a Product Lifecycle Management (PLM).
2 Implementing Concurrent engineering for the entire process.
3 Our company focuses on less energy consumption, lubricant consumption and
Durability in order to minimize lifecycle, cost and increase cost efficiency.
4 Maintain high standards quality for the product manufacturing.
5 Develop\Maintain good customer relationship.
6 Reduce the overall cost of the product and the services
PART 0: Rework of Assignments
I did not rework on my Assignments as I got full marks on all the assignments (from
Assignment 0- 4).
PART 1:

1. Innovative Green PLM Design:

Flight crashes and carbon emitted by the flights is one of the major concerns, which
should be improved. The flight crashes causes numerous loss to the human life and the
carbon emission for U.S on an annual average was about 6.6 tons of carbon dioxide,
which is very harmful, and pollutant to the environment. So, New type of airplanes,
which are free of emissions, should be designed in order for a greener environment. In
case of flight crash or an emergency, the cabin should be designed in a way that it can be
detached from the flight, so that the lives of people will be saved.
The New Product designs and Requirements:

The new airplanes should have zero emissions to lessen the effect of carbon
footprint to provide a greener environment.
Efficient solar panels should be placed on the airplane so that power
consumption is directly from the sun i.e., using renewable energy resources.
The cabin of the flight should be designed in a way it should be detachable in
case of emergency to save the lives of the people.
The airplane should be made of materials with less weight and high durability
and reliability to lower the overall cost.

2. Product/Process Innovation, Introduction Methods and Processes:

CORA Analysis:
CORA is team-oriented problem solving tool to minimize dissatisfaction and financial
loss due to inadequate requirement specifications and poor communication between
company and customers. The CORA is applied during the electronic support system
planning stages of a product or process development life cycle, as well as later for
PLM/CE purposes are updated on a regular basis to document changes in requirements
and best practice engineering and management solutions.
By CORA analysis we Robofusion Inc. can understand the process in details and
how engineering functions can be applied in order to satisfy the customer requirements
with the help of engineering solutions. This will help improve quality of the products to
satisfy important customer requirements with engineering solutions optimum utilization,
quality & safety standards, effective design and sustainable green focus. This analysis
also compares the customer requirements with other competitors, which help identify
the weakness and strengths of the company.
The weaknesses can be improved with the help of applying appropriate engineering
solutions. Robofusion will also include the customer requirements from CORA sheets of
each collaborating companies.
The Design being the most powerful phase of a product, consumer requirement will be
notified in the CORA sheet to examine the customer necessities. The building

arrangements will be enhanced keeping in mind the end goal to incite more
maintainability and green designing. The CORA investigation will likewise actualize
and trigger changes keeping in mind the end goal to acquire nonstop enhancements to
meet the organization objectives to accomplish client characterized quality and useful
necessities with an accentuation on supportable green core interest. Along these lines
CORA will deliver a Green product that meets the customer requirements.
Ranky Taguchi Calculator:
The Ranky-taguchi calculator is used to determine acceptance criteria for the CORA
model. This calculator will also be used extensively in Robofusion for product/process
innovation. This is really very useful tool when it comes to the analysis of my project.
The calculation, which we did with the help of Ranky-Taguchi Calculator on the earlier
product, gave us the best accurate result.

PFRA Model:
Process Failure Risk Analysis is used to identify and minimize potential failure risks in
the process as well as the components such as machines, assemblies, sub assemblies and
the effects of these failures on the product and ultimately on the customers. PFRA is
applied during the planning phase and upgraded during the life cycle and a historical
data is documented which can be used in the future for analysis and further
improvements. PFRA is a part of the family of Failure Mode and Effect Analysis
(FMEA), aimed at minimizing dissatisfaction and financial loss for process related
failure risks and is applied usually during the planning stages. Once the riskiest
failure modes have been identified, corrective actions will be developed with the help of
our collaborating companies, in an effort to mitigate and/or eliminate these risks.
Going forward, as corrective measures are employed, the PFRA method can be used to
reflect these improvements, and identify additional risks that may require future
attention. PFRA will help Robofusion to avoid material waste and financial waste due to
failures. The risk analysis helps take preventive measures as well as corrective measures
in order to keep the processes stable and avoid down times and material wastes.
Rapid Prototyping:
I would like to suggest this method to the engineers of Robofusion. I think this is an
important method in the product development. The failure and the risks involved can be
identified in the early stages of the product development and necessary steps can be
taken. The rapid prototyping method will help us to know the assembly of the product
and the changes can be brought about before handing it over to the manufacturing
department.
Digital Designing:

Robofusion will be using this technique in the design department to use it extensively in
product/process development. Digital manufacturing helps the designers to create the
product digitally on their desktop and to analyze it online. Even if there are any faults in
the product development it can be discussed with the other engineer online and the
changes can be brought about. In this way the company can save a lot of its resources.
Continuous Improvement:
I think we should implement this method throughout its product development process
and also in PLM. Continuous improvement process helps in continuously improving the
product or process delivered thus achieving customer satisfaction. This can be
implemented with the help of the collaborating companies by providing them the
information regarding the customer and the engineers demands.
Poka-Yoke:
Poka-Yoke is a technique for avoiding simple human error and aiming for zero defects
at all levels of work. (Poka-Yoke means "mistake-proofing). The fundamental concept
of Poka-Yoke is to respect the intelligence, knowledge and experience of machine
operators and assembly line workers, designers and manufacturing engineers trying to
eliminate the possibility of failure, or defects through design and sound practices. It uses
the existing resources in the form of knowledge of the employees efficiently to
completely eliminate the defects. Poka-yoke emphasizes on 100% inspection right from
the products creation to its assembly.
3. New GREEN Product Innovations and Introduction:
1) Eco-Navigation System:
Eco-Navigation system by My Guide allows us to be more conscious about
environment while driving. It helps us to pick the most eco-friendly road, which save us
gas and create less pollution.
2) New Mitsubishi Outlander PHEV:
It is a new interesting offer from Japanese manufacture of cars - Mitsubishi. The First
Medium size SUV that is completely electric. It is not available in the U.S. yet, but we
buy it Europe now. Besides its good size, it capable off-roading car.
3) Tommy Hilfiger solar power jacket:
Tommy Hilfiger - famous clothes designer has developed a new range of solar powered
jackets that can charge our phones. It is worth to mention that 50% of revenue will go
towards Fresh Air Fund.

4) New highly efficient solar cells:

French-German collaboration achieved new amazing efficiency for solar cells that is
46%. It is amazing news because it can completely change the way we think about solar
power.
5) Zero-Emission Building:
Architecture firm Snohetta with partnership of Norway's Research Center creating
fascinating building capable of producing 3 times more energy than it needs. This was
possible to do by using the newest sustainable technologies and building practices.
6) Learning thermostats:
Nest Corporation created thermostats, which can learn our schedule and program
themselves in order to save energy. Nest estimates that it can save up to 50% of energy a
year.
7) Zero-Emission Motorcycles:
Company called Zero Motorcycles introduced recently new exciting line of zeroemission motorcycles. Motorcycles are very advanced and they have range of 185 miles.
The basic model costs: $13,345.00
8) Vacuum Insulated Panels:
Vacuum insulated panels are very effective insulation (R-value = 50). They are still thin
and light so they can be used on roofs.
9) BMW 3 Series Plug-in:
New version of legendary model of BMW was announced and is going to be plug-in. It
is still in prototyping phase, but probably soon will be available for everyone. It is rated
117.5 MPG.
10) Wind farm locator app:
This is a simple application, which allows us to find wind farms. It increases awareness
among people about wind power energy, and helps promote renewable energy.
4. CORA Spreadsheet Analysis:
1.

Define scope function and purpose

The team should define the system and sub-system of the product, process and
service system, which needs to be designed and analyzed. Likewise it is very
Important to realize the scope and functions of the CORA change as it develops and
is applied. We will use this as we instigate our requirements of eco friendly
products into the CORA, to see what people would like to see, what the scope of
our projects are and how far will our products go when we analyze the different stages,
processes of the products we design.
2.

Identify User Requirements

Need for various changes in products are considered and thus product having customer
defined quality and functional properties is re designed . So we will identify the needs of
our companies. The CORA chart shows some of the sustainability and green principles
Eco friendly principles Robofusion is planning to implement first.
3.

Prioritize potential requirements

We rank the priorities of each of the functional activities with Absolute Importance
Rating (AIR) to give priority according to user requirements. Correlation values of 1
(Low), 3 (Medium) and 9 (High) are used by the team to prioritize the requirements.
This function should be done in a team to allow better understanding and correct level of
customer satisfaction required.
The Absolute Importance Rating (AIR) values are considered on the foundation of the
necessary priority level, and the correlation values, therefore the team must measure the
level of value, in regards to how an engineering solution will respond to each specified
customer / user need.
If the AIR value is very high, the CORA team should go back to the matrix to trace
back
to the column of the matrix and take the following steps.
1. For every high correlation value (9) check the customer requirement and make sure
that it is satisfied.
2. Repeat the same at every correlation value of 3 (meaning, medium
level importance).

Calculating AIR Values

Considering each row, in which there is a requirement, and for each column where there
is a correlation value of 1 (low), or 3 (medium), or 9 (high), the importance rating value
is multiplied by the correlation value, then the result is added to the sum of the next
row, Until there are no more rows left.

Critical Requirements:
1. Zero-Emission
2. Aerodynamics
3. Well-Insulated
4. Battery Charging during flight
5. No fuel dumping
6. Low Noise Pollution
7. Light weight
8. Design
9. Low Price
10. Low maintenance cost
11. Zero Defects
12. Fast
13. Long Range
14. Safe
15. Easy to fly
List of Engineering/Software Solutions:
1. Electric Engines
2. Batteries
3. Solar Cells on Wings
4. Slender Wings
5. Composite Materials
6. Limited number of parts
7. Fly-by-wire system
8. LED screen instead of windows
9. Lean Six Sigma
10. RFID system
11. Smart Cockpit
12. Sophisticated Safety Systems
13. Back-up gasoline engine
14. Advanced Simulation Software
15.Quality Design
Analysis of CORA Results:
After analyzing CORA excel sheet the CORA team will focus on higher Absolute
Importance Rating (AIR) value. These values will help company to improve
continuously by satisfying customer requirements with the highest AIR value and
ultimately lowest through engineering solutions.

The Highest AIR Values Observed:

Electric Engines 383 (AIR Value)

Batteries
252 (AIR Value)
Slender wings
283 (AIR Value)

These three solutions are the most important solutions to meet the customer
requirements. Attaining the company of goal of attaining customer defined quality and
functional requirements will be possible only through focusing on the above three
solutions.
Electric Engines: (AIR Value 383)
In order to create zero-emission plane, the main solution is the design of electric engines
with zero emission thus reducing the carbon footprint in the environment.
Batteries: (AIR 252)
One of the important solution is batteries (AIR: 252). They are various types of batteries
which are available now but the main fact is that the reliability of the batteries. Batteries
that last long should be used in flights to fly long distances without much power
consumption.
Slender Wings: (AIR 283)
Another important solution is Slender Wings (AIR: 283). Slender wings are key aspect
of aerodynamics, long range and speed. In order to make them we have to do more
research on composite materials.

5. PFRA Analysis:
PFRA system developed for new-sophisticated flights 12 following processes:
1. Inspection of raw materials received
2. Inspection of Electric engines
3. Casting of Engine Blades
4. Air-frame Assembly
5. Wiring
6. Installation of safety systems
7. Aerodynamics analysis of air frame
8. Painting of the product
9. Final Quality Control of Air-frame, Engines and wings
10. Inspection of Interior Finishing

11. Inspection of passenger multimedia system

12. Test Flight
Process Failure Risk Analysis helps to find the risky process and in the case of new
zero-emission airplane following results were obtained:

The highest risk is assembled with Air-Frame assembly. It is also by far the most
expensive process. Accumulated RPN is 790.92. A lot of resources have to be
accumulated into the process to make is risk-free, but with such a high score - it
has to be done.
The second the most risky process is installation of safety systems. The biggest
problem that theses systems are responsible for safety of hundreds of passengers.
Safety is the priority number one and that means the hole process has to be
audited, optimized and checked frequently.
The third the most risky process is inspection of electric engines. Electric
engines are the one of the most important elements of the product. They are
responsible for safety, efficiency, range and almost every other aspect of the
plane. Therefore, processes associated with electric engines will be audited,
optimized and checked on weekly basis.

6. Rapid prototyping method for the product development:

Although several rapid prototyping techniques exist, all employ the same basic five-step
process. The steps are:
Create a CAD model of the design
Convert the CAD model to STL format
Slice the STL file into thin cross-sectional layers
Construct the model one layer atop another
Clean and finish the model
CAD Model Creation:
First, the object to be built is modeled using a Computer-Aided Design (CAD)
software package. Solid modelers, such as Pro/ENGINEER, tend to represent 3-D
objects more accurately than wire-frame modelers such as AutoCAD, and will
therefore yield better results. The designer can use a pre-existing CAD file or may
wish to create one expressly for prototyping purposes.
Conversion to STL Format:
The various CAD packages use a number of different algorithms to represent solid
objects. To establish consistency, the STL (stereolithography, the first RP
technique) format has been adopted as the standard of the rapid prototyping

industry. The second step, therefore, is to convert the CAD file into STL format.
This format represents a three-dimensional surface as an assembly of planar
triangles, "like the facets of a cut jewel." The file contains the coordinates of the
vertices and the direction of the outward normal of each triangle. Because STL
files use planar elements, they cannot represent curved surfaces exactly.
Increasing the number of triangles improves the approximation, but at the cost of
bigger file size. Large, complicated files require more time to pre-process and
build, so the designer must balance accuracy with manageability to produce a
useful STL file. Since the .stl format is universal, this process is identical for all of
the RP build techniques.
Slice the STL File:
In the third step, a pre-processing program prepares the STL file to be built.
Several programs are available, and most allow the user to adjust the size,
location and orientation of the model. Build orientation is important for several
reasons. First, properties of rapid prototypes vary from one coordinate direction to
another. For example, prototypes are usually weaker and less accurate in the z
(vertical) direction than in the x-y plane. In addition, part orientation partially
determines the amount of time required to build the model. Placing the shortest
dimension in the z direction reduces the number of layers, thereby shortening build
time. The pre-processing software slices the STL model into a number of layers
from 0.01 mm to 0.7 mm thick, depending on the build technique. The program
may also generate an auxiliary structure to support the model during the build
Supports are useful for delicate features such as overhangs, internal cavities, and
thin-walled sections. Each PR machine manufacturer supplies their own
proprietary pre-processing software.
Layer by Layer Construction:
The fourth step is the actual construction of the part. Using one of several
techniques (described in the next section) RP machines build one layer at a time
from polymers, paper, or powdered metal. Most machines are fairly autonomous,
needing little human intervention.
Clean and Finish:
The final step is post-processing. This involves removing the prototype from the
machine and detaching any supports. Some photosensitive materials need to be
fully cured before use. Prototypes may also require minor cleaning and surface
treatment. Sanding, sealing, and/or painting the model will improve its appearance
and durability.
7. Further Work Proposed:
The CORA analysis chart should be monitored and continuous improvement plan will
be constructed based on CORA. The CORA chart has to be updated with time to time
feedback from customers and apply improved engineering solutions to satisfy the

requirements. The collaborating companies also influence the engineering solutions to

customer requirements. Thus Robofusion will also include the customer requirements
from CORA sheets of each collaborating companies. The design being
the most influential factor in customer satisfaction detailed CORA sheet will be
produced to analyze the customer requirements related to design. A strong customer
feedback loop will be applied with improvements in the existing loop. The engineering
solutions will be improved in order to induce more sustainability and
green engineering.
The PFRA needs to be kept up to date and new safety risk factors discovered need to be
added in with possible solutions for further use. The database of risk analysis should be
documented in an Information system, which can be used in order to solve similar
problems. The PFRA spreadsheets should be continuously monitored and updated on
regular basis to ensure all risky processes are addressed to prevent catastrophic failure
from happening.
3. Part 2
1. PLM/Digital Design & Digital Manufacturing & Sustainable Green
Transition Plan:
Product lifecycle management (PLM) is the process of managing the entire lifecycle of a
product from its conception, through design and manufacture, to service and disposal. It
is one of the four cornerstones of a corporation's information technology structure. All
companies need to manage communications and information with their customers
(CRM-Customer Relationship Management) and their suppliers (SCM-Supply Chain
Management) and the resources within the enterprise (ERP-Enterprise Resource
Planning). In addition, manufacturing engineering companies must also develop,
describe, manage and communicate information about their products (PLM).
1. Conceive
Imagine, Specify, Plan, Innovate
The first stage in the development of a product idea is the definition of its requirements
based on customer, company, market and regulatory bodies viewpoints. From this a
specification of the products major technical parameters can be defined. Although often
this task is carried out using standard office software packages there are for the field of
requirements management a number of specialized software tools available.
Parallel to the requirements specification the initial concept design work is carried out
defining the visual aesthetics of the product together with its main functional aspects.
For the Industrial Design, Styling, work many different Medias are used from pencil and
paper, clay models to 3D CAD Computer-aided industrial design software.

2. Design
Describe, Define, Develop, Test, Analyze and Validate
This is where the detailed design and development of the products form starts,
progressing to prototype testing, through pilot release to full product launch. It can also
involve redesign and ramp for improvement to existing products as well as planned
obsolescence. The main tool used for design and development is CAD Computer-aided
design. This can be simple 2D Drawing / Drafting or 3D Parametric Feature Based
Solid/Surface Modeling, Such software includes technology such as Hybrid Modeling,
Reverse Engineering, KBE (Knowledge-Based Engineering), NDT
(Nondestructive testing), and Assembly construction.
3. Realize
Manufacture, Make, Build, Procure, Produce, Sale and Deliver
Once the design of the products components is complete the method of manufacturing
is defined. This includes CAD tasks such as tool design; creation of CNC Machining
instructions for the products parts as well as tools to manufacture those parts, using
integrated or separate CAM Computer-aided manufacturing software. This will also
involve analysis tools for process simulation for operations such as casting, molding,
and die press forming. Once the manufacturing method has been identified MPM
(Manufacturing Process Management) comes into play. This involves CAPE (Computeraided Production Engineering) or CAP/CAPP (Production Planning) tools for
carrying
out Factory, Plant and Facility Layout and Production Simulation. For example: PressLine Simulation; and Industrial Ergonomics; as well as tool selection management. Once
components are manufactured their geometrical form and size can be checked against
the original CAD data with the use of Computer Aided Inspection equipment and
software. Parallel to the engineering tasks, sales product configuration and marketing
documentation work will be taking place. This could include transferring engineering
data (geometry and part list data) to a web based sales configuration and other Desktop
Publishing systems.
4. Service
Use, Operate, Maintain, Support, Sustain, Phase-out, Retire, Recycle and Disposal
The final phase of the lifecycle involves managing of in service information. Providing
customers and service engineers with support information for repair and maintenance, as
well as waste management/recycling information. This involves using such tools as
Maintenance, Repair and Operations Management (MRO) software.
2. Transition Plan CIMpgr:
Quality Objectives:

Use of process modeling in order to achieve efficiency over each process

operation with proper allocation of resources taking into consideration control
factors, inputs and outputs required for each task.
Exercise a set of methodologies to manufacture a quality product at the first
attempt to save rework.
Observe methods and processes, which will ensure optimum use of raw
materials.
Use of most efficient processes and machinery to create a sustainable product
along with sustainable environment.

Process Modeling Methodologies Applied:

Process modeling at Robofusion is based on CIMpgr proposed by Paul G. Ranky. This
method complies with U.S. initiated, international standard object-oriented UML
(Unified Modeling Language) and the European CIM-OSA standard CIM reference
architecture. This modeling process makes use of graphics and models to illustrate the
object-to-object relationship, which can help visual understanding of the relationship
between processes and the outcomes of each process and the inputs required. CIMpgr
enables the user to breakdown the parent process into smaller child processes identifying
the information such as inputs, outputs, resources and controlling factors for each
process. This model will help Robofusion Eco-MHE in identifying the most important
and urgent tasks from a group of routine tasks.
Process Model:
CIMpgr method is well tested for integrated methods, tools and technologies for the
purpose of analyzing, specifying, designing, implementing, operating, maintaining all
the process.
Therefore adopting this method Robofusion will achieve its goals with accordance to
PAT; a system for designing, analyzing, and controlling manufacturing through timely
measurements (i.e., during processing) of critical quality and performance attributes of
raw and in-process materials and processes with the goal of ensuring final product
quality.
The process is broken down into many layers depending upon the need or importance of
the process in to total outcome. Robofusion has represented three layers of the CIMpgr.
Layer 0 is the parent layer while layers 1 and 2 are the child layers.
Layer 0:
This process diagram describes the Global view of all processes implemented in
Robofusion Eco-MHE. Layer 0, is the parent layer and encompasses all processes and
activities for the project. It shows the inputs, outputs, constraints and the Resources that
are necessary or implemented. The inputs are termed from I1A0 to I4A0, outputs O1A0
to O5A0, constraints C1A0 to C7A0 and resources R1A0 to R6A0.This model
efficiently shows the goals of a business and set of inputs which would help produce the

output with certain constraints and resources available.

Layer 1:
Layer 1 is a child layer and helps break down the parent into smaller fragment with
details related to each task in the business. Layer 1 of Robofusion eco-MHE consists
of the processes such as customer requirements &manufacturing analysis, product
design, manufacturing and assembly, quality control & testing and marketing,
sales & services. This layer allows the specific details such as information flow, material
flow, allocation of human resources and allocation of finance. This will allow each
department to interact with each other and identify the inputs required from other
departments and outputs required to deliver to other departments under
the set of constraints and resources allocated to each department. This model allows data
flow in a detailed fashion and thus help managers keep projects on track.

Layer 2:
Layer 2 shows the required stages during quality control and testing in order to achieve
the quality standards promised to the customers. A4 stage also includes testing for

functional requirements and safety testing and thus is integrated with quality controlThis
stage is considered crucial in order to obtain data to propose changes in manufacturing
and assembly process in order to meet the quality standards and customer
requirements.

3. Implementation of Transition Plan:

Implementation of the integrated PLM system

Train employees about the Green PLM systems
Upload Main Data from legacy systems
Verify Main Data is accurate and make changes
Upload software into Product Development, Manufacturing, and Marketing
systems
Verify functionality of equipment with new software.
Establish criteria for integrated user testing.
Training for integrated user testing.
Execute integrated user testing.

Verifying whether the product meets the customer requirement and fix bugs
where found
Conduct trial run.
Conduct end-user training for all functions and update SOPs.
Execution of green integrated PLM system with zero defects, no carbon
footprints and a greener environment.

4. Return On Investment Analysis:

Revenue
Material Cost
Labor Cost
Overhead
PLM
Implementation
PLM Training
PLM service
Gross Profit

2015
6,700,000
2,800,000
3,000,000
1,200,000
0.00

2016
6,900,000
2,500,000
2,500,000
1,100,000
500,000

2017
7,300,000
2,200,000
2,400,000
1,000,000
0.00

2018
7,900,000
2,400,000
2,500,000
1,000,000
0.00

0.00
0.00
-300,000

300,000
0.00
0.00

200,000
60,000
1,34,000

0.00
20,000
1,980,000

The total Investment of cost over the three years is around 1,080,000 and the gain from
the investment is about 3,320,000. The return of investment over 3 years is 2.07 or
207%. The return of investment is analyzed for a period of four years from 2015-2018
and the gross profit is shown for the respective years.

Video Conference:

Q1) What is a product design review? How did you prepare your files for this web-based
VC product design review?
The product design review is used to review the product design and quality of the
product designed. Different ideologies were shared for a better green environment.
Q2) What were the most important steps in your product design review process?

During our review process the following steps were followed and discussed:
1: knowing what the product is?
2: the green and sustainability factor
3: methodologies used.
4: cost and maintenance factor
5: reviewing the analysis.
6: how user friendly the product is
7: its use and adaptability in the market.
Q3) What software did you use for VC and how?
We both used Skype for the video conferencing. The screen shot of our video
conferencing is provided in the above attachment.
Q4) What did you discuss and achieve during the VC session?
During the VC session we discussed each others project in detail. We also had a look
on each others analysis and methodologies.
Achievement:
We were able to discuss each others project and know the technologies used. We came
to know about new methods and the sustainability and reliability of the product.
Q5) How do you like this video-conferencing approach for collaborative CE/PLM
problem solving?
It was a very useful and innovative approach. A totally new experience.
Q6) What were the main challenges?
The main challenge was to apply the learned methodologies and concepts in our
company to provide sustainable and green product.
Q7) What worked well, and what did not, and why?
I did not find any flaw in the Video Conferencing Session. The VC made the
conversations seem more like face-to-face discussion. It was interesting to learn from
each others projects. Many methodologies and ideas were shared between us.
Video conferencing is a good tool in order to reduce overhead time for the meetings.
Q8) How much is Carbon footprint saved?
Using a very good carbon foot print calculator following results were obtained:
According to the daily consumption of gas and electricity for our house in Harrison:
Our yearly carbon footprint

7,454 lbs CO2 per year i.e. 20.42/day

If I use a car to drive to drive to NJIT for a meeting then my total carbon footprint
annually is 17,785 lbs CO2 per year i.e. 48.7 lb/day
So totally I am saving
48.7-20.42= 28.28 lbs CO2
5. Summary:
This project helped me to understand better methods used throughout the whole class.
Also, video conference proved to be very important tool.
6. Social Networking Articles:
Ford, Alcoa team to add more aluminum for F-150
Ford and Alcoa are teaming up to use newer form of aluminum thats very strong and
easily molded into body parts and other shapes for their popular F-150 series pickup
trucks. Alcoas micromill aluminum technology is the latest technology, which makes
the inside panels of doors and external fenders easier to shape, and this aluminum will
be used in the production of F-150 trucks in 2016.
Bezos Space Company to build, launches rockets in Florida
Jeff Bezos has joined the craze for space travel as his space company, Blue Origin, has
announced that they will build and launch rockets into the orbit from the Cape
Canaveral Air Force Base in Florida. They plan to have their first rocket launch With
Blue Origin joining; Space travel has had a promising first step and is moving in the
right direction.
Multi Tasking, Task-Switching and Auto Safety
Attention lapses are common in humans, but how dangerous it is while driving a car
where you are prone to do multi-tasking with the advancement of technology. With a
GPS technology to look for the maps and other functionalities a person is easily
diverted to other unimportant things at the moment than the traffic and the road
leading to accidents. The U.S. National Highway Traffic Safety Administration
(NHTSA) proposed a set of guidelines that had to be followed in 2013. NHTSA also
recommended the driver to lock-out devices that is not involved while driving as it
diverts the attention of the driver to a secondary object leaving behind the primary one.
References:
Paul G Ranky Concurrent Engineering 3D e-book and videos
http://www.g-technology.com
http://www.bmw-motorrad.com
http://www.interroll.us

https://www.safariltd.com

Self-Assessment:
I would give myself a 10/10; this assignment has been one great task, as it covers
various aspects. I have completely covered all the areas required.