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MSE-415: Product
Product Design
Design
Lecture
Lecture #9
#9
Chapter 9
Product Architecture
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Lecture
Lecture Objectives:
Objectives:
Discuss midterm result
Discuss presentation results
Lecture on Product Architecture
Lecture on Design for Manufacturing
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Product
Product
Architecture
Architecture
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Product
Product
Architecture
Architecture
The way the functions of the product are implemented through
the use of chunks defines its architecture.
Modular Architecture
Chunks implement one or a few function elements
Interactions between chunks are well defined and fundamental
to the primary functions of the product.
Process
Design changes are relatively easy.
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Product
Product
Architecture
Architecture
The way the functions of the product are implemented through
the use of chunks defines its architecture.
Integral Architecture
Functional elements are implemented using more than one chunk.
Single Chunk implements several functions.
Interactions between chunks are ill defined and may be incidental
to the primary functions of the product.
C
AB
D
Process
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Example:
Example: Coffee
Coffee
Maker
Maker
Overall
Function
Brew
Coffee
Electricity
Supporting
Sub-Functions
Auxiliary
Functions
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Water
Ground
Coffee
Coffee
Beans
Store
Water
Heat
Water
Heat
Coffee
Store
Grounds
Mix Coffee
and Water
Store
Coffee
Grind
Beans
Coffee
Shut-off
Heater
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How
How to
to Create
Create aa Function
Function
Structure
Structure
1. Formulate the overall
product function
2. Split up overall function into sub-functions
3. Determine simplified functions structure
4. Identify material, energy, and information/signal
flows
5. Add secondary/auxiliary functions and flows
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Morphological
Morphological
Matrix
Matrix
Search for solution principles
to fulfill sub-functions
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Heat
Coffee
Filter
Heat
Water
S11
Si1
Store
Store
Grounds Water
Brew
Coffee
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Morphological
Morphological Matrix
Matrix for
for
Coffee
Coffee Maker
Maker
S12
Osmosis Dissolve
S1j
S1m
Ionize
Stir
Si2
Sij
Sn1
Sim
Sn2
Snj
Snm
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Modularity
Modularity
Defined
Defined
After we brainstorm solutions for each subfunction, we combine them to create the product
architecture.
As part of this process, we seek to identify
modules.
Modularity is defined as:
1.
2.
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Product
Product Architecture
Architecture
Definition
Definition
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Types
Types of
of Modularity:
Modularity:
Slot
Slot
In a slot architecture, each module
has a different interface with the
overall system.
Examples:
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Types
Types of
of Modularity:
Modularity:
Bus
Bus
In a bus architecture,
there is a
common bus to which modules
connect via the same interface.
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Types
Types of
of Modularity:
Modularity:
Sectional
Sectional
Examples:
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Legos
Selecting
Selecting
Architecture
Architecture
Decisions about how to divide the product into chunks and about
how much modularity to impose on the architecture are tightly linked
to several issues of importance:
Product Change
Product Variety
Component Standardization
Product Performance
Manufacturability
Product Development Management
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Selecting
Selecting
Architecture
Architecture
Product Change
Add-ons
Adaptation
Wear
Consumption
Flexibility of Use
Reuse
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Product Variety
Selecting
Selecting
Architecture
Architecture
Variety refers to the range of product models the firm can produce
within a particular time period in response to market demand.
Modular = Easier variation without adding tremendous complexity
to the manufacturing system.
Integral = Variation of product can add complexity to the manufacturing
system.
B1
A
B2
ABC-D
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Selecting
Selecting
Architecture
Architecture
Component Standardization
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Selecting
Selecting
Architecture
Architecture
Product Performance
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Selecting
Selecting
Architecture
Architecture
Manufacturability
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Selecting
Selecting
Architecture
Architecture
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Establishing
Establishing the
the
Architecture
Architecture
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Creating
Creating aa Module-Based
Module-Based Product
Product
Family
Family
Product
Family
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Specific
Function 1
Specific
Function 2
Specific
Function k
Derivative
Product 1
Derivative
Product 2
Derivative
Product k
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Example:
Example: Braun
Braun Family
Family of
of
Coffee
Coffee Makers
Makers
Electricity
Water
Ground
Coffee
Store
Water
Heat
Water
Heat
Coffee
Store
Grounds
Mix Coffee
and Water
Store
Coffee
Basic
Model
Water
Filter
Thermos
Karafe
KF130
KF145
KF170
KF180
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Common
Function
Brew
Coffee
Coffee
Adjustable
Heater
Frothing
Attachment
KF185
KF190
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Developing
Developing Modular
Modular
Architectures
Architectures
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Establishing
Establishing the
the
Architecture
Architecture
2. Function sharing
3. Capabilities of vendors
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Establishing
Establishing the
the
Architecture
Architecture
6. Accommodating Variety
Elements should be grouped together to enable the firm to vary the product
in ways that will have value for the customers.
7. Enabling Standardization
8. Portability of interfaces
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Establishing
Establishing the
the
Architecture
Architecture
Print
Cartridge
Position
Cartridge
In X-axis
Position
Cartridge
In Y-axis
User Interface
Accept
User
Inputs
Control
Printer
Pick
Paper
Comm.
With
Host
Print
Mechanism
Connect
to
Host
Flow of forces/energy
Flow of material
Flow of signals/data
Display
Status
Power Cord
Supply
DC
Power
Command
Printer
Driver Software
Logic Board
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Establishing
Establishing the
the
Architecture
Architecture
Logic Board
User Interface
Print Cartridge
Paper Tray
Print Mechanism
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Establishing
Establishing the
the
Architecture
Architecture
Identify the Fundamental and Incidental Interactions
Fundamental: Identified in the schematic.
Incidental: Shown in an incidental interaction graph.
Enclosure
Thermal
Distortion
Styling
Paper Tray
Vibration
Print
Mechanism
User Interface
Board
Logic Board
RF Interface
Chassis
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Thermal Distortion
RF Shielding
Host Driver
Software
Power Cord
Brick
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Platform
Platform
Planning
Planning
The collection of assets shared by various products to meet various
markets is called the product platform.
There are market advantages to have several distinct versions of a
product.
There are design/manufacturing advantages to have when versions
share many components.
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Platform
Platform
Planning
Planning
Differentiation Plan
Commonality Plan
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Platform
Platform
Planning
Planning
Differentiation Plan
Explicitly represents the ways in which multiple versions of a product
will be different from the perspective of the customer and the market.
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Differentiating
Attributes
Family
Student
SOHO
Laser quality
Laser quality
Equivalent to DJ 600
Equivalent to DJ 600
Print Speed
6 pages/minute
8 pages/minute
10 pages/minute
Footprint
360mm x 400mm
340mm x 360mm
400mm x 450mm
Paper storage
100 sheets
100 sheets
150 sheets
Style
Consumer
Youth consumer
Commercial
Connectivity to Computer
USB/Parallel
USB
USB
Mac/Windows
Mac/Windows
Windows
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Platform
Platform
Planning
Planning
Commonality Plan
Explicitly represents the ways in which multiple versions of a product
will be the same physically.
Chunks
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Number of
Types
Family
Student
SOHO
Print Cartridge
Manet Cartridge
Picasso Cartridge
Picasso Cartridge
Print Mechanism
Aurora Series
Narrow Aurora
Series
Aurora Series
Paper Tray
Front-in/Front-out
Front-in/Front-out
Tall Front-in/out
Logic board
Enclosure
Home Style
Youth Style
Driver Software
Version A-PC
Version A-Mac
Version B-PC
Version B-Mac
Version C
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Platform
Platform
Planning
Planning
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MSE-415:
MSE-415: Product
Product
Design
Design
Lecture
Lecture #10
#10
Chapter 11
Design for Manufacturing
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Lecture
Lecture Objectives:
Objectives:
Overview of the DFM process
Estimate manufacturing cost
Reduce cost of components
Reduce cost of assembly
Reduce cost of supporting production
Consider impact of DFM decisions on other factors
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Gathering
Gathering DFM
DFM
Information
Information
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DFM
DFM Method
Method
Proposed Design
Recompute the
Manufacturing Costs
Good
enough
?
Y
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Acceptable Design
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1.
1. Estimate
Estimate the
the Manufacturing
Manufacturing
Costs
Costs
Equipment
Information Tooling
Raw Materials
Labor
Manufacturing System
Finished Goods
Purchased
Components
Energy
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Supplies Services
Waste
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Manufacturing
Manufacturing Costs
Costs
Defined
Defined
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Elements
Elements of
of the
the Manufacturing
Manufacturing Cost
Cost of
of aa
Product
Product
Manufacturing Cost
Components
Standard
Raw
Material
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Custom
Processing
Assembly
Labor
Overhead
Equipment
and Tooling
Support
Indirect
Allocation
Tooling
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Manufacturing
Manufacturing Cost
Cost of
of aa
Product
Product
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Fixed
Fixed Costs
Costs vs.
vs. Variable
Variable
Costs
Costs
Fixed
Variable
N
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2.
2. Reduce
Reduce the
the Cost
Cost of
of
Components
Components
Understand the Process Constraints and Cost
Drivers
Redesign Components to Eliminate Processing
Steps
Choose the Appropriate Economic Scale for the
Part Process
Standardize Components and Processes
Adhere to Black Box Component Procurement
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Understand
Understand the
the Process
Process Constraints
Constraints and
and Cost
Cost
Drivers
Drivers
Redesign costly parts with the same performance
while avoiding high manufacturing costs.
Work closely with design engineersraise
awareness of difficult operations and high costs.
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Redesign
Redesign Components
Components to
to Eliminate
Eliminate
Processing
Processing Steps
Steps
Reduce the number of steps of the
production process
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Choose
Choose Appropriate
Appropriate Economics
Economics of
of
Scale
Scale
Economies of Scale As production volume
increases, manufacturing costs usually decrease.
Fixed costs divided among more units.
Variable costs are lower since the firm can use
more efficient processes and equipment.
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Standardize
Standardize Components
Components and
and
Processes
Processes
Economies of Scale The unit cost of a
component decreases as the production volume
increases.
Standard Componentscommon to more than
one product
Analysis tools group technology and mass
customization
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Adhere
Adhere to
to Black
Black Box
Box Component
Component
Procurement
Procurement
Black boxonly give a description of what the
component has to do, not how to achieve it
Successful black box design requires clear
definitions of the functions, interfaces, and
interactions of each component.
What
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What
What
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3.
3. Reduce
Reduce the
the Costs
Costs of
of
Assembly
Assembly
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Advantages
Advantages of
of Integrated
Integrated
Parts
Parts
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Part
Part
Part
Part
Part
Part
Part
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Minimize
Minimize Ease
Ease of
of
Assembly
Assembly
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Consider
Consider Customer
Customer
Assembly
Assembly
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4.
4. Reduce
Reduce the
the Costs
Costs of
of Supporting
Supporting
Production
Production
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5.
5. Consider
Consider the
the Impact
Impact of
of DFM
DFM Decisions
Decisions
on
on Other
Other Factors
Factors
Development Time
Development Cost
Product Quality
External Factors
Component reuse
Life cycle costs
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Next
Next Week
Week November
November 14,
14, 2007
2007
(Lecture
#11)
(Lecture
Homework #7 - Handout #11)
Read Chapter 12 Prototyping
Read Chapter 13 Robust Design
Prepare for a potential quiz on:
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