Product Development in the World Auto Industry

macroeconomics, auto industry, management efficiency, productivity

Linking design and manufacturing domains via web-based and enterprise integration technologies

The manufacturing industry faces many challenges such as reducing time-to-market and cutting costs. In order to meet these increasing demands, effective methods are need to support the early product development stages by bridging the gap of communicating early design ideas and the evaluation of manufacturing performance. This paper introduces methods of linking design and manufacturing domains using disparate technologies. The combined technologies include knowledge management supporting for product lifecycle management (PLM) systems, enterprise resource planning (ERP) systems, aggregate process planning systems, workflow management and data exchange formats. A case study has been used to demonstrate the use of these technologies, illustrated by adding manufacturing knowledge to generate alternative early process plan which are in turn used by an ERP system to obtain and optimise a rough-cut capacity plan

Using social engagement to inspire design learning

Social design and ‘design for need’ are important frameworks for establishing ethical understanding amongst novice product designers. Typically, product design is a value-adding activity where normally aesthetics, usability and manufacturability are the key agendas. Howard [1] in his essay “Design beyond commodification” discusses the role of designers in contributing to cultural expressions designed to influence consumer aspirations and desires. He argues that designers are impelled “to participate in the creation of lifestyles that demand the acquisition of goods as a measure of progress and status.” As emerging consumers, student designers tend to reflect this consumer culture in their work, seeking to add ‘marketability’ by focusing on aesthetic development. However value adding can occur in many different manifestations, often outside commercial expectations and the students’ experience. Projects that may be perceived as having limited market potential can often have significant personal impact for both recipient and designer. Social engagement provides a valuable insight for design students into the potential of design to contribute solutions to societal well-being, rather than serve market forces. Working in a local context can enhance this, with unlimited access to end users, their environs and the product context, enabling the development of user empathy and a more intgrated collaborative process. The ‘Fixperts’ social project discussed in this paper has proved to be an effective method of engaging undergraduate students in participatory design within their local community. This model for social engagement has provided an unprecedented learning experience, and established a strong ethical framework amongst Brunel design students

Redesign optimization for manufacturing using additive layer techniques

Improvements in additive manufacturing technologies have the potential to greatly provide value to designers that could also contribute towards improving the sustainability levels of products as well as the production of lightweight products. With these improvements, it is possible to eliminate the design restrictions previously faced by manufacturers. This study examines the principles of additive manufacturing, design guidelines, capabilities of the manufacturing processes and structural optimisation using topology optimisation. Furthermore, a redesign methodology is proposed and illustrated through a redesign case study of an existing bracket. The optimal design is selected using multi-criteria decision analysis method. The challenges for using additive manufacturing technologies are discussed

New directions for Artificial Intelligence (AI) methods in optimum design

Developments and applications of artificial intelligence (AI) methods in the design of structural systems is reviewed. Principal shortcomings in the current approach are emphasized, and the need for some degree of formalism in the development environment for such design tools is underscored. Emphasis is placed on efforts to integrate algorithmic computations in expert systems

Power-Assist Wheelchair Attachment

This senior design project sought to combine the best characteristics of manual and power wheelchairs by creating a battery-powered attachment to propel a manual wheelchair. The primary customer needs were determined to be affordability, portability, and travel on uneven surfaces. After the initial prototype, using a hub motor proved unsuccessful, so a second design was developed that consisted of a gear reduction motor and drive wheel connected to the back of the wheelchair by a trailing arm that could be easily attached/detached from the frame. The prototype of the second design succeeded in meeting most of the project goals related to cost, off-road capability, inclines, and range. Improvements can be made by reducing the attachment weight and improving user control of the device

Mapping customer needs to engineering characteristics: an aerospace perspective for conceptual design

Designing complex engineering systems, such as an aircraft or an aero-engine, is immensely challenging. Formal Systems Engineering (SE) practices are widely used in the aerospace industry throughout the overall design process to minimise the overall design effort, corrective re-work, and ultimately overall development and manufacturing costs. Incorporating the needs and requirements from customers and other stakeholders into the conceptual and early design process is vital for the success and viability of any development programme. This paper presents a formal methodology, the Value-Driven Design (VDD) methodology that has been developed for collaborative and iterative use in the Extended Enterprise (EE) within the aerospace industry, and that has been applied using the Concept Design Analysis (CODA) method to map captured Customer Needs (CNs) into Engineering Characteristics (ECs) and to model an overall ‘design merit’ metric to be used in design assessments, sensitivity analyses, and engineering design optimisation studies. Two different case studies with increasing complexity are presented to elucidate the application areas of the CODA method in the context of the VDD methodology for the EE within the aerospace secto

Study of orifice fabrication technologies for the liquid droplet radiator

Eleven orifice fabrication technologies potentially applicable for a liquid droplet radiator are discussed. The evaluation is focused on technologies capable of yielding 25-150 microns diameter orifices with trajectory accuracies below 5 milliradians, ultimately in arrays of up to 4000 orifices. An initial analytical screening considering factors such as trajectory accuracy, manufacturability, and hydrodynamics of orifice flow is presented. Based on this screening, four technologies were selected for experimental evaluation. A jet straightness system used to test 50-orifice arrays made by electro-discharge machining (EDM), Fotoceram, and mechanical drilling is discussed. Measurements on orifice diameter control and jet trajectory accuracy are presented and discussed. Trajectory standard deviations are in the 4.6-10.0 milliradian range. Electroforming and EDM appear to have the greatest potential for Liquid Droplet Radiator applications. The direction of a future development effort is discussed

Target value design: using collaboration and a lean approach to reduce construction cost

Target Costing is an effective management technique that has been used in manufacturing for decades to achieve cost predictability during new products development. Adoption of this technique promises benefits for the construction industry as it struggles to raise the number of successful outcomes and certainty of project delivery in terms of cost, quality and time. Target Value Design is a management approach that takes the best features of Target Costing and adapts them to the peculiarities of construction. In this paper the concept of Target Value Design is introduced based on the results of action research carried out on 12 construction projects in the USA. It has been shown that systemic application of Target Value Design leads to significant improvement of project performance – the final cost of projects was on average 15% less than market cost. The construction industry already has approaches that have similarities with elements of the Target Value Design process or uses the same terminology, e.g. Partnering and Target Cost Contracts, Cost planning, etc. Following an exploration of the similarities and differences Target Value Design is positioned as a form of Target Costing for construction that offers a more reliable route to successful projects outcomes