Managerial model and process for set-based design

Tese (doutorado) - Universidade Federal de Santa Catarina, Centro Tecnológico, Programa de Pós-Graduação em Engenharia Mecânica, Florianópolis, 2023.O Lean Product Development (LPD) representa o caminho para uma organização Lean. O LPD é complexo e exige um conjunto de elementos, que são muito difíceis de adotar. Soma-se a esse cenário uma base de conhecimento incipiente e a falta de fundamentos teóricos e práticos consistentes, sendo a Toyota o único caso de combinação bem-sucedida de ferramentas e práticas para o desenvolvimento Lean de produtos. Set-Based Design (SBD) é a espinha dorsal do LPD, representando seu elemento mais fundamental, orientando toda a cadência e fluxo do projeto. No entanto, sua complexidade constitui a principal barreira para a disseminação do LPD, pois mais do que apenas uma prescrição de atividades está por trás de seu sucesso. A SBD preconiza a experimentação além do projeto para aprender com o processo ao invés de buscar eficiência operacional. Como resultado, encontra mais resistência entre os desenvolvedores, pois sua implementação consome muito mais recursos do que as estratégias tradicionais. Esta Pesquisa é motivada pela necessidade de avançar em SBD, abrindo caminho para casos de sucesso de LPD nos mais variados ambientes e produtos. Esta Dissertação tem por objetivo apresentar um modelo e processo gerencial para a SBD, orientando sua implementação e organizando o conhecimento sobre esta área de estudo. Primeiro, uma revisão aprofundada da literatura foi realizada para identificar o estado da arte atual. A partir disso, foram identificadas oportunidades sob uma perspectiva gerencial e diretrizes foram derivadas para a proposição de um modelo e processo gerencial para a SBD. Por fim, a proposta foi estudada no desenvolvimento de produtos por meio de pesquisa-ação. O desdobramento e definição do valor, trade-off-curves, estratégia de desenvolvimento híbrido e o Toyota Kata aplicado ao desenvolvimento de produto formaram uma estrutura para projetar o produto de maneira integrada, construindo conhecimento para tomar decisões lentamente, apoiadas em dados. A separação dos subsistemas em domínios ajudou a concentrar esforços e recursos nas partes mais críticas. Os insights gerenciais desta Dissertação podem auxiliar os decisores a superar as barreiras para o SBD. Pode encorajar os profissionais a adotar o SBD, fornecendo uma perspectiva clara dos benefícios e caminhos de implementação.Abstract: Lean Product Development (LPD) emerged as the next step organisations must take toward a Lean Enterprise. LPD is complex to implement and demands a set of well-defined enablers, which are very difficult to adopt. Added to this scenario is the insipient knowledge background and lack of a consistent theoretical and practical basis, being Toyota the only case of a successful combination of lean tools and practices for well-succeeded product development. Set-Based Design (SBD) is the backbone of LPD, representing its most fundamental element, guiding all design cadence and flow. Nevertheless, the complexity of SBD implementation forms the major barrier to LPD dissemination since more than just a prescription of activities is behind its success. SBD preconises experimentation beyond the project to learn with the process instead of seeking operational efficiency. As a result, it finds more resistance among developers as its implementation consumes far more resources than traditional strategies. This research is motivated by the necessity to advance in SBD, paving the way for successful cases of LPD in the most variated environments and products. This Doctoral Dissertation aims to present a managerial model and process for SBD, providing guidelines for its implementation and organising knowledge regarding this field of study. First, a comprehensive in-depth review of the literature was undertaken to identify the current state-of-the-art. Based on this, opportunities from a managerial and engineering-oriented perspective were identified, originating guidelines for the proposal of a managerial model and process for SBD. Finally, the proposal was studied in real-world product development through action research. Value deployment and definition, model-based trade-off-curves, hybrid development strategy, and the Toyota Kata applied to product development formed a framework for designing the product in an integrated manner, building knowledge to make decisions slowly, supported by data. Separating subsystems into domains assisted in focusing efforts and resources on the most critical parts. The managerial insights from this Dissertation can assist decision-makers in overcoming barriers to SBD adoption. It encourages practitioners to adopt SBD by providing a clear perspective of benefits and implementation paths

Development of a lean design framework for enhancing the application of product design

Substantial benefits can be achieved through the adoption of lean type thinking earlier at the design stage to create more viable products. A complex design cannot be easily leaned out in production; therefore, the production of affordable and sustainable products requires effective lean design considerations at the conceptual level. The research presented in this thesis investigates and demonstrates the application of lean design for product enhancement. The aim of the research was to develop a novel lean design framework that would support the generation of product design with attributes such as maximise value, manufacturable, and operable with minimum waste and resources ensuring avoidable harm is eliminated. The framework consists of a systemised process which is organised in to phases and activities that provides a unique practical manner to lean out a design. The construction of the framework initiated with an extensive literature review and proceeded with an industrial field study which consisted of 34 interviews with 11 manufacturing companies in Europe. The findings were amalgamated to generate a lean design definition and principles which would form the foundations of the framework. A real-life industrial case study of an offshore oil/water separator was used to validate the framework. In conclusion, the lean design framework provides the necessary means by which a lean design can be achieved. As a result a functionally viable and enhanced design that is cheaper to manufacture through controlling waste and eliminating avoidable harm occurrence can be realised with minimal effort. The research makes the following contributions: (1) identification of essential elements in lean design, (2) generation of a lean design definition and principles, (3) Lean Design Framework development and (4) illustrative guidelines based on the framework to be used by designers in realising a lean product design

Total Ownership Cost Modeling Of Technology Adoption Using System Dynamics: Implications For Erp Systems

Investment in new technologies is considered by firms as a solution to improve their productivity, product and service quality and their competitive advantages in the global market. Unfortunately, not all technology adoption projects have met their intended objectives. The complexity of technology adoption along with little consideration of the long term cost of the technology, are among the factors that challenge companies while adopting a new technology. Companies often make new technology adoption decision without enough attention to the total cost of the technology over its lifecycle. Sometimes poor decision making while adopting a new technology can result in substantial recurring loss impacts. Therefore, estimating the total cost of the technology is an important step in justifying the technology adoption. Total Ownership Cost (TOC) is a wildly-accepted financial metric which can be applied to study the costs associated with the new technology throughout its lifecycle. TOC helps companies analyze not only the acquisition and procurement cost of the technology, but also other cost components occurring over the technology usage and service stage. The point is that, technology adoption cost estimation is a complex process involving consideration of various aspects such as the maintenance cost, technology upgrade cost and the cost related to the human-resource. Assessing the association between the technology characteristics (technology upgrades over its life cycle, compatibility with other systems, technology life span, etc) and the TOC encompasses a high degree of complexity. The complexity exists because there are many factors affecting the cost over time. Sometimes decisions made today can have long lasting impact on the system costs and there is a lag between the time the decision is taken and when outcomes occur. iv An original contribution of this dissertation is development of a System Dynamics (SD) model to estimate the TOC associated with the new technology adoption. The SD model creates casual linkage and relationships among various aspects of the technology adoption process and allows decision makers to explore the impact of their decisions on the total cost that the technology brings into the company. The SD model presented in this dissertation composes of seven sub-models including (1) technology implementation efforts, (2) workforce training, (3) technology-related workforce hiring process, (4) preventive and corrective maintenance process, (5) technology upgrade, (6) impact of technology on system performance and (7) total ownership cost sub model. A case study of Enterprise Resource Planning (ERP) system adoption has been used to show the application of the SD model. The results of the model show that maintenance, upgrade and workforce hiring costs are among the major cost components in the ERP adoption case study presented in Chapter 4. The simulation SD model developed in this dissertation supports trade-off analysis and provides a tool for technology scenarios evaluation. The SD model presented here can be extended to provide a basis for developing a decision support system for technology evaluation

Metodología de implantación de modelos de gestión de la información dentro de los sistemas de planificación de recursos empresariales. Aplicación en la pequeña y mediana empresa

La Siguiente Generación de Sistemas de Fabricación (SGSF) trata de dar respuesta a los requerimientos de los nuevos modelos de empresas, en contextos de inteligencia, agilidad y adaptabilidad en un entono global y virtual. La Planificación de Recursos Empresariales (ERP) con soportes de gestión del producto (PDM) y el ciclo de vida del producto (PLM) proporciona soluciones de gestión empresarial sobre la base de un uso coherente de tecnologías de la información para la implantación en sistemas CIM (Computer-Integrated Manufacturing), con un alto grado de adaptabilidad a la estnictura organizativa deseada. En general, esta implementación se lleva desarrollando hace tiempo en grandes empresas, siendo menor (casi nula) su extensión a PYMEs. La presente Tesis Doctoral, define y desarrolla una nueva metodología de implementación pan la generación automática de la información en los procesos de negocio que se verifican en empresas con requerimientos adaptados a las necesidades de la SGSF, dentro de los sistemas de gestión de los recursos empresariales (ERP), atendiendo a la influencia del factor humano. La validez del modelo teórico de la metodología mencionada se ha comprobado al implementarlo en una empresa del tipo PYME, del sector de Ingeniería. Para el establecimiento del Estado del Arte de este tema se ha diseñado y aplicado una metodología específica basada en el ciclo de mejora continua de Shewhart/Deming, aplicando las herramientas de búsqueda y análisis bibliográfico disponibles en la red con acceso a las correspondientes bases de datos

A metamodel to annotate knowledge based engineering codes as enterprise knowledge resources

The encoding of Knowledge Based Engineering (KBE) software applications is becoming a prominent tool for the automation of knowledge intensive tasks carried out using Computer Aided Design (CAD) technology. However, limitations exist on the ability to manage the engineering knowledge models embedded in these executable KBE applications. This research proposes a metamodel to annotate encoded KBE applications. Resulting from the annotation, XKMs become explicit knowledge resources whose content can be better accessed and managed. The attachment of metadata to data sets in enterprise repositories is a necessary step to identify and index them so they can be queried, browsed and changed. The sophistication of metadata models for these data “items” ranges from the simple indexing using numbers to more sophisticated representations describing their context information (i.e. author, creation date, etc.), their internal structure and their content. Current engineering data repositories like Product Data Management and Product Lifecycle Management systems offer predefined metamodels to annotate a range of engineering data items including CAD files or special types of documents. At the moment, there is no metadata model specifically designed to annotate KBE codes. In this situation, an undifferentiated metadata model needs to be used for XKMs. However, in this case the only information retained by the system about them would be context metadata. Once an instance of the metadata is attached to an XKM, it can be used as its identifier within an enterprise data repository. The proposed metamodel contains abstract entities to annotate XKMs. The resulting descriptive model for an XKM pays attention to its internal structure and its operation at different levels of granularity. The particular design of the proposed metamodel positions it at a level of abstraction between non executable domain knowledge models and executable KBE applications. This design choice is made to support the use of the metadata not only as an informative model but also as an executable one. The achievement of this target is becoming possible through the emergence of semantic modelling standards that allow the description of data models independently from the language of implementation. Using this approach, the generation of code and metadata is made automatically using mapping rules resulting from the semantic agreement between models and specific syntax rules. The immediate application of the developed metamodel is to annotate XKMs within PLM systems. The approach shall contribute not only to systematically store instances of XKMs but also to manage the lifecycle of the engineering knowledge encoded within them. The proposed representation provides a more comprehensive approach for non KBE language experts to understand the code. On this basis, the change on the metamodels can be automatically traced back to the code and vice-versa. During the research, evidence has been gathered from the community of KBE technology users and vendors on the need to support this research effort. In the long term, the research contributes to the use of PLM systems as a platform for engineering knowledge management.EThOS - Electronic Theses Online ServiceGBUnited Kingdo

Improvement of construction process by adopting lean construction principles: a construction model development

Lessons learned from the construction industry have shown that adopting lean principles within construction processes can significantly enhance the overall success of a construction project. However, currently the potential benefits of such an approach are still not being fully realised in a uniform way. The application of lean principles in construction projects has an underlying aim to increase the value of projects and to eliminate construction waste, in order to achieve project targets of time, cost, and quality while reducing damage to the environment consistent with the underlying principles of sustainable development. This research project presents a newly developed framework that contains a set of lean methods and techniques to support the application of lean principles to construction project practice. In so doing the method helps those within the construction industry to more consistently achieve the full benefits that lean construction approaches can offer. The aim of this research project is to investigate the lean construction techniques currently used in the industry and the principles of lean construction applications, particularly, the problems and challenges, and develop a new construction process model in which lean methods/tools can be integrated. This will provide an effective and efficient way for managing construction projects in the construction industry. A parallel aim is to improve the construction process to better manage construction waste, time and cost and to improve the levels of quality and sustainability achieved. The adaptation of lean principles with identified enablers has been assessed where a combination of different lean principles and techniques were considered as the main enablers to develop a framework for the construction process. The RIBA Plan of Work was used to integrate and incorporate several lean construction principles and techniques to develop a standardised model where both the construction stages and the associated activities of the construction process in projects can be described. The underlying philosophy of the developed framework is to increase the efficiency of transformation activities (known as value-adding activities – processing). The innovative construction process models presented in this research are developed based on the core enablers that can be used to identify and eliminate waste in the construction process. These include set-based concurrent engineering (SBCE) integrated with the Last Planner® System (LPS) and lean thinking (LT) within traditional construction process activities. A number of measurement and control methods and guidelines for implementation of the framework are presented. In addition, case study materials have been collected from the industry in order to test and validate the framework. The results provide useful information and guidance to the construction industry as a whole. The novelty and contribution to knowledge of the research includes: improvement of construction process and performance through the development and implementation of an integrated lean-enabled pull flow construction process framework (i.e. pull flow control embedded within lean construction management) integrated with measurement and control methods within the RIBA Plan of Works. The research concludes by suggesting that the most effective way to implement lean methods and techniques in construction activities is to use the framework proposed and developed in this research which is integrated with the RIBA Plan of Work

Advances in Manufacturing Technology XXVII: Proceedings of the 11th International Conference on Manufacturing Research (ICMR2013)

ICMR2013 was organised by Cranfield University on the 19-20 September 2013. The conference focuses on any aspects of product development, manufacturing technology, manufacturing systems, information systems and digital technologies. It provides an excellent avenue for researchers to present state-of-the-art multidisciplinary manufacturing research and exchange ideas. In addition to the four keynote speeches from Airbus and Rolls-Royce and three invited presentations, there are 108 papers in these proceedings. These papers are split into 24 technical sessions. The International Conference on Manufacturing Research is a major event for academics and industrialists engaged in manufacturing research. Held annually in the UK since the late 1970s, the conference is renowned as a friendly and inclusive environment that brings together a broad community of researchers who share a common goal; developing and managing the technologies and operations that are key to sustaining the success of manufacturing businesses. For over two decades, ICMR has been the main manufacturing research conference organised in the UK, successfully bringing researchers, academics and industrialists together to share their knowledge and experiences. Initiated a National Conference by the Consortium of UK University Manufacturing Engineering Heads (COMEH), it became an International Conference in 2003. COMEH is an independent body established in 1978. Its main aim is to promote manufacturing engineering education, training and research. To achieve this, the Consortium maintains a close liaison with government bodies concerned with the training and continuing development of professional engineers, while responding to the appropriate consultative and discussion documents and other initiatives. COMEH is represented on the Engineering Professor’s council (EPC) and it organises and supports national manufacturing engineering education research conferences and symposia

Improvement of cost estimating internal practice

This thesis is concerned with understanding the internal costing practices employed by commercial and engineering disciplines of cost estimating for generating estimates at the conceptual design stage of complex hardware products. It examines whether there is a formal structure in the interaction between the two groups that can be represented within a model. The aim is to develop a framework that will formalise and improve the communication of commercial and engineering disciplines in cost estimating. A literature review examines the role of different costing techniques and the information requirements for generating cost estimates. The review identifies that there is a lack of research in the information requirements for cost estimating of specific manufacturing industries, and that the interaction of commercial and engineering disciplines of cost estimating at conceptual design stage is hindered by the different focuses of these groups. By conducting a survey study the author identifies the internal practice in cost estimating for the automotive industry. The survey establishes that in order to improve the internal practice it is essential to establish a data infrastructure that formalises and enables the reuse of the cost estimates and improves the interaction between the two groups. The author identifies a common cost estimating process for the automotive industry. This study establishes the required data and information elements and information sources that need to be collected in order to have reliable data infrastructure. Using a case study approach, the author also establishes that it is essential to analyse the product functions in such a way that will enable the development of a detailed cost estimating model at the conceptual design stage, which will improve interaction between the commercial and engineering groups. The function-based cost estimating process becomes the focus of detailed studies using experts from the automotive industry. This results in a generic framework that provides a formalised structure to represent functional requirements in the form of a detailed cost estimating model. The thesis concludes that product functions need to be captured and analysed during the conceptual development of a product and be associated to cost estimates. The developed results provide both groups of cost estimating a structured, consistent approach to developing cost estimates at the conceptual design stage. The data infrastructure and the function-based cost estimating framework is validated through case studies and expert evaluation. The approach contributes towards improvement of the internal cost estimating practice with the automotive industry.EThOS - Electronic Theses Online ServiceGBUnited Kingdo