Balancing Global Customer Needs and Profitability Using a Novel Business Model for New Model Programmes in the Automotive Industry

AbstractBusiness models need to evolve and respond to changing customer requirements and this is only further exaggerated when considered in the context of a ‘Global Market’ which has shifted in the last 60 years from ‘Manufacturer’ led to ‘Customer’ led ‘fashion’ based industry. The automotive industry is one example of an emerging fashion based industry.The objective of most viable businesses is to make a profit for their shareholders but, given the typical gestation period between concept establishment and the start of the production volume build, it is a challenge to establish a structured method to ensure programme and business profitability against the backdrop of a fashion based market. In this paper, a data driven methodology is proposed which focuses on data, structure, and the customer to maximise the probability of profitability. To achieve this goal, joins between Multi Criteria Decision Analysis, Parametric Cost Estimating and ‘Should’ Cost Estimating are explored. ‘Margin engineering’ is thus proposed as a new foundation for a future business model to guide medium term (one to six years) development projects towards a profitable outcome

EXPERT SYSTEM BASED APPROACH FOR MATERIAL SELECTION OF AUTOMOBILE BODY-IN-WHITE STRUCTURAL PANELS USING NUMERICAL RANKING AND SUSTAINABILITY INDICES

The goal of this work is to establish a set of quantifiable measures for design for sustainability (DFS) that can be applied to automotive applications in terms of environmental, social, economic and technical aspects. In this study, a comprehensive analysis was made in order to develop a methodology that can evaluate different body-in-white designs in terms of major sustainability aspects. Besides the complete life cycle analysis, environmental impacts and cost factors will be analyzed over vehicle\u27s entire life-cycle (fuel extraction and refining, Pre-manufacturing, Manufacturing, Use, and Post-use stages). The considered material options include: conventional steel, high strength steel, aluminum, magnesium, titanium and composites that are currently used in body-in-white (BIW) structures and exterior body panels. Sustainability scoring method was developed and used to decide on how using lighter materials in auto body applications is beneficial or not. The proposed major sustainable factors are categorized into four major groups: environmental, economical, social and technical groups. Also, each group has corresponding factors which were chosen by extensive search and screening, so only important sustainability aspects for auto body design have been selected in this study. Then the dissertation proceeds to show some sustainability scoring methods in order to get better understanding as well as relative ranking for different materials from sustainability point of view. Moreover, this work discusses the role and application of some multi-criteria decision making methods in materials selection, namely quality function deployment (QFD) and analytic hierarchy process (AHP). However, multi-criteria decision making methods are efficient tools to choose alternative from large set of alternatives, especially when two or more conflicting goals are present. Besides that, knowledge based system (KBS) was established for eco-material selection for auto-body structural panels. The goal behind using KBS is to help designers in material selection process which usually needs experience, time and effort

A COMPREHENSIVE ASSESSMENT METHODOLOGY BASED ON LIFE CYCLE ANALYSIS FOR ON-BOARD PHOTOVOLTAIC SOLAR MODULES IN VEHICLES

This dissertation presents a novel comprehensive assessment methodology for using on-board photovoltaic (PV) solar technologies in vehicle applications. A well-to-wheels life cycle analysis based on a unique energy, greenhouse gas (GHG) emission, and economic perspective is carried out in the context of meeting corporate average fuel economy (CAFE) standards through 2025 along with providing an alternative energy path for the purpose of sustainable transportation. The study includes 14 different vehicles, 3 different travel patterns, in 12 U.S. states and 16 nations using 19 different cost analysis scenarios for determining the challenges and benefits of using on-board photovoltaic (PV) solar technologies in vehicle applications. It develops a tool for decision-makers and presents a series of design requirements for the implementation of on-board PV in automobiles to use during the conceptual design stage, since its results are capable of reflecting the changes in fuel consumption, greenhouse gas emission, and cost for different locations, technological, and vehicle sizes. The decision-supports systems developed include (i) a unique decision support systems for selecting the optimal PV type for vehicle applications using quality function deployment, analytic hierarchy process, and fuzzy axiomatic design, (ii) a unique system for evaluating all non-destructive inspection systems for defects in the PV device to select the optimum system suitable for an automated PV production line. (iii) The development of a comprehensive PV system model that for predicting the impact of using on-board PV based on life cycle assessment perspective. This comprehensive assessment methodology is a novel in three respects. First, the proposed work develops a comprehensive PV system model and optimizes the solar energy to DC electrical power output ratio. Next, it predicts the actual contribution of the on-board PV to reduce fuel consumption, particularly for meeting corporate average fuel economy (CAFE) 2020 and 2025 standards in different scenarios. The model also estimates vehicle range extension via on-board PV and enhances the current understanding regarding the applicability and effective use of on-board PV modules in individual automobiles. Finally, it develops a life cycle assessment (LCA) model (well-to-wheels analysis) for this application. This enables a comprehensive assessment of the effectiveness of an on-board PV vehicle application from an energy consumption, Greenhouse Gas (GHG) emission, and cost life-cycle perspective. The results show that by adding on-board PVs to cover less than 50% of the projected horizontal surface area of a typical passenger vehicle, up to 50% of the total daily miles traveled by a person in the U.S. could be driven by solar energy if using a typical mid-size vehicle, and up to 174% if using a very lightweight and aerodynamically efficient vehicle. In addition, the increase in fuel economy in terms of combined mile per gallon (MPG) at noon for heavy vehicles is between 2.9% to 9.5%. There is a very significant increase for lightweight and aerodynamic efficient vehicles, with MPG increase in the range of 10.7% to 42.2%, depending on location and time of year. Although the results show that the plug-in electric vehicles (EVs) do not always have a positive environmental impact over similar gasoline vehicles considering the well-to-wheel span, the addition of an on-board PV system for both vehicle configurations, significantly reduces cycle emissions (e.g., the equivalent savings of what an average U.S. home produces in a 20 month period). The lifetime driving cost ($per mile) of a gasoline vehicle with adding on-board PV, compared to a pure gasoline vehicle, is lower in regions with more sunlight (e.g., Arizona) even of the current gasoline price in the U.S. ($4.0 per gallon) assuming battery costs will decline over time. Lifetime driving cost ($per mile) of a plug-in EV with added PV versus pure plug-in EV (assuming electricity price 0.18$/kWh) is at least similar, but mostly lower, even in regions with less sunlight (e.g., Massachusetts). In places with low electricity prices (0.13 $/kWh), and with more sunlight, the costs of operating an EV with PV are naturally lower. The study reports a unique observation that placing PV systems on-board for existing vehicles is in some cases superior to the lightweighting approach regarding full fuel-cycle emissions. An added benefit of on-board PV applications is the ability to incorporate additional functionality into vehicles. Results show that an on-board PV system operating in Phoenix, AZ can generate in its lifetime, energy that is the equivalent of what an American average household residential utility customer consumes over a three-year period. However, if the proposed system operates in New Delhi, India, the PV could generate energy in its lifetime that is the equivalent of what an Indian average household residential utility customer consumes over a 33-year period. Consequently, this proposed application transforms, in times of no-use, into a flexible energy generation system that can be fed into the grid and used to power electrical devices in homes and offices. The fact that the output of this system is direct current (DC) electricity rather than alternative current (AC) electricity reduces the wasted energy cost in the generation, transmission, and conversion losses between AC-DC electricity to reach the grid. Thus, this system can potentially reduce the dependency on the grid in third world countries where the energy consumption per home is limited and the grid is unstable or unreliable, or even unavailable

Three Decades of Fuzzy AHP: A Bibliometric Analysis

[EN] For decades, Fuzzy Sets Theory (FST) has been consistently developed, and its use has spread across multiple disciplines. In this process of knowledge transfer, fuzzy applications have experienced great diffusion. Among them, Fuzzy Analytic Hierarchy Process (fuzzy AHP) is one of the most widely used methodologies today. This study performs a systematic review following the PRISMA statement and addresses a bibliometric analysis of all articles published on fuzzy AHP in journals indexed in Web of Science, specifically in Science Citation Index Expanded (SCIE) and Social Science Citation Index (SSCI). The analyzed database includes 2086 articles published between 1994 and 2022. The results show the thematic clusters, the evolution of the academic conversation and the main collaboration networks. The main contribution of this article is to clarify the research agenda on fuzzy AHP. The results of the study allow academics to detect publication opportunities. In addition, the evidence found allows researchers and academics setting the field¿s agenda to advise the editors of high-impact journals on gaps and new research trends.Castello-Sirvent, F.; Meneses-Eraso, C.; Alonso-Gómez, J.; Peris-Ortiz, M. (2022). Three Decades of Fuzzy AHP: A Bibliometric Analysis. Axioms. 11(10):1-34. https://doi.org/10.3390/axioms11100525134111

Investigation on Multi-Criteria Decision Making Methods Application in Sustainable Product Design

Background: Integrating sustainability development' aspects in the design process is becoming, a growth area in companies. Consequently, sustainable product design has to consider the different aspects of sustainability throughout its life cycle phases in addition of other requirements. This integration is becoming more complicated due the difficulty of managing the constraints and alternatives related to the product and stakeholders needs. This study aims to highlights the most used Multi-Criteria Decision Making (MCDM) tools and methods used in sustainable product design process. Contribution: Product design process involves interesting decisional tasks such as the choice of materials, standard parts, technical solutions. Hence, the contribution of this work is to help designer to adopt relevant MCDM tools and methods that can be integrated to other tools to facilitate and to justify their decisional tasks. Method: Several methods have been affected to solve the problems related to this complexity such as MCDM. A literature review was conducted based on Siencedirect and GoogleScholar articles databases. After filtering more than 200 articles only 62 articles were considered to analyze the correlation between sustainable product design and MCDM. Results: Classified MCDM use according to the type of choices to achieve SPD goals. This paper allowed us to find matches between MCDM methods and SPD problem. The majority of case studies result show that a large portion of sustainable design methods, techniques, and tools are applied to the sustainable product’ along its different life cycle phases Conclusion: It is noticed that the use of MCDM methods are an important outcome in the sustainable product design process and deeply helps designers to make suitable choices. Also, several matches relating MCDM, other methods and sustainable product design sphere are discusse

The state of the art development of AHP (1979-2017): A literature review with a social network analysis

Although many papers describe the evolution of the analytic hierarchy process (AHP), most adopt a subjective approach. This paper examines the pattern of development of the AHP research field using social network analysis and scientometrics, and identifies its intellectual structure. The objectives are: (i) to trace the pattern of development of AHP research; (ii) to identify the patterns of collaboration among authors; (iii) to identify the most important papers underpinning the development of AHP; and (iv) to discover recent areas of interest. We analyse two types of networks: social networks, that is, co-authorship networks, and cognitive mapping or the network of disciplines affected by AHP. Our analyses are based on 8441 papers published between 1979 and 2017, retrieved from the ISI Web of Science database. To provide a longitudinal perspective on the pattern of evolution of AHP, we analyse these two types of networks during the three periods 1979?1990, 1991?2001 and 2002?2017. We provide some basic statistics on AHP journals and researchers, review the main topics and applications of integrated AHPs and provide direction for future research by highlighting some open questions

EXTENDING ORIGAMI TECHNIQUE TO FOLD FORMING OF SHEET METAL PRODUCTS

This dissertation presents a scientific based approach for the analysis of folded sheet metal products. Such analysis initializes the examination in terms of topological exploration using set of graph modeling and traversal algorithms. The geometrical validity and optimization are followed by utilizing boundary representation and overlapping detection during a geometrical analysis stage, in this phase the optimization metrics are established to evaluate the unfolded sheet metal design in terms of its manufacturability and cost parameters, such as nesting efficiency, total welding cost, bend lines orientation, and maximum part extent, which aides in handling purposes. The proposed approach evaluates the design in terms of the stressed-based behavior to indicate initial stress performance by utilizing a structural matrix analysis while developing modification factors for the stiffness matrix to cope with the stress-based differences of the diverse flat pattern designs. The outcome from the stressed-based ranking study is mainly the axial stresses as exerted on each element of folded geometry; this knowledge leads to initial optimizing the flat pattern in terms of its stress-based behavior. Furthermore, the sheet folding can also find application in composites manufacturing. Thus, this dissertation optimizes fiber orientation based on the elasticity theory principles, and the best fiber alignment for a flat pattern is determined under certain stresses along with the peel shear on adhesively bonded edges. This study also explores the implementation of the fold forming process within the automotive production lines. This is done using a tool that adopts Quality Function Deployment (QFD) principle and Analytical Hierarchy Process (AHP) methodology to structure the reasoning logic for design decisions. Moreover, the proposed tool accumulates all the knowledge for specific production line and parts design inside an interactive knowledge base. Thus, the system is knowledge-based oriented and exhibits the ability to address design problems as changes occur to the product or the manufacturing process options. Additionally, this technique offers two knowledge bases; the first holds the production requirements and their correlations to essential process attributes, while the second contains available manufacturing processes options and their characteristics to satisfy the needs to fabricate Body in White (BiW) panels. Lastly, the dissertation showcases the developed tools and mathematics using several case studies to verify the developed system\u27s functionality and merits. The results demonstrate the feasibility of the developed methodology in designing sheet metal products via folding

The state of the art development of AHP (1979-2017): a literature review with a social network analysis

Although many papers describe the evolution of the analytic hierarchy process (AHP), most adopt a subjective approach. This paper examines the pattern of development of the AHP research field using social network analysis and scientometrics, and identifies its intellectual structure. The objectives are: (i) to trace the pattern of development of AHP research; (ii) to identify the patterns of collaboration among authors; (iii) to identify the most important papers underpinning the development of AHP; and (iv) to discover recent areas of interest. We analyse two types of networks: social networks, that is, co-authorship networks, and cognitive mapping or the network of disciplines affected by AHP. Our analyses are based on 8441 papers published between 1979 and 2017, retrieved from the ISI Web of Science database. To provide a longitudinal perspective on the pattern of evolution of AHP, we analyse these two types of networks during the three periods 1979–1990, 1991–2001 and 2002–2017. We provide some basic statistics on AHP journals and researchers, review the main topics and applications of integrated AHPs and provide direction for future research by highlighting some open questions

A product design framework for one-of-a-kind production using integrated quality function deployment and operational research techniques

The process of product design as an early stage of new product development provides systematic approaches that can lead to the success of a company’s competitive strategy in the current turbulent market. By launching an efficient product design procedure can result in the reduction of engineering modifications, cost and production time. One-of-a-Kind Product (OKP) is known as a particular manufacturing system of new product design and development with emphasis on the special order concept. Quality Function Deployment (QFD) is a comprehensive design framework with cross-functional team members that leads to the development of new or improved products. QFD starts with the House of Quality (HOQ) as an organizing matrix to identify the customers’ requirements (CRs) and translate them into the technical attributes (TAs) of the product and followed by determining the target values for the sets of technical attributes. An evaluation approach to determine the relative importance of CRs and TAs should be considered. In previous researches, the traditional methods such as simple scoring method and application of operational research techniques such as Analytic Hierarchy Process (AHP) were reported to weigh the requirements and attributes. Despite the obvious inner-relationships among the elements, considering the HOQ as a hierarchical system may be inefficient. In addition, the contradictory effects of a TA on two or more CRs, is the problem that has been neglected. Here, a mathematical model was developed for calculating the TAs target values. A case study (dry gas filter, Namdaran Petro-Gas Industries (NPI™)) is presented to exhibit and verify the procedure of OKP product design. Initially, the framework was developed by integrating QFD-operational research (Analytic Network Process (ANP)) as a systematic method for improvement of dry gas filter design. Interview and study of documents were used to identify the CRs. A robust evaluation on customers’ priority and attributes’ importance with respect to inner-relationships among criteria/sub-criteria was performed. Furthermore, the effects of TAs on CRs with regard to their direction (positive/negative) were considered as the fundamental for developing a Multi-Objective Decision Model (MODM) to be used for determining the TAs target values. For this purpose, the fuzzy conversion scaling technique followed by formulating the partial satisfaction separately was applied. Modified TOPSIS was used to select the basic design among the available designs for further modification. Later, the process continues with the second phase, translating the TAs into the key parts. The available options (retailers) to supply the key parts were identified. As the normal procedure of QFD the relative importance’s of key parts and the options were determined. Finally, a zero-one goal programming was presented to select the optimum options for each key part subject to the budget constraint. Overall, the developed QFD-ANP framework provides a systematic approach that has the potential to be used for designing OKP product