A knowledge based expert system for moulded part design

In today's competitive market many consumer products are designed with complex curved shapes to meet customers' demands for styling and ergonomics. These styled products are commonly manufactured using moulding processes because they can produce a wide range of freeform shapes at relatively low cost. However, although injection moulding and metal casting allow a great deal of design freedom they also make significant demands on the designer to ensure that parts are designed with due regard for manufacturability. This paper describes a knowledge based moulding advisor that has been developed to provide design for moulding advice to designers during the design process. The main contributions of the research are the development of a hierarchical knowledge representation to allow moulding advice to be generated at different levels of detail and the integration of the expert system with a geometric part description extracted from a Computer Aided Design (CAD) solid model. A demonstrator for the manufacturing advisor has been implemented using the expert system shell CLIPS and integrated with CAD using feature recognition. The moulding advisor is able to generate tailored design for moulding advice for a range of manufacturing processes and materials and evaluate the manufacturability of a designed part at the feature level. The paper provides a case study for a simple moulded test part

Observing Suppliers observing Early Supplier Involvement: An Empirical Research based upon the Social Systems Theory of Niklas Luhmann.

supplier, involvement, Luhmann

A Student-Centered Learning Approach to Design for Manufacturability: Meeting the Needs of an Often- Forgotten Customer

A hands-on learning module was implemented at Marquette University in 2012 to teach biomedical engineering students about basic manufacturing processes, lean manufacturing principles, and design for manufacturability. It incorporates active and student-centered learning as part of in-class assembly line simulations. Since then, it has evolved from three class periods to five. The module begins with two classroom presentations on manufacturing operations and electronics design, assembly, and testing. Students then participate in an in-class assembly line simulation exercise where they build and test an actual product per written work instructions. They reflect on this experience and suggest design and process changes to improve the assembly line process and quality, save time, and reduce cost and waste. At the end of the module students implement their suggested design and process improvements and repeat the exercise to determine the impact of their improvements. They learn of the importance of Design for Manufacturability, well-written work instructions, process design, and designing a product not only for the end user, but also for the assemblers and inspectors. Details of the module, and its implementation and assessment are presented along with student feedback and faculty observations

A Hands-On, Active Learning Approach to Increasing Manufacturing Knowledge in Engineering Students

This paper describes a new learning module implemented as part of the senior capstone design course at Marquette University to teach engineering students about basic manufacturing processes, lean manufacturing principles, and design for manufacturability. The module includes several examples of active and student centered learning as part of an in-class assembly line simulation exercise. Students reflected on this experience, and suggested process improvements to save time, reduce cost and waste, and improve the assembly line process. They learned of the importance of manufacturing documentation, process design, and design for assembly. At the end of the module, students understood the importance of designing a product not only for the end user, but also for the assemblers and inspectors. Details of the module design and implementation will be presented along with comments from students

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

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

Automated Manufacturability Analysis for Conceptual Design in New Product Development

This paper presents ANA, a software package that provides automated manufacturability feedback to product designers, enabling first time quality of design and avoiding later stage change requests. Manufacturing knowledge is critical to the design process. Decisions made early in the conceptual design phase can significantly affect downstream production cost. Manufacturing engineers may have a limited role in the design process which can lead to designs that are difficult to manufacture. ANA is the implementation of numerous feature-free geometric algorithms that determine manufacturability metrics related to machining, casting, die-casting, and welding processes. These metrics are accompanied by colored 3D graphical models to provide rich feedback similar to finite element models, for example. The iterations of a design are tracked over time, allowing users to review how certain design decisions impact the expected manufacturability of the part. ANA is intended for use inside existing CAD systems, in the cloud, or as a standalone application. The feedback from ANA, combined with built-in learning modules, aids the user in making design improvements and assists in selecting an appropriate manufacturing process. This feedback can be shared across platforms via interactive 3D PDFs

Review of research in feature-based design

Research in feature-based design is reviewed. Feature-based design is regarded as a key factor towards CAD/CAPP integration from a process planning point of view. From a design point of view, feature-based design offers possibilities for supporting the design process better than current CAD systems do. The evolution of feature definitions is briefly discussed. Features and their role in the design process and as representatives of design-objects and design-object knowledge are discussed. The main research issues related to feature-based design are outlined. These are: feature representation, features and tolerances, feature validation, multiple viewpoints towards features, features and standardization, and features and languages. An overview of some academic feature-based design systems is provided. Future research issues in feature-based design are outlined. The conclusion is that feature-based design is still in its infancy, and that more research is needed for a better support of the design process and better integration with manufacturing, although major advances have already been made