Modelling Engineering Change Management in a New Product Development Supply Chain

The changes within a new product development (NPD) process are handled differently depending on the stage of the project. The changes during the initial stages of the project are addressed by design iterations, while the changes after the product design is complete are addressed using a formal engineering change management (ECM) process. The ECM process is a complex process, especially under a collaborative environment, where various independent entities work together for a common cause of product development. The interactions between the NPD and ECM processes have rarely been investigated in the research community. In this paper, we attempt to study the interactions between the various NPD and ECM process parameters by modelling the processes and simulated the model to understand the parameter interactions. The organisations in a supply chain have been characterised based on their interactions with the original equipment manufacturer (OEM) during the NPD process. The organisation process templates representing the NPD and ECM processes of each type of organisation in the supply chain have been modelled. The templates have been used to develop a simulation model representing the NPD and ECM processes for a supply chain. The process variables, such as processing rates, resources, resource composition, resource allocation priority, processing quality and phase overlap, have been included in the model. The results indicate that most of the variables and interactions among the variables have a significant influence on the NPD lead time. By identifying the status of the NPD process, the decision-makers can use these results to develop appropriate management policies to govern their product development projects

Modeling and Managing Engineering Changes in a Complex Product Development Process

Today\u27s hyper-competitive worldwide market, turbulent environment, demanding customers, and diverse technological advancements force any corporations who develop new products to look into all the possible areas of improvement in the entire product lifecycle management process. One of the areas that both scholars and practitioners have overlooked in the past is Engineering Change Management (ECM). The vision behind this dissertation is to ultimately bridge this gap by identifying main characteristics of a New Product Development (NPD) process that are potentially associated with the occurrence and magnitude of iterations and Engineering Changes (ECs), developing means to quantify these characteristics as well as the interrelationships between them in a computer simulation model, testing the effects of different parameter settings and various coordination policies on project performance, and finally gaining operational insights considering all relevant EC impacts. The causes for four major ECM problems (occurrence of ECs, long EC lead time, high EC cost, and occurrence frequency of iterations and ECs), are first discussed diagrammatically and qualitatively. Factors that contribute to particular system behavior patterns and the causal links between them are identified through the exploratory construction of causal/causal-loop diagrams. To further understand the nature of NPD/ECM problems and verify the key assumptions made in the conceptual causal framework, three field survey studies were conducted in the summer of 2010 and 2011. Information and data were collected to assess the current practice in automobile and information technology industries where EC problems are commonly encountered. ased upon the intuitive understanding gained from these two preparation work, a Discrete Event Simulation (DES) model is proposed. In addition to combining essential project features, such as concurrent engineering, cross functional integration, resource constraints, etc., it is distinct from existing research by introducing the capability of differentiating and characterizing various levels of uncertainties (activity uncertainty, solution uncertainty, and environmental uncertainty) that are dynamically associated with an NPD project and consequently result in stochastic occurrence of NPD iterations and ECs of two different types (emergent ECs and initiated ECs) as the project unfolds. Moreover, feedback-loop relationships among model variables are included in the DES model to enable more accurate prediction of dynamic work flow. Using a numerical example, different project-related model features (e.g., learning curve effects, rework likelihood, and level of dependency of product configuration) and coordination policies (e.g., overlapping strategy, rework review strategy, IEC batching policy, and resource allocation policy) are tested and analyzed in detail concerning three major performance indicators: lead time, cost, and quality, based on which decision-making suggestions regarding EC impacts are drawn from a systems perspective. Simulation results confirm that the nonlinear dynamics of interactions between NPD and ECM plays a vital role in determining the final performance of development efforts

Simulation in Automated Guided Vehicle System Design

The intense global competition that manufacturing companies face today results in an increase of product variety and shorter product life cycles. One response to this threat is agile manufacturing concepts. This requires materials handling systems that are agile and capable of reconfiguration. As competition in the world marketplace becomes increasingly customer-driven, manufacturing environments must be highly reconfigurable and responsive to accommodate product and process changes, with rigid, static automation systems giving way to more flexible types. Automated Guided Vehicle Systems (AGVS) have such capabilities and AGV functionality has been developed to improve flexibility and diminish the traditional disadvantages of AGV-systems. The AGV-system design is however a multi-faceted problem with a large number of design factors of which many are correlating and interdependent. Available methods and techniques exhibit problems in supporting the whole design process. A research review of the work reported on AGVS development in combination with simulation revealed that of 39 papers only four were industrially related. Most work was on the conceptual design phase, but little has been reported on the detailed simulation of AGVS. Semi-autonomous vehicles (SA V) are an innovative concept to overcome the problems of inflexible -systems and to improve materials handling functionality. The SA V concept introduces a higher degree of autonomy in industrial AGV -systems with the man-in-the-Ioop. The introduction of autonomy in industrial applications is approached by explicitly controlling the level of autonomy at different occasions. The SA V s are easy to program and easily reconfigurable regarding navigation systems and material handling equipment. Novel approaches to materials handling like the SA V -concept place new requirements on the AGVS development and the use of simulation as a part of the process. Traditional AGV -system simulation approaches do not fully meet these requirements and the improved functionality of AGVs is not used to its full power. There is a considerflble potential in shortening the AGV -system design-cycle, and thus the manufacturing system design-cycle, and still achieve more accurate solutions well suited for MRS tasks. Recent developments in simulation tools for manufacturing have improved production engineering development and the tools are being adopted more widely in industry. For the development of AGV -systems this has not fully been exploited. Previous research has focused on the conceptual part of the design process and many simulation approaches to AGV -system design lack in validity. In this thesis a methodology is proposed for the structured development of AGV -systems using simulation. Elements of this methodology address the development of novel functionality. The objective of the first research case of this research study was to identify factors for industrial AGV -system simulation. The second research case focuses on simulation in the design of Semi-autonomous vehicles, and the third case evaluates a simulation based design framework. This research study has advanced development by offering a framework for developing testing and evaluating AGV -systems, based on concurrent development using a virtual environment. The ability to exploit unique or novel features of AGVs based on a virtual environment improves the potential of AGV-systems considerably.University of Skovde. European Commission for funding the INCO/COPERNICUS Projec

Simulating intertwined design processes that have similar structures: A case study of a small company that creates made-to-order fashion products

The authors use simulation to analyse the resource-driven dependencies between concurrent processes used to create customised products in a company. Such processes are uncertain and unique according to the design changes required. However, they have similar structures. For simulation, a level of abstraction is chosen such that all possible processes are represented by the same activity network. Differences between processes are determined by the customisations that they implement. The approach is illustrated through application to a small business that creates customised fashion products. We suggest that similar techniques could be applied to study intertwined design processes in more complex domains.The case study was carried out as part of Considerate Design for Personalised Fashion funded by the EPSRC/AHRC Design in the 21st century programme. The context of a multi-project environment was analysed as part of the EU Framework 7 CONVERGE project CP-FP 228746-2.Post-prin

Testing in the incremental design and development of complex products

Testing is an important aspect of design and development which consumes significant time and resource in many companies. However, it has received less research attention than many other activities in product development, and especially, very few publications report empirical studies of engineering testing. Such studies are needed to establish the importance of testing and inform the development of pragmatic support methods. This paper combines insights from literature study with findings from three empirical studies of testing. The case studies concern incrementally developed complex products in the automotive domain. A description of testing practice as observed in these studies is provided, confirming that testing activities are used for multiple purposes depending on the context, and are intertwined with design from start to finish of the development process, not done after it as many models depict. Descriptive process models are developed to indicate some of the key insights, and opportunities for further research are suggested

Modelling iteration in engineering design

This paper examines design iteration and its modelling in the simulation of New Product Development (NPD) processes. A framework comprising six perspectives of iteration is proposed and it is argued that the importance of each perspective depends upon domain-specific factors. Key challenges of modelling iteration in process simulation frameworks such as the Design Structure Matrix are discussed, and we argue that no single model or framework can fully capture the iterative dynamics of an NPD process. To conclude, we propose that consideration of iteration and its representation could help identify the most appropriate modelling framework for a given process and modelling objective, thereby improving the fidelity of design process simulation models and increasing their utility

Survey instrument for measuring level of preparedness amongst healthcare personnel in radiation emergency

Drills and exercises are globally practiced to investigate the level of preparedness towards disaster events. However, these activities are rarely conducted because they require substantial investment, specifically to budget and time. A self-reported survey may serve as an alternative approach, although it may not be as effective as drills and exercises. As part of the survey development process, this article discusses preliminary validation of a survey instrument to measure the level of preparedness towards radiation emergency amongst healthcare personnel. Prior to this validation process, extensive literature reviews pointed out that the instrument consists of three constructs of preparedness, namely readiness, willingness, and ability. A total of seven subject matter experts were invited to judge the contents for verification purposes. Randolph Kappa analysis was then conducted to analyse their judgment to allow irrelevant items to be filtered from the rest prior to any improvements. Initially, the survey instrument consisted of 69 items; however, the analysis omitted 16 of them. The following values for each preparedness construct were: Readiness (0.77), Willingness (0.70), and Ability (0.73). These findings indicate that contents of the instrument are valid. Further analysis should be fulfilled to complete validation process to ensure its practicality prior to using it as an evaluation tool

CAN CHANGE PREDICTION HELP PRIORITISE REDESIGN WORK IN FUTURE ENGINEERING SYSTEMS?

Future design environments will necessitate improved management of the propagation and impacts of changes. To ascertain whether change prediction can assist in making better work prioritisation decisions, this paper develops a new simulation approach and applies it to a model of a complex aerospace product, which was elicited from industry. We use an accepted technique to generate potential change propagation trees and apply Monte Carlo methods to generate a sample space within which multiple scheduling policies could be evaluated and compared. The experiments reveal that poor coordination of change activity can result in significant process inefficiencies, that the potential for inefficiency increases for larger change networks, and that a modest ability to accurately predict change propagation in the specific case at hand could have a dramatic effect in reducing unnecessary rework. The experiments also suggest that the capability of predicting multiple steps of change propagation would provide only minimal additional improvement.International Design Conference - DESIGN 201

Hybrid Prototypes to Assist Modeling Automotive Seats

The development of new modular seats is an important issue in the automotive industry. However, is very time consuming and costly. Virtual models and hybrid prototypes could accelerate the car seats development process. The hybrid prototypes are mainly manufactured by rapid prototyping with multi materials. The objective of this paper is to establish a methodology to develop innovative lightweight multi-functional, modular car seats to be used in Multi-Purpose Vehicles (MPV), by means of FEA simulation and rapid prototyping additive/subtractive technologies utilizing multi materials. A case study is presented to validate the developed methodology. The manufactured hybrid prototype’s reproduces the main functionalities of the MPV modular seat, namely its three key positions: normal, stored and table.Mechanical Engineerin