Knowledge-based Engineering in Product Development Processes - Process, IT and Knowledge Management perspectives

Product development as a field of practice and research has significantly changed due to the general trends of globalization changing the enterprise landscapes in which products are realized. The access to partners and suppliers with high technological specialization has also led to an increased specialization of original equipment manufacturers (OEMs). Furthermore, the products are becoming increasingly complex with a high functional and technological content and many variants. Combined with shorter lifecycles which require reuse of technologies and solutions, this has resulted in an overall increased knowledge intensity which necessitates a more explicit approach towards knowledge and knowledge management in product development. In parallel, methods and IT tools for managing knowledge have been developed and are more accessible and usable today. One such approach is knowledge-based engineering (KBE), a term that was coined in the mid-1980s as a label for applications which automate the design of rule-driven geometries. In this thesis the term KBE embraces the capture and application of engineering knowledge to automate engineering tasks, regardless of domain of application, and the thesis aims at contributing to a wider utilization of KBE in product development (PD). The thesis focuses on two perspectives of KBE; as a process improvement IT method and as a knowledge management (KM) method. In the first perspective, the lack of explicit regard for the constraints of the product lifecycle management (PLM) architecture, which governs the interaction of processes and IT in PD, has been identified to negatively affect the utilization of KBE in PD processes. In the second perspective, KM theories and models can complement existing methods for identifying potential for KBE applications.Regarding the first perspective, it is concluded that explicit regard for the PLM architecture decreases the need to develop and maintain software code related to hard coded redundant data and functions in the KBE application. The concept of service oriented architecture (SOA) has been found to enable an the explicit regard for the PLM architecture.. Regarding the second perspective, it is concluded that potential for KBE applications is indicated by: 1.) application of certain types of knowledge in PD processes 2.) high maturity and formalization of the applied knowledge 3.) a codification strategy for KM and 4.) an agreement and transparency regarding how the knowledge is applied, captured and transferred. It is also concluded that the formulation of explicit KM strategies in PD should be guided by knowledge application and its relation to strategic objectives focusing on types of knowledge, their role in the PD process and the methods and tools for their application. These, in turn, affect the methods and tools deployed for knowledge capture in order for it to integrate with the processes of knowledge origin. Finally, roles and processes for knowledge transfer have to be transparent to assure the motivation of individuals to engage in the KM strategy

Knowledge-based Engineering in Product Development Processes - Process, IT and Knowledge Management perspectives

Product development as a field of practice and research has significantly changed due to the general trends of globalization changing the enterprise landscapes in which products are realized. The access to partners and suppliers with high technological specialization has also led to an increased specialization of original equipment manufacturers (OEMs). Furthermore, the products are becoming increasingly complex with a high functional and technological content and many variants. Combined with shorter lifecycles which require reuse of technologies and solutions, this has resulted in an overall increased knowledge intensity which necessitates a more explicit approach towards knowledge and knowledge management in product development. In parallel, methods and IT tools for managing knowledge have been developed and are more accessible and usable today. One such approach is knowledge-based engineering (KBE), a term that was coined in the mid-1980s as a label for applications which automate the design of rule-driven geometries. In this thesis the term KBE embraces the capture and application of engineering knowledge to automate engineering tasks, regardless of domain of application, and the thesis aims at contributing to a wider utilization of KBE in product development (PD). The thesis focuses on two perspectives of KBE; as a process improvement IT method and as a knowledge management (KM) method. In the first perspective, the lack of explicit regard for the constraints of the product lifecycle management (PLM) architecture, which governs the interaction of processes and IT in PD, has been identified to negatively affect the utilization of KBE in PD processes. In the second perspective, KM theories and models can complement existing methods for identifying potential for KBE applications.Regarding the first perspective, it is concluded that explicit regard for the PLM architecture decreases the need to develop and maintain software code related to hard coded redundant data and functions in the KBE application. The concept of service oriented architecture (SOA) has been found to enable an the explicit regard for the PLM architecture.. Regarding the second perspective, it is concluded that potential for KBE applications is indicated by: 1.) application of certain types of knowledge in PD processes 2.) high maturity and formalization of the applied knowledge 3.) a codification strategy for KM and 4.) an agreement and transparency regarding how the knowledge is applied, captured and transferred. It is also concluded that the formulation of explicit KM strategies in PD should be guided by knowledge application and its relation to strategic objectives focusing on types of knowledge, their role in the PD process and the methods and tools for their application. These, in turn, affect the methods and tools deployed for knowledge capture in order for it to integrate with the processes of knowledge origin. Finally, roles and processes for knowledge transfer have to be transparent to assure the motivation of individuals to engage in the KM strategy

Experiences from starting and running a software company within the context of design research

This paper deals with the story and experiences of setting up a new start-up company with the ambition to scale using a software-based product. The paper is written by researchers for researchers interested in doing the same thing. The paper concludes that it can be very beneficial for research as the startup-can be seen as a data collection machine, but to set up a start-up company, comes with unforeseen problems along the way. A few of them involves: Do not rely on rational arguments (only), when marketing your product. Expect long lead-times. Work with multiple threads and secure funding early to ensure that you can finance your startup. Finally, you need to be committed, and you have to have a strategy to manage both your research and your commercial activities

Integrating KBE and PLM Through a Service Oriented Architecture

Globalization has made a large impact on product development, especially in mature businesses such as the automotive and aerospace industries. As product and manufacturing technologies become more common and widespread, the competitive advantage for many companies shifts to knowledge about using those technologies. This knowledge is based on many years of experience and relates both to the product design and to the process for designing and manufacturing the product. Engineering knowledge thus is an asset that needs to be captured, stored and managed, which provides strategic long-term benefits. In parallel, IT tools for storing and executing different kinds of knowledge, such as expert systems for diagnosis or rule-based systems for mechanical design, have been developed and are more usable and accessible today. In the field of engineering, rule-based applications are available in many IT tools for computer-aided design (CAD), computer-aided engineering (CAE) and so on. The term knowledge-based engineering (KBE) was coined in the mid-1980s as a label for the CAD-integrated applications for designing rule-based geometries. There is no widely accepted definition of the term. In this thesis KBE embraces the capture and reuse of engineering knowledge in general, regardless of domain of application.The focus of this thesis is on how KBE, both as an IT application and as a method, is integrated with the product development process. The focus has been on integration of KBE with product lifecycle management (PLM) which embraces methods and IT tools for managing product and process information throughout a product’s lifecycle. KBE should be an integral part of PLM in the same way as CAD, CAE, PDM and so on. The thesis considers architectural issues in order to investigate which conceptual solutions for the PLM architecture are the most suitable for integrating KBE and PLM.It is concluded that a service-oriented PLM architecture is the most promising integration concept, not only from an IT perspective to integrate KBE with CAD, CAE, PDM and so on, but also from a process perspective to ensure optimal support for the way engineering knowledge can be captured and reused in the product development process. The service-oriented architecture is based on standardized interfaces which support the exchange of data across applications, and modularization which supports increased reuse of solutions. From an implementation point of view, it makes it possible to create KBE applications of any size, without the need to duplicate information that already exists somewhere else – thus decreasing the implementation costs. The ability to create KBE applications at a low cost raises the potential to integrate KBE with the product development process, since engineers can create their own small applications without having to organize large IT projects. Two other PLM architectures, single-source architecture and a peer-to-peer architecture, have been studied and both entail disadvantages, not only for the integration of KBE but also for management of IT. The main drawback of the single-source architecture is related to its implementation, as a “one application fits all engineers” mindset is impossible to implement in practice. In the peer-to-peer architecture every new IT implementation brings about large costs and requires many resources, which affects the possibility to support the idea of each engineer making a small KBE application that adds to a bigger whole

Integrating KBE and PLM Through a Service Oriented Architecture

Globalization has made a large impact on product development, especially in mature businesses such as the automotive and aerospace industries. As product and manufacturing technologies become more common and widespread, the competitive advantage for many companies shifts to knowledge about using those technologies. This knowledge is based on many years of experience and relates both to the product design and to the process for designing and manufacturing the product. Engineering knowledge thus is an asset that needs to be captured, stored and managed, which provides strategic long-term benefits. In parallel, IT tools for storing and executing different kinds of knowledge, such as expert systems for diagnosis or rule-based systems for mechanical design, have been developed and are more usable and accessible today. In the field of engineering, rule-based applications are available in many IT tools for computer-aided design (CAD), computer-aided engineering (CAE) and so on. The term knowledge-based engineering (KBE) was coined in the mid-1980s as a label for the CAD-integrated applications for designing rule-based geometries. There is no widely accepted definition of the term. In this thesis KBE embraces the capture and reuse of engineering knowledge in general, regardless of domain of application. The focus of this thesis is on how KBE, both as an IT application and as a method, is integrated with the product development process. The focus has been on integration of KBE with product lifecycle management (PLM) which embraces methods and IT tools for managing product and process information throughout a product’s lifecycle. KBE should be an integral part of PLM in the same way as CAD, CAE, PDM and so on. The thesis considers architectural issues in order to investigate which conceptual solutions for the PLM architecture are the most suitable for integrating KBE and PLM. It is concluded that a service-oriented PLM architecture is the most promising integration concept, not only from an IT perspective to integrate KBE with CAD, CAE, PDM and so on, but also from a process perspective to ensure optimal support for the way engineering knowledge can be captured and reused in the product development process. The service-oriented architecture is based on standardized interfaces which support the exchange of data across applications, and modularization which supports increased reuse of solutions. From an implementation point of view, it makes it possible to create KBE applications of any size, without the need to duplicate information that already exists somewhere else – thus decreasing the implementation costs. The ability to create KBE applications at a low cost raises the potential to integrate KBE with the product development process, since engineers can create their own small applications without having to organize large IT projects. Two other PLM architectures, single-source architecture and a peer-to-peer architecture, have been studied and both entail disadvantages, not only for the integration of KBE but also for management of IT. The main drawback of the single-source architecture is related to its implementation, as a “one application fits all engineers” mindset is impossible to implement in practice. In the peer-to-peer architecture every new IT implementation brings about large costs and requires many resources, which affects the possibility to support the idea of each engineer making a small KBE application that adds to a bigger whole

Effective method for creating engineering checklists

This paper presents the results of an empirical study of a project whose aim was to develop a driveline for commercial vehicle applications containing a totally new mechatronic sub-system with a significant amount of new functions and interfaces. The purpose of the empirical study was to identify areas where explicit knowledge management efforts are needed in the development process of a mechatronic systems integrator. The results show that the management of knowledge related to component/system interfaces is not addressed neither in the state of practice nor the state of the art. Based on these findings, the method of engineering checklists to manage interface related knowledge was found suitable. Methods on how to implement engineering checklists however are largely lacking and the main contribution of this paper is a method dedicated to creating engineering checklists from a knowledge management perspective. The evaluation of the developed method indicates a high level of both usefulness and usability of the method in the processes of the studied company along with potential improvement mainly regarding the instructions for the application of the method

Requirements Management When Introducing New Mechatronic Sub-systems - Managing the Knowledge Gaps

This paper describes an empirical study of a driveline development project, featuring a new mechatronic sub-system, aiming to investigate the effect of knowledge gaps regarding the new sub-system on the development process. Findings indicate that knowledge gaps regarding interfaces and suppliers of the new sub-system and a lack of appropriate processes, methods and IT-tools have negatively affected requirements management. A set of recommendations on likely knowledge gaps when introducing new mechatronic sub-systems and how to bridge them prior to development project initiation are presented

Manufacturing Experience In a Design Context Enabled By a Service Oriented PLM Architecture

An increased competition on the product development market pushes the industry to continually improve product quality and reduce product cost. There is also a trend towards considering a products life cycle aspects including environmental sustainability. The manufacturing process is a major cost driver in the product life cycle; hence, there are many initiatives to improve manufacturability and reduce production cost. Learning from earlier projects is essential to avoid recurrence of problems and is generally realized through use of concurrent engineering and design for manufacturing (DFM). Other research provides general DFM principles which state detailed guidelines for how different geometries combined with different manufacturing processes affect component quality and cost. The real competitive edge lies however in the development and application of company specific DFM principles that are based on manufacturing experiences. To do so requires an overview of and access to the collected manufacturing experiences. The aim of this paper is to point out key enablers for efficient reuse of manufacturing experience, which is considered to contribute to lower product cost and higher product quality. A study performed at an automotive and at an aerospace engine manufacturer pointed out the apparent need and lack of reuse of manufacturing experiences in product development. Applications supporting reuse of manufacturing experience through embedded DFM knowledge in designer’s CAD system were found in the literature. The issue of integrating these applications with the enterprise environment, in order to capitalize on existing sources of manufacturing experience, is addressed with a proposed solution applying a service oriented PLM architecture. In addition, a graphical user interface visualizing the manufacturing experience in a combined product and process context was developed. The validation of these proposed and developed solutions was done through interviews and workshops. The conclusions are that visualization of manufacturing experiences in a combined product and process context provides improved understanding of how the experiences relate to each process history and that a key enabler for integration of information in heterogeneous environments is the use of standard service oriented architectures and neutral formats

Implementing a Wiki to Capture and Share Engineering Knowledge

This paper describes the implementation of a wiki system based on the wiki engine MediaWiki for the purpose of engineering knowledge capture and sharing in an internal R&D unit that is part of a global group of companies in the commercial vehicle industry. Three different knowledge processes are studied; 1. Knowledge creation that is based on a socialization process that mainly creates tacit knowledge distributed across individuals; 2. Knowledge transfer that is based on reuse of tacit knowledge by physical transferral of knowledge holders; and 3. Knowledge application which entails a core team of individuals applying their collective knowledge base to solve a given problem. It is found that a wiki system’s features of collaborative and web based input make it possible to support all three of the processes by making the tacit knowledge base explicit. It is concluded however that the implementation of a wiki also needs: 1. A structure that reflects the business processes in the unit; 2. A clear definition of knowledge as a deliverable in the processes; 3. A model for how the time spent on contributing to the wiki is financed; and 4. A strategy for tackling corporate IT governance policies’ inability to manage interactive Web 2.0 technologies

Lean Product Development: Hype or Sustainable New Paradigm

The idea of lean product development (LPD), with Toyota used as the main case in point of demonstrating its abilities, has gained attention among managerial levels of companies dealing with product development. Allegedly the main gains of LPD are a high rate of successful projects in terms of cost and quality along with shorter lead times as well as fewer overruns in time and budget. This paper investigates the lean product development concept in comparison with established models in the current product development paradigm in order to map out the main differences. It also compares LPD to the way product development is carried out in practice on the example of two large European automotive companies.The results show that the main differences, among others, can be found first in the way knowledge is honored and managed, and second how and when decisions are made along the process. From the discussion of the results, conclusions are drawn for potential improvements to traditional product development models