INTRODUCTION TO PRODUCT AND PROCESS DEVELOPMENT J JAYARAMAN

INTRODUCTION TO PRODUCT AND PROCESS DEVELOPMENT J. JAYARAMAN CENTRE FOR AEROSPACE SYSTEMS DESIGN ENGINEERING INDIAN INSTITUTE OF TECHNOLOGY, BOMBAY

STUCTURE OF THE PRESENTATION CONCEPTS : PRODUCT , PROCESS, INTEGRATED PRODUCT AND PROCESSES WHY AND WHEN: INTEGRATED PRODUCT AND PROCESS DEVELOPMENT BENEFITS OF IPPD WHAT IS IPPD : Do. D’s DEFINITION OF IPPD 5 PRINCIPLES OF IPPD THE TENETS OF IPPD GENERAL PNICIPLES OF IPPD INTEGRATED PRODUCT TEAM KEY CONCEPTS OF IPT HOW IPPD : IMPLEMENTING IPPD TOOLS OF IPPD CONCLUSION

PRODUCT AND PROCESS ØPRODUCT: -IS WHAT IS DELIVERED TO THE CUSTOMER e. g. HARDWARE, SOFRTWARE, SERVICES, TRAINING -IT IS THE PHYSICAL HIERARCHY OF THE SYSTEM OR PHYSICAL ARCHITECTURE - IS ALWAYS ACCOMPANIED BY A SPECIFICATION Ø PROCESS : - MAKES THE PRODUCT POSSIBLE - IT IS AN ACTIVITY OR GROUP OF ACTIVITIES THAT TAKES AN INPUT ADDS VALUE TO IT TO GET AN OUTPUT FOR AN INTERNAL OR EXTERNAL CUSTOMER e. g. DESIGN, MANUFACTURING, TEST& EVALUATION, LOGISTICS

3 TYPES OF PROCESSES • TOP LEVEL : FUNCTIONAL. OVERARCHING PROCESS SUCH AS SYTEMS ENGINEERING, TEST AND EVALUATION Ø DEVELOPMENT PROCESSES : ARE PROCESSES THAT FACILITATE MAKING OF A PRODUCT. THESE PROCESSES ARE NOT DELIVERED TO THE CUSTOMERINCLUDE INTEGRATION, PRODUCTION, COMPUTER SUPPORT, MODELLING AND SIMULATION Ø DELIVERABLE PROCESSES : CAN BE THE PRODUCT OR PROCESS TO SUPPORT THE PRODUCT- INCLUDES SUPPORT, TRAINING, MAINTENANCE

INTEGRATED PRODUCT REALISES THAT: -THE WHOLE IS MORE THAN THE SUM OF THE PARTS -WHAT IS BEST FOR THE SUBSYSTEM (OR COMPONENTS) IS NOT NECESSARILY THE BEST FOR OVERALL SYSTEM OR VICE-VERSA

INTEGRATED PRODUCT AND PROCESS BECAUSE OF THE LIMITED TIME AVAILABLE TO BRING A PRODUCT TO THE MARKET MUCH OF THE PLANNING AND DEVELOPMENT STAGES DOWNSTREAM FROM DESIGN ( MANUFACTURING, TESTING, DISTRIBUTION etc. ) OCCURS PRIOR TO THE COMPLETION OF FINAL ENGINEERING DRAWINGS AND SPECIFICATION. THIS RESULTS IN THE CONCURRENT DEVELOPMENT OF THE PRODUCT AND THE PROCESS

ADE ASSET

COMPETITIVENESS THE THREE ELEMENTS OF COMPETITIVENESS ARE: ØTIMELINESS: CAN THE PRODUCT BE DELIVERED JUST IN TIME DEMANDED BY THE CUSTOMER ØQUALITY: WILL THE PRODUCT WORK AS WELL AS INTENDED ØAFFORDABILITY: WILL THE CUSTOMERS WISH TO BUY THE PRODUCT TO GAIN COMPETITIVE ADVANTAGE WE MUST DESIGN FOR VALUE

BENEFITS OF IPPD ØREDUCED TIME TO FIELD SYSTEMS ØREDUCED SYSTEM COST ØIMPROVED QUALITY ØPROGRAMMES THAT ARE EASIER TO MANAGE

AS A RESULT OF IPPD IN A FIGHTER AIRCRAFT PROGRAMME 10% REDUCTION IN DEVELOPMENT COSTS 50% REDUCTION IN ENGINEERING CHANGE PROPOSALS 50% REDUCED REWORK/ REPAIR/ SCRAP IN A NAVAL SYSTEM PROGRAM 40% REDUCED MANUFACTURING COSTS 25% REDUCED LIFE CYCLE COSTS IN A MAJOR NAVY PROGRAM FOLLOWING BOEING 777 FOOTSTEPS REDUCED CYCLE TIME AND DEVELOPMENT COSTS

BOEING 777 - IPPD SUCCESS STORY ØBOEING 777 AIRCRFT IS HERALDED IN THE US AS AN UNPARALLED SUCCESS IN ADVANCED CAD/CAM, IPPD & USE OF SIMULATION. ØIT IS STILL UNDETERMINED AS TO WHEN BOEING WILL RECOUP IT’S MASSIVE FINANCIAL INVESTMENT

DESIGN CHANGES

A GENERIC IPPD ITERATIVE PROCESS

DEFINITION OF IPPD DOD’S DEFINITION ØA MANAGEMENT PROCESS THAT INTEGRATES ALL ACTIVITIES FROM CONCEPT THROUGH PRODUCTION, FIELD SUPPORT USING A MULTIFUNCTIONAL TEAM TO SIMULTANEOUSLY OPTIMISE THE PRODUCT AND IT’S MANUFACTURING AND SUSTAINMENT PROCESS TO MEET COST AND PERFORMANCE OBJECTIVES

IPPD Ø IPPD IS SOMETIMES CALLED IPD Ø IPPD IS A MANAGEMENT APPROACH Ø IPPD IS NOT A SET OF STEPS TO BE FOLLOWED Ø IPPD HAS NO SINGLE SOLUTION OR IMPLEMENTATION STRATEGY Ø IPPD HAS IT’S ROOTS IN INTEGRATED DESIGN AND PRODUCTION PRACTICE , CONCURRENT ENGINEERING PRACTICE AND TOTAL QUALITY MANAGEMENT ØIT IS PERFORMANCE DRIVEN NOT PROCESS DRIVEN ØAPPLICATION OF SYSTEMS ENGINEERING PROCESS IS FUNDAMENTAL TO IPPD

5 PRINCIPLES OF IPPD 5 Ø STAKEHOLDER INVOLVEMENT AND CUSTOMER FOCUS ØCONCURRENT DEVELOPMENT OF PRODUCT AND PROCESSES ØEARLY AND CONTINUOUS LIFE CYCLE PLANNING ØPROACTIVE IDENTIFICATION AND MANAGEMENT OF RISK ØMAXIMUM FLEXIBILITY FOR OPTIMISATION AND USE OF CONTRACTOR APPROACHES

THE TENETS OF IPPD ØCUSTOMER FOCUS ØCONCURRENT DEVELOPMENT OF PRODUCTS AND PROCESSES ØEARLY AND CONTINUOUS LIFE CYCLE PLANNING ØMAXIMISE FLEXIBILITY FOR OPTIMISATION AND USE OF CONTRACTOR APPROACHES ØENCOURAGE ROBUST DESIGN AND IMPROVED PROCESS CAPABILITY ØEVENT DRIVEN SCHEDULING ØMULTIDISCIPLINARY TEAM WORK

THE TENETS OF IPPD ØEMPOWERMENT ØSEAMLESS MANAGEMENT TOOLS ØPROACTIVE IDENTIFICATION AND MANAGEMENT OF RISK

CUSTOMER REQUIREMENTS Mission Need Statement Operational Requirement Document Translate Customer Requirement Level 0 system specification document ESTABLISH AN INTGD. MGMT. FRAMEWORK Prepare integrated Master schedule define TPMs IMS doc. TPMs Prepare Integrated Master Plan Event driven IMP doc Allocate Resources Organisation (People) Funds Time Outline programme Product broken down to 2 levels below System level OUTLINING THE PROGRAMME Specification tree that follows Product Break. OUT Prepare WBS doc Define Core Prepare SOWs Program Key SOW Doc Events Planning the Program Track and execute program General Principles of IPPD

KEY FEATURES OF IPPD ØPRODUCT ORIENTATION: PRODUCTS DICTATE THE ULTIMATE SUCCESS OF THE ORGANISATION IN THE EYES OF THE CUSTOMER ØCROSS FUNCTIONAL TEAMING: EFFECTIVE TEAMING BETWEEN FUNCTIONAL REPS. INTELLIGENT DECISIONS BASED ON COMBINED EFFORT OF ENGG. PRODN. LOGISTICS, PGMME. MGMT. , CONTRACTING, FINANCIAL MGMT. , SUSTAINMENT, OPS. , & OTHER DISCIPLINES ØEMPOWERMENT: GIVE REQUISITE AUTHORITY AND ESPONSIBILITY CONTD.

KEY FEATURES OF IPPD ØUPFRONT PLANNING: DELIBERATE UPFRONT PLANNING EARLY IN THE PRODUCT LIFE CYCE. EVENT BASED PLANNING

IMPLEMENTING IPPD ØCULTURAL CHANGE: INTEGRATED DECISION MAKING , EMPOWERMENT ØFRAMEWORK: IN NEW ACQUISITION THE FRAMEWORK IS ESTABLISHED IN THE RFP ØIT’S IMPLEMENTATION IS PRODUCT AND PROCESS DEPENDENT

INTEGRATED PRODUCT TEAM ØTHE PROCESS SIDE OF THE EQUATION INCLUDES ALL THE INDIVIDUALS ADDING VALUE TO THE PRODUCT. THESE INDIVIDUALS ARE MULTIFUNCTIONAL IPT’S

KEY CONCEPTS OF IPT ØHIGH PREMIUM ON INFORMATION AND COMMUNICATION ØTEAM LEADERS ARE KEY ØCHECKS AND BALANCES PROVIDED BY TECHNICAL CONSCIENCE ØSTRONG TEAM CULTURE ØINDIVIDUALS EMPOWERED WITHIN CLEARLY DEFINED ROLES AND RESPONSIBILITIES

TEAM PARTICIPATION AND CROSS FUNCTIONAL INTEGRATION Phase Requirements Development Product Design & Development Research & Technology Establish Extend Technology Limits availability limits Engg Propose Concepts, Functions & Features w. r. t. benchmarks -Dev. Concepts Configurations Marketing Establish market wants & needs w. r. t. benchmarks Establish -target markets , Customer parameters, sales margins, interact with customers in evaluation Manufacturing Establish Process Estimate cost, Process Capabilities , Simulate processes, Identify suppliers, Develop Tooling Product Distribution Sales & Services Learn from Customer Response Evaluate Pilot Runs Tune out Problems Learn from Customer response -Dev. Processes Plan Market Rollout, Train Sales & Service Prepare for sales Interact with customers Listen to Customers monitor market trends Build pilots Refine Processes Verify Suppliers Ramp up Time & Customize processes

CONCURRENT ENGINEERING TECHNIQUES AND BENIFITS AEROSPACE COMPANY BOEING COMPANY MCDONNEL DOUGLAS AIRCAFT PROGRAM 777 C-17 F-15 F F/A-18 E/F MD-11 BRITISH AEROSPACE BAE-146 BENEFITS TECHNIQUES 50%REDUCTION IN ENGINEERING IPT, CI, SI, DPD CHANGES DUE TO DESIGN ERRORS DPA, DFX, CIM SIGNIFICANT REDUCTION IN DEFECTS THAT REACHED THE FACTORY SAVED $68 m DUE TO COMMON ATE IPT, CI, SI, DFX REDUCED NO. OF PARTS AND FASTENERS TQM, LM, QFD ON CARGO DOOR ASSY. FUSELAGE FORMERS 38% FEWER IPT, SI, CIM, PARTS, 49% FEWER FASTENERS, 45% FEWER DPD, DFX, TQM FASTENER TYPES, 55%FEWER FAB. & ASSY. TOOLS, QFD 75% LESS ASSY TIME, 29% REDUCTION IN DEFECTS 33% FEWER PARTS (4400 PARTS, FEWER FASTENERS) 1500 LB UNDER WEIGHT, FIRST MAJOR A/C BELOW COST ESTIMATE REDUCED NO. OF PARTS BY 3800, WEIGHT BY 240 LB COST PER A/C BY $ 1, 27, 000 DEVELOPMENT TIME REDUCED FROM 36 TO 18 MONTHS IPT, SI, CIM DPD, DFX, TQM QFD IPT, SSI, TQM, , DFX, QFD, LM IPT, SI, QFD, LM

IPPD TOOLS • • Information Technology and decision support Trade off studies and Prioritization Cost Performance trade offs Design for Manufacturing Prototyping Modeling Simulation and CAE/CAD/CAM Metrices (Measures of Success) Education and Training

VIRTUAL FACTORY ENVIRONMENT

APPLICATIONS OF VIRTUAL REALITY TO AIRCRAFT DESIGN & MANUFACTURE Ø VIRTUAL MOCK-UP-BOEING COMPUTER SERVICES IN SEATTLE - VAST AMOUNT OF CAD DATA INTO VR ENVIRONMENT - EXPLORE THE AIRCRAFT BEFORE MANUFACTURING - ENGINEERS COULD CLIMB AROUND TO FIGURE OUT WHERE TO RUN CABLES & HYDRAULICS PIPES - TO ENSURE MECHANICS COULD REACH ALL THE PARTS FOR MAINTENANCE - PROOF OF CONCEPT STARTED IN 1990. COMPLETED NON-REAL TIME DEMO

APPLICATIONS OF VIRTUAL REALITY TO AIRCRAFT DESIGN AND MANUFACTURE Ø AUGMENTED REALITY – BOEING - TO PROVIDE MORE INFORMATION IN FRONT OF THE ENGINEERS DESIGNING THE AIRCRAFT AND THE MANUFACTURING WORKER WHO BUILDS THEM - SIMPLE TEXTS & GRAPHICS, VOICE ACTIVATED THROUGH “SEE-THOUGH HMD” - REGISTRATION OF DATA? VR WALK THROUGH MARKETING – BOEING Ø ENGINE ASSEMBLY – FOR F 18 ENGINE RE-DESIGN AT NORTHROP

CONCLUSION IPPD IS SEEN TO BE A NEW WAY OF SIMULTANEOUS DEVELOPMENT OF A SYSTEM’S PRODUCTS WITH THE OBJECTIVE OF ACHIEVING REDUCED TIME COST ALONG WITH OPTIMISED PRODUCTS

ORGANISATION EVOLUTION THE OLD WAYS MISSION TO MAXIMISE FINANCIAL PERFORMANCE HIERARCHIAL AUTHORITARIAN STRUCTURE NARROWLY DEFINED INDIVIDUAL JOBS THE NEW WAYS MISSION OF TOTAL CUSTOMER SATISFACTION, CONTINUOUS IMPROVEMENT , LEARNING FLEXIBLE TEAM STRUCTURES WITH AUTHORITY CLOSEST TO WORK CAPABILITY INTEGRATED WORK TEAMS WITH BROAD SCOPE MANAGE PEOPLE TO MANAGE RESULTS MANAGE PROCESS TO MANAGE RESULTS RECRUIT PEOPLE WITH FUNCTIONAL EXPERTISE RECRUIT PEOPLE WITH COMMITMENT TO MISSION, SKILLS AND KNOWLEDGE. PROVIDE TRAINING FOR PERSONAL GROWTH

SYSTEMANTICS ØSYSTEMS IN GENERAL WORK POORLY OR NOT AT ALL (PRIMAL SCENERIO) ØNEW SYSTEMS GENERATE NEW PEOBLEMS ( THE FUNDAMENTAL THEOREM) ØBIG SYSTEMS EITHER WORK ON THEIR OWN OR THEY DON’T. YOU CAN’T MAKE THEM ( BASIC AXIOM OF SYSTREMS FUNCTION) ØA SIMPLE SYSTEM , DESIGNED FROM SCRATCH, SOMETIMES WORKS ØA COMPLEX SYSTEM THAT WORKS IS INVARIABLYFOUND TO HAVE EVOLVED FROM A SIMPLE SYSTEM THAT WORKS

SYSTEMANTICS(CONTD. ) ØA COMPLEX SYSTEM DESIGNED FROM SCRATCH NEVER WORKS AND CANNOT BE MADE TO WORK. YOU HAVE TO START OVER , BEGINNING WITH A WORKING SIMPLE SYSTEM ØCOMPLEX SYSTEMS ARE BEYOND HUMAN CAPACITY TO EVALUATE

VIRTUAL PROTOTYPING Ø BRINGS VISUAL SIMULATION TECHNOLOGY TO PRODUCT DESIGN AND MANUFACTURING TEAMS Ø PERMITS ASSEMBLY STUDIES – FIND OPTIMUM ASSEMBLY AND DISASSEMBLY SEQUENCES, CLEARANCE BETWEEN PARTS AND REAL TIME INTERFERENCE CHECKS Ø MAKES DIGITAL MOCK UP A REALITY Ø CAN CHECK INTERFERENCES EVEN IN LOADED VIBRATING STRUCTURES. COULD BE USED TO PREDICT SHORTS IN ELECTRONIC PACKAGING

VIRTUAL PROTOTYPE Ø PREDICT AND PREVENT TRADITIONAL APPROACH TO DESIGN “ FIND & FIX”

VR APPLICATION CAD / CAM Ø STYLING & CONCEPTUAL DESIGN - ALLOWS DESIGNERS (GEOGRAPHICALLY SEPARATED) TO WORK TOGETHER WITH GREATER SYNERGY BY “VIRTUALLY COLOCATING”. RESULTS IN SHORTER DESIGN CYCLE. Ø ERGONOMIC STUDIES - IS THE USER COMFORTABLE? USER CAN FEEL, LOOK, OPERATE AND UNDERSTAND HOW IT OPERATES. USER CAN FEEL WHETHER THE DESIGN MEETS EXPECTATIONS AND BELIEVES THE DESIGN MEETS HIS NEEDS

VR APPLICATION CAD / CAM ØASSEMBLY & MODELLING - ENGINEERS CAN FLY THROUGH A DESIGN FROM ANY PERSPECTIVE AND STUDY THE ASSEMBLY PROBLEMS - STRUCTUTAL, MECHANICAL, THERMA, FLUID, ELECTRONIC AND ACOUSTIC SIMULATIONS TO UNDERSTAND THE s DYNAMIC BEHAVIOUR OF THE SYSTEM

VIRTUAL PROTOTYPE Ø VIRTUAL WIRE – HARNESS PROTOTYPE GENERATED ELIMINATES THE PHYSICAL PROTOTYPES NEEDED FOR VERIFICATION Ø USING ELECTRONICS THERMAL MANAGEMENT SOFTWARE ONE CAN BUILD AND TEST VIRTUAL PROTOTYPES – AIRFLOW AND TEMPERATURE GRADIENTS CAN BE PREDICTED WHICH HELPS TO CORRECT THE PROBLEMS AND OPTIMIZE A DESIGN BEFORE CUTTING METAL

VIRTUAL TESTING Ø CIRCUIT SIMULATION – LOW TEMP, HIGH TEMP ETC. AVAILABILITY OF COMPONENT PERFORMANCE LIBRARIES Ø DESIGN FLIGHT SIMULATORS – CONTROL LAW VALIDATION HANDLING QUALITIES ASSESSMENT Ø COMBAT SIMULATORS – ASSESS PERFORMANCE OF THE AIRCRAFT BEING DESIGNED IN A DOG FIGHT WITH KNOWN AIRCRAFT – PILOT IN THE LOOP OR COMPUTER PILOT

PROCESS SIMULATION USED FOR Ø RAPID PROCESS DEVELOPMENT Ø REDUCE PRODUCT DEVELOPMENT CYCLE TIME Ø LOWER THE COST OF DEVELOPING PARTS

PROCESS SIMULATION (Contd. . ) APPLIED TO Ø RESIN TRANSFER MOULDING (RTM) OF COMPOSITE PART TO SIMULATE RESIN FLOW Ø CURE SIMULATION IN COMPOSITE PARTS Ø RESIN INJECTION MOULDING (RIM) OF COMPOSITE PARTS

PROCESS SIMULATION (Contd. . ) APPLIED TO Ø FORGING – METAL FLOW Ø SHEET METAL FORMING Ø CASTINGS – METAL FLOW IN CAVITIES

PROCESS SIMULATION Ø INCREASES THE CHANGES OF BEING RIGHT FIRST TIME Ø RESLUTS IN SAVINGS Ø PERMITS PREDICTION OF COMPONENTS RESLUTANT PROPERTIES Ø OFFERS AN OPPORTUNITY TO DEVELOP A GREATER UNDERSTANDING OF THE PROCESS ITSELF Ø IS AN EFFECTIVE TOOL THAT OFFERS ENGINEERS TO MAKE FASTER MORE EFFECTIVE DECISIONS REGARDING THE MANUFACTURE OF A COMPONENT

VIRTUAL MANUFACTURING Ø VIRTUAL MANUFACTURING HAS BEEN SHOWN TO BE AN ESPECIALLY POWERFUL TOOL FOR IMPROVING EFFICIENCIES OF MANUFACTURING PROCESSES, ESPECIALLY IN EARLY PRODUCTION Ø MANUFACTURING SIMULATION

MANUFACTURING SIMULATION IS USED FOR Ø EVALUATING AND FINE TUNING OF NEW PROCESSES Ø ANALYZING THE OPERATING CHARACTERSITICS OF EXISTING OPERATIONS AND Ø VERIFYING CONTROL STRATEGIES

MANUFACTURING SIMULATION Ø HELPS PINPOINT THE CAUSE OF PROBLEMS Ø DIFFICULTIES ON THE PLANT FLOOR CAN BE READILY VISUALIZED Ø THE FLOW, PINCH POINTS, BOTTLENECKS ARE APPARENT Ø ITS SOMETHING AN INDIVITUAL OR GROUP ORDINARILY CAN’T SEE Ø IT WILL PROVIDE A PATH TO GET MORE OUT OF THE SYSTEM Ø IT IS AN EXTREMELY IMPORTANT PLANNING AND PROBLEM SOLVING TOOL Ø IT IS A CAPACITY ANALYSIS TOOL

VR APPLICATION CAD / CAM Ø MANUFACTURING AND ENGINEERING - VERIFY INTERFERENCE OF MOVEMENT, ENGINEERS WALK THROUGH Ø MARKETING

SITUATION OF AIRCRFT COMPANIES TO COMPETE GLOBALLY AIRCRAFT COMPANIES MUST DEVELOP AT: ØHALF THE COST ØIN HALF THE TIME ØWITH HALF THE RESOURCES USED EARLIER DRIVING FORCE- AFFORDABILITY REDUCE COST WITHOUT COMPROMISING QUALITY

DESIGN +DRAWING RELEASE ( 40 M 0 NTHS ) BOEING 767 & 777 SCHEDULES

IPPD EXPANDED ON CONCURRENT ENGINEERING INCLUDING DEVELOPING ALL THE PROCESSES PARELLEL WITH THE PRODUCT. MORE THAN THE PRODUCT AND PROCESS ENGINEERING FUNCTIONS IPPD ALSO INCLUDES ALL STAKEHOLDERS- THOSE NOT ONLY DEVELOPING THE PRODUCT BUT ALL PRODUCT RELATED PROCESSESS SUCH AS TEST AND EVALUATION , MANUFACTURING , SUPPORT OPERATIONS AND TRAINING AS WELL AS BUISINESS PROCESSES

IPT TYPICAL IPT

CONCURRENT PRODUCT AND PROCESS DEVELOPMENT

COST OF MODIFICATIONS 10000 R E L A T I V E C O S T 1000 RULE OF TEN 100 10 1 CONCEPT DETAIL ENGG. PRODUCT TOOLING COST OF CHANGES MADE THROUGH THE PRODUCT CYCLE

COST AND EASE OF MODIFICATIONS

BENIFITS OF IMPROVED ASSY. MANUAL DESIGN ASSEMBLY EFFICIENCY (%) ( DFA INDEX ) IMPROVED ASSEMBLY DESIGN EFFICIENCY RESULTS IN INCREASED RELIABILITY