Concurent Engineering

Lean Production 1st definition

"More and more with less and less-less human effort, less equipment, less time, and less space-while coming closer and closer to providing customers with exactly what they want". - An adaptation of mass production in which workers and work cells are made more flexible and efficient by adopting methods that reduce waste in all forms

Agile Manufacturing - Enrich the customer

- An agile company is perceived by its customers as enriching them in a significant way, not only itself. - The products of an agile company are perceived as solutions to customer's problems. - Pricing of the product can be based on the value of the solution to customer rather than on manufacturing costs.

Agile Manufacturing - Cooperate to enhance competitiveness

- Cooperation internally and with other companies is an agile competitors operational strategy of first choice. - Involves partnering with other companies to form virtual enterprises.

Lean Production (4 principles)

1. Minimize waste 2. Perfect first-time quality 3. Flexible production lines 4. Continuous improvement

Concurrent Engineering : Design for Manufacturing And Assembly

70% of the life cycle cost of a product is determined by basic decisions made during product design. These include: - Material choice - Part geometry - Tolerances - Surface finish - Number of sub-assemblies - Assembly methods to be used.

Production Operation

A substantial impact on the agility of the production systems can be achieved by reorganizing factory operations and the procedures and systems that support these operations. • Objectives in production operations and procedures that are consistent with an agility strategy are the following: - Be a cost-effective, low-volume producer - Be able to produce to customer order - Master mass customization - Use reconfigurable and reusable processes, tooling, and resources - Bring customer closer to the production process - PC configuration - Integrate business procedures with production • Production systems should include: - Sales, marketing, order entry, accounts receivable, etc. - Treat production as a system that extends from suppliers through to customers.

Concurrent Engineering in detail

Also called as simultaneous engineering. • Includes several elements - Design for manufacturing and assembly - Design for quality - Design for cost - Design for life cycle • Requires - Rapid prototyping - Virtual prototyping - Organizational changes

Agile Manufacturing definition

An enterprise level manufacturing strategy of introducing new products into rapidly changing markets. - An organizational ability to thrive in a competitive environment characterized by continuous and sometimes unforeseen change. The objective is to bring products to market as rapidly as possible.

Concurrent Engineering Approach

Becomes involved in - Manufacturing cycle - Product development cycle • Quality engineering • Manufacturing departments • Field service • Vendors supplying critical components • Contacting customers who will use the products

Reorganizing the Production System for Agility

Companies seeking to be agile must make changes in three basic areas: 1. Product design 2. Marketing 3. Production operation

Agile Manufacturing - Market forces and agility 2

Cooperative Business Relationships - There is more cooperation occurring among corporations in the USA. This includes: • Increasing inter-enterprise cooperation • Increased outsourcing • Global sourcing • Improve labor-management relationships • Formation of virtual enterprises among companies Customer Expectations of the product - Customers are becoming more sophisticated and individualistic - Rapid delivery of the product - Support throughout the product life - High quality

Product Design

Decisions made in product design determine approximately 70% of the manufacturing cost of a product. • For a company to be more agile, the product should be: - Customizable (for individual niche markets) - Upgradebale - Reconfigurable - Design modularity - Frequent model changes - Platforms for information and services

Process Planning definition

Determines the sequence of processing and assembly steps to make the product. • Concerned with the engineering and technological issues of how to make the product and assemble the product. • Production planning ---is concerned with the logistics issues of making the product.

Flexible Production Lines principles)

In Lean Production: - Worker teams organize the tasks - Worker involvement to solve technical problems. - Fewer number of job classifications - Procedures are designed to reduce setup times

Agile Manufacturing - Market Forces and agility 3

Increasing Societal Pressures • Modern companies are expected to be responsive to: - Social issues - Including workforce training and education - Legal pressures - Environmental impact issues - Gender issues - Civil rights issues

Process Planning in detail

Interpretation of design drawings - Analyze the product or part design (materials, dimensions, tolerances, surface finishes, etc.) at the start of the process planning procedure. • Processes and sequence • Equipment selection - Utilize existing equipment - Purchase new equipment • Tools, dies, molds, fixtures, and gages - Must decide what tooling is required for each processing step • Methods analysis - Involves workplace layout, small tools, hoists for lifting heavy parts, etc. - Responsibility of the industrial engineering department • Work standards - Set time standards for each operation using work measurement techniques • Cutting tools and cutting conditions - Must be specified for machining operations (often with reference to standard handbook recommendations)

Perfect First-time quality (4 principles)

Quality is distinctly different between mass production and lean production • In Mass Production: - Quality control is defined in terms of an acceptable quality level (or AQL) • A certain level of fraction defects is sufficient, even satisfactory • In Lean Production: - Perfect quality control is required. - The just-in-time delivery discipline used in lean production necessitates a zero defects level in parts quality - A single defect draws attention to the quality problem, forcing corrective action and a permanent solution.

Agile Manufacturing - Market Forces and Agility 1

Market forces that are driving the evolution of agility and agile manufacturing in business. These forces include: - Intensifying competition • Signs of intensifying competition include: - Global competition - Decreasing cost of information - Growth in communication technologies - Pressure to reduce time-to-market - Shorter product lives - Increasing pressures on costs and profits Fragmentation of Mass Markets - Emergence of niche markets - High rate of model changes - Declining barriers to market entry from global competition - Shrinking windows of market opportunity

Marketing

Objectives of an agile marketing company: - Aggressive and proactive product marketing - Cannibalize successful products - Frequent new product introductions - Life cycle product support - Pricing by customer value - Effective niche market competitors

Agile Manufacturing - Principles

Organize to Master Change - An agile company is organized in a way that allows it to thrive on change and uncertainty. - Can be rapidly reconfigured to adapt to changing environment and market opportunities. • Leverage the Impact of People and Information - Knowledge is valued - Innovation is rewarded - Authority is distributed to the appropriate level of organization. - Organization has entrepreneurial in spirit. - There is a "climate of mutual responsibility for joint success.

Concurrent Engineering definition

Refers to the approach used in product development in which the functions of design engineering, manufacturing engineering and other functions are integrated to reduce the elapsed time required to bring a new product to market

Continuous Improvement

Supports the policy of continuous improvement. - Constantly searching for and implementing ways to: • Reduce cost • Improve quality • Increase productivity Carried out one project at a time. • Following problem areas are focused: - Cost reduction - Quality improvement - Productivity improvement - Setup time reduction - Cycle time reduction - Manufacturing lead time - Work-in-process inventory reduction - Improvement of product design to increase performance and customer appeal.

Minimize waste (4 principles)

Waste forms include: 1. Production of defective parts 2. Production of more than the number of items needed 3. Unnecessary inventories 4. Unnecessary processing steps 5. Unnecessary movement of people 6. Unnecessary transport of materials 7. Workers waiting

Mass production

Workers had to be told every details of their work methods and were incapable of planning their own tasks. - Goal is to maximize efficiency. - Achieved using long production runs of identical parts

Benefits of Concurrent Engineering

improves product's function and performance • Improves product's-Producebility, Inspect-ability, Test-ability Serviceability, Maintainability • Through early involvement, the duration of the product development cycle is substantially reduced.

Concurrent Engineering : Design for Manufacturing And Assembly (contd.)

• Manufacturing engineer should be given an opportunity to advise the design engineer as the product is evolving, to favorably influence the manufacturability of the product. • Design for Manufacturing and Assembly (DFM/A). This includes: - Organizational changes - Design principles and guidelines