Product design for modularity

Tai ngay!!! Ban co the xoa dong chu nay!!! PRODUCT DESIGN FOR MODULARITY PRODUCT DESIGN FOR MODULARITY Ali K Kamrani, Ph.D University of Michigan-Dearborn Sa' ed M Salhieh Wayne State University SPRINGER SCIENCE+BUSINESS MEDIA LLC Library of Congress Cataloging-in-Publication Data A C.LP Catalogue record for this book is available from the Library of Congress ISBN 978-4613-5697-4 ISBN 978-1-4615-1725-2 (eBook) DOI 10.1007/978-1-4615-1725-2 Copyright © 2000 by Springer Science+Business Media New York Originally published by Kluwer Academic Publishers in 2000 Softcover reprint ofthe hardcover Ist edition 2000 AII rights reserved No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form ar by any means, mechanical, photocopying, recarding, or otherwise, without the prior written permission of the publisher, Springer Science+Business Media, LLC Printed 01/ acid-fi·ee paper Dedicated to our parents, our brothers and sisters, and Sonia Contents vii Contents List of Figures List of Tables IX Xlll xv Preface Acknowledgements xix Chapter 1: Product Development Process: An Introduction I The Evolution of Product Development Sequential Product Development Simultaneous/Integrated Product Development Generic Product Development Process Product Development Categories Chapter 2: Modular Design I Modularity Types Modular Systems Characteristics Modular Systems Development Modularity Advantages Chapter 3: Design for Modularity I Needs Analysis Product Requirements Analysis I 16 19 19 21 25 47 49 51 63 Contents Product/Concept Analysis Product/Concept Integration Case Study: Decomposition Analysis of a Four-Gear Speed Reducer Design Based on the Methodology Chapter 4: Design for Assembly I DFMA Methodology Case Study : DFMA Analysis of a Fog Lamp Design Summary and Conclusion Chapter 5: Design for Manufacture and Template-Based Process Planning I Geometric and Parametric Design Group Technology (GT) Design for Manufacture Structure for a Template-Based Process Planning System APPENDIX A: Crankshaft Parametric File Structure and Listings APPENDIX B: GD&T Data File APPENDIX C: Formulation Used for Material Removal APPENDIX D: Sample Process Plan Chapter 6: Flexible and Modular Cell Design I Traditional Manufacturing Systems-An Overview Cellular Manufactuirng Systems Cellular Manufacturing Systems Design 65 69 73 97 97 III 121 123 123 126 129 134 140 147 148 162 169 170 172 174 References 195 Index 201 List of Figures Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure 1.1 1.2 1.3 1.4 1.5 1.6 1.7 I.B 1.9 1.10 1.11 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.B 2.9 10 Figure 2.11 Figure 2.12 Figure /3 Design for Modularity Life Cycle Sequential Product Development Simultaneous/Integrated Product Development Product Development Process Needs Recognition Parametric Analysis Plot Matrix Analysis Establishing Design Specifications Needs-Metrics Matrix Concept Generation Concept Selection Detail Design Function and Module Types Component-Swapping Modularity Component-Sharing Modularity Fabricate-to-Fit Modularity Bus Modularity PC Assembly Diagram Structural Decomposition of a Vehicle System Structural Decomposition of a Carriage Unit Requirements Decomposition Ball Bearing Design Constraint-Parameter Incidence Matrix Decomposed Constraint-Parameter Incidence Matrix Hierarchical Decomposition of a Complex System Monocode Structure xv 10 10 12 13 14 21 23 23 24 24 26 26 27 28 29 30 30 33 List of Figures Figure 2.14 Figure 2.15 Figure 2.16 Figure 3.1 Figure 3.2 Figure 3.3 Figure 3.4 Figure 3.5 Figure 3.6 Figure 3.7 Figure 3.8 Figure 3.9 Figure 3.10 Figure 3.1 Figure 3.12 Figure 3.13 Figure 3.14 Figure 3.15 Figure 3.16 Figure 3.17 Figure 3.18 Figure 3.19 Figure 3.20 Figure 3.21 Figure 3.22 Figure 4.1 Figure 4.2 Figure 4.3 Figure 4.4 Figure 4.5 Figure 4.6 Figure 4.7 Figure 4.8 Figure 4.9 Figure 4.10 Figure 4.11 Figure 4.12 Figure 4.13 Figure 14 Figure 4.15 Figure 16 Figure /7 Po lycode Structure Hybrid Structure Part-Machine Incidence Matrix Overview of the Proposed Design Environment Design for Modularity Customer Satisfaction Process Kano's Model The House of Quality Function-Structure Diagram Computer Physical Decomposition Overall Function Flow Diagram Function Flow Diagram System-Level Specification Decomposition Hierarchy System Diagram Four-Gear Speed Reducer Physical Decomposition of Pump System Overall Function of the Speed Reducer Components' Functions System-Level Specification Hierarchy Structure Functional Similarity Matrix Physical Similarity Matrix Combined Similarity Matrix Functional Modules Physical Modules Combined Modules Elements ofDFMA Traditional Process vs Concurrent Engineering Process The Subtract and Operate Procedure Paper Clip Example [51] DFMA Functional Criteria Flowchart [8] Original Arm Bracket Assembly DFMA-Designed Arm Bracket Assembly Design for Manual Assembly Worksheet [8, 9] Manual Handling-Estimated Times (seconds) [8,9] Manual Insertion-Estimated Times (seconds) [8,9] Exploded View of Fog Lamp (current design) Assembly Sequence of Current Fog Lamp Design Functionality Tables for Fog Lamp Design Exploded View of Fog Lamp (proposed design) Alternative Design I Alternative Design Alternative Design 33 34 35 49 51 52 53 58 66 66 68 68 70 74 76 76 77 77 79 81 82 82 83 83 83 100 100 102 102 103 104 104 106 107 108 112 112 117 119 120 120 121 Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.B 5.9 5.10 5.11 5.12 6.1 6.2 6.3 Geometric Modeling Classification DFM Process CAPP Characteristics Integrated Product Design and Process Planning Sample Parametric File Format Surfaces that Require Machining General Crank Dimensions Fillet Radii Oil Hole Coordinate System Counterweight Dimensions Lightening Hole Dimensions Balance Hole Dimensions The Three Kinds of Traditional Manufacturing Systems Layouts of Manned and Unmanned Cells The Dendrogram Constructed for Sample Parts 124 130 133 134 137 138 140 140 141 141 142 142 171 173 190 187 Flexible and Modular Cell Design where: BM = Budget available to purchase and maintain machines of all types BF = Budget available to purchase and maintain fixtures of all types BT = Budget available to purchase and maintain tools of all types BI = Budget available for inspection of all parts BMH = Budget available for material handling of all parts in all cells Machine capacity: Equations developed in this section will ensure that the capacity of each machine type in each cell is not violated If so, a number of duplicates will be calculated and proposed in order that the shop meets the annual demand for parts This constraint is formulated as follows: Vm,c where: TP m = Total annual processing time available on machine type m NMmc = Number of machines of type m assigned to cell c TMDpm = Total time required to meet annual demand for part p on machine type m f3 if part p is processed on machine type m = , otherwise I, pm ° = I, if part p is assigned to cell c y 0, pc otherwise Machine-fixture balance: Since each process machine will require at least one fixture for production, this constraint will assure the minimum number required In case of a duplicate number of machines, the same number of duplicates for the fixtures is proposed This constraint is formulated as follows: V/,m,c where: NFfmc = Number of fixtures oftypejassigned to machine type m in cell c NMmc = Number of machines of type m is assigned to cell c I, if fixture type jis required by machine type m (Jfin =0, otherwise Chapter 188 Tool life: Equations developed in this section will ensure that the tool life of each tool type on each machine assigned in each cell is not violated If so, a number of duplicates will be calculated in order to meet the annual demand This constraint is formulated as follows: '2:)3 pm * {3'tp *(JIm * TMdpm * Y pc $, TLI * NI;m C '1/ m,c,t p where: TMDpm = Total time required to meet annual demand for part p on machine type m TL, = Total lifetime of tool type t NT,mc = Number of tools of type t assigned to machine type m in cell c {3 pm - 1, if part p is processed on machine type m 0, otherwise = 1, {3' Ip 0, if tool type t is required by part p otherwise (JIm =0, 1, if tool type t is required by machine type m y = 1, pc 0, otherwise if part p is assigned to cell c otherwise Cell capacity: In order to have a high degree of flexibility in each cell, a limit is required to be set to the total number of parts assigned to each cell This constraint is formulated as follows: where: ICc = Maximum number of parts allowed in cell c d p = Total number ofpartp demanded annually Y pc = 1, 0, if part p is assigned to cell c otherwise Flexible and Modular Cell Design 189 Part group assignment: To reassure the assignment of each part family to only one cell and the assignment of the parts in these families to a cell, the following constraints are proposed: gc a pg * ~c=Xgc where: = 1, if group g is assigned to cell c 0, otherwise X gc =1, y pc if part P is assigned to cell c 0, otherwise 1, if part p is a member of group g a pg = 0, otherwise Decision variable binary and integerality: Since the cost equation is a mixed-integer expression, the decision variables should be promptly identified for the solution method used (branch-and-bound) Therefore: (0,1) Vgc (O,l)Vp,c NMmc~ and Integer Vmc NFfmc ~ and Integer Vf,m,c NT,mc ~ and Integer Vt,m,c Xgc E fpc E ° ° ° A situation in which the production of fifteen parts is required is under analysis These parts require fifteen operations (nine process operations and six end operations) There are eight process machines and five end-operation devices available A rating factor of is assumed for all machines performing process operations This assumption indicates that the machines selected are the most suitable ones for performing the process operations Nine types of tools are available for the process operation Table 6.7 illustrates the values of the disagreement measure between parts for the proposed method Chapter 190 r.a ble 67 D'Isagreement M easures between AllP arts Part \'S I I 0.00 1.00 0.60 0.98 0.60 1.00 Part 0.68 0.86 0.73 10 11 12 13 14 15 0.96 0.85 0.88 0.89 1.00 0.74 1.00 0.00 0.90 0.45 1.00 0.63 0.94 0.66 0.92 0.78 0.51 0.65 0.71 0.36 0.88 0.60 0.90 0.00 0.74 0.62 1.00 0.65 0.69 0.84 0.92 1.00 0.80 0.85 0.93 0.77 0.45 0.74 0.00 0.84 0.60 0.94 0.51 1.00 0.76 0.43 0.55 0.70 0.44 1.00 1.00 0.62 0.84 0.00 0.97 0.76 71 076 0.77 1.00 0.88 89 1.00 0.82 1.00 0.63 1.00 0.60 0.97 0.00 1.00 0.59 1.00 0.67 0.63 0.78 0.71 0.51 1.00 0.68 0.94 0.65 0.94 0.76 1.00 0.00 0.82 0.75 0.94 0.88 0.76 0.99 97 0.56 0.86 0.66 0.69 51 0.71 0.59 0.82 0.00 1.00 0.75 0.75 0.65 0.87 0.63 0.78 0.73 0.92 0.84 1.00 0.76 1.00 0.75 1.00 0.00 0.68 1.00 0.65 0.91 1.00 0.49 10 0.96 0.78 0.92 0.76 0.77 0.67 0.94 0.75 0.68 0.00 0.92 0.72 0.81 0.75 0.59 11 0.85 0.51 1.00 0.43 1.00 0.63 0.88 75 1.00 0.92 0.00 0.73 0.74 0.54 1.00 12 0.88 0.65 0.80 0.55 0.88 0.78 0.76 0.65 0.72 0.73 0.00 0.55 0.77 0.66 13 0.89 0.71 0.85 0.70 0.89 0.71 0.99 0.87 0.91 81 0.74 0.55 000 0.86 0.97 14 1.00 0.36 0.93 0.44 1.00 0.51 0.97 63 1.00 0.75 0.54 77 0.86 0.00 093 15 0.74 0.88 0.77 1.00 0.82 1.00 0.56 0.78 0.49 0.59 1.00 0.66 0.97 0.93 0.00 Using the proposed formulation and by setting p (required number of part families) to be four, parts and their associated families are as G J (1 ,3,5), G2(2,4,6,8,1l,J4), G3(7,9, JO, J5), and G4(12,J3) The dissimilarity values are also used to set up the dendrogram of this example, shown in Figure 6.3 0.66 0.65 Thre.hold v.4ii-;rr -1 0.59 0.56 0.55 I i, : ! I i I I ~::: i I I i I 0.36 I I I j, L r- i I i i -1r,=F,l II! Ii Ii II i I i II i i i ii i i i _"- II I I I iii I 043 iii iii I I I I i 0441 r -! r II ii II II il II I Ii! ! i i j i i i I I I I i I j I Ii i il: _~ ~ _~~ _~ ~ ! !L'12 _ 13'I _ 15 10 1 J11 L:3 _ I G2 G4 I G3 Figure 6.3 The Dendrogram Constructed for Sample Parts G1 191 Flexible and Modular Cell Design For the threshold assignment of 0.60, the four families are as follows: Gl(2,4,6,S,11 ,14), G2(7,9,10,15), G3(l,3,5), and G4(l2,13) Table 6.S lists the annual investment and maintenance associated with each machine and tool It also contains the annual available machining time on each machine and the tool life associated with each tool The annual demand for each part is given in Table 6.9 Machine reliability is illustrated in Table 6.10 The inspection time and cost are assumed to be similar for all parts, and all machines have the same rework cost Setup cost and time are assumed to be similar for all machines The intracellular material handling cost associated with parts is similar in all cells The model is solved using LINDO software, and the results are listed in Tables 6.11, 6.12, and 6.13 Table 6.8 Machine Investment Cost, and Tool Life Machine CMm ($) Type 30,000 42,000 24,000 35,000 41 ,000 22,000 20,750 30,000 22,460 10 27,000 11 32,000 26,000 12 13 30,490 Costs, Annual Available Machine Time, Tool Investment TPm (min) 102,000 139,000 111,000 114,000 140,000 100,000 162,000 156,000 130,000 155,000 90,000 99,000 89,000 Table 6.9 Annual Demand for Various Parts (d) , Part Type 10 11 12 13 14 15 Tool Type CMt TLt(min) I 2538 2576 2526 2436 2562 2334 2454 2154 2244 490 444 430 427 488 413 412 414 442 d, 1728 2000 2145 1729 1948 2263 2226 2236 2160 1777 1758 1824 2089 1929 2308 Chapter 192 Table 6.10 Machine Reliability (R) Machine Type I R" (%) 10 II 12 13 93 95 94 89 75 85 95 94 97 85 82 85 91 - T,able 11 Ce II Con fi19uratlOn Part Number I Family Number 1, Cell Number I 12 13 2 3 II 14 10 15 - - Flexible and Modular Cell Design 193 ToahIe 612 N urn bero fM ac 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387-400,1986 78 Willett, P., Similarity and Clustering in Chemical Information Systems, New York: John Wiley and Sons, 1987 79 Zhang, H c., and L Alting, Computerized Manufacturing Process Planning Systems, Chapman and Hall, 1994 80 Zisk, B 1., "Flexibility is Key to Automated Material Transfer for Manufacturing Cells," Industrial Engineering, pp 58-64, November 1983 Index Action statements, 12 Anderberg's equation, 175 Assembly worksheet, 106 Association coefficients, 174 Attractive requirements, 53, 54 Automatic insertion, 109 Auxiliary functions, 22, 67 Binary variable, 35-37, 70, 174, 177, 178, 189 Boothroyd-Dewhurst method, 105 Cellular manufacturing, 172-174 Classification and coding, 32, 174 Clustering, 34, 35, 38, 42-45, 128, 129, 174 Coding, 32, 33,127,128,138,175, 177 Computer-controlled configuration, 169 Computer-integrated manufacturing, 169, 172 Concept analysis, 50, 65 Concept generation, 12, 75 Concept integration, 50, 69 Concept selection, 13, 75 Continuous variables, 177, 178 Correlation coefficients, 174 Customer loyalty, 52 Customer needs, 2,8, 10, 16, 18, 51-53,55,58,59,61-63,65,74 Customer requirements, 18, 31, 47, 48,54,56-63 Customer satisfaction, 10, 14,52-56, 71 Decomposition analysis, 50, 73 Dendrogram, 34, 128, 190 Design efficiency, 101, 103, 108, 109, 112, 125 Design for functionality, 49 Design for manual assembly, 105, 106 Design for manufacture, 50, 98, 123, 129, 135 Design for manufacture and assembly (DFMA), 15, 16, 122 Design for modularity, 49-51, 73 Distance coefficients, 174 Dutta's equation, 175 Expected requirements, 54, 55 202 Feature-based design, 123, 124 Flexible manufacturing, 169, 172 Flow shop, 170 Force flow diagrams, 101, 102 Function flow diagram, 67-69, 84 Functional criteria, 103 Functionality flowchart, 103, 112 General functional requirements, 63-65,70, 71,75,80,81 General Functional requirements' weights, 65, 75 Generative process planning, 132 Geometric and parametric design, 123 Global database, 135 Group technology, 32,44,50, 123, 126,132, 135,172 Hamming metric, 174, 175, 178 Hybrid structure, 33, 34, 127,134 Integer program, 175 Intracell material handling, 175, 182, 185 Jaccard's coefficient, 175 Job shop, 170 Kano's model, 53, 54 Knowledge-based system, 124 Linear disagreement index, 177, 178 Manned and unmanned cells, 172, 173 Manufacturing cells production, 169 Modularity, 19,20,22-25,31, 47-49,97,122,130 Monocode structure, 33 , 127 Must-be requirements, 53, 54 Index Needs analysis, 6, 7, 50-52,64, 74, 80 Nominal variable, 177, 178 Operational functional requirements, 63,64,75 Ordinal variables, 9, 177-179 Parametric data, 123, 135, 136, 137, 139 Performance requirements, 53, 54 Physical characteristics, 25, 69, 70 Planning matrix, 58 Polycode structure, 33, 127 Primary functions, 67 Probabilistic coefficients, 174 Process analysis, 50 Process planning, 15,62,123,130, 131,132,134,136,138, 139,166 Product analysis, 50 Product concept analysis, 65, 75 Product design, 2, 15, 16, 18, 19, 31, 49, 50, 62,69,97,105, 124, 131, 134, 170 Product features , 2, 50, 55-61, 109 Product functional decomposition, 65, 67,76 Product physical decomposition, 65, 66, 76 Product requirements analysis, 63, 74 Production planning, 3, 15, 32, 62, 139 Project shop, 170 Quality, 1-4, 13,48,62,97,101, 111,121,125,130,139,173 Quality function deployment, 57, 59, 61 Requirement analysis, 57, 70 Requirements analysis, 50 Index Rule-based systems, 133, 134 Self-aligning, 105, 110, 111 Serviceability, 80 Similarity index, 71, 72, 81 Special-purpose transfer machine, 109 Spoken requirements, 54, 55 Subtract and operate procedure (SOP), 101, 102 System-level specifications, 69-71, 78,79,81 203 Template-based design, 123 The house of quality, 57-60, 62 Tolerance, 121 , 126, 131, 137, 139 Tooling, 98,122,128,131,136 Unexpected requirements, 54-56 Unspoken requirements, 54, 55 Variant design, 32, 129, 139 Variant process planning, 50, 132 Z-axis assembly, 109-111