Product Design for Modularity Second Edition PRODUCT DESIGN FOR MODULARITY Second Edition Goar (G2) Koy (K2) Shaft (52) Goar (G3) Koy (K3) Ali K Kamrani, Ph.D Sa'ed M Salhieh, Ph.D ~ " Springer Science+Business Media, LLC " Electronic Services Library of Congress Cataloging-in-Publication Data Product Design for Modularity, 2nd Edition ISBN 978-1-4419-5286-8 ISBN 978-1-4757-3581-9 (eBook) DOI 10.1007/978-1-4757-3581-9 A C.I.P Catalogue record for this book is available from the Library of Congress Copyright © 2002 by Springer Science+Business Media New York Originally published by Kluwer Academic Publishers in 2002 Softcover reprint ofthe hardcover 2nd edition 2002 All rights reserved No part ofthis work may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, microfilming, recording, or otherwise, without the written permission from the Publisher, with the exception of any material supplied specifically for the purpose ofbeing entered and executed on a computer system, for exclusive use by the purchaser of the work Pcrrnission for books publishcd in Europe: perrnissions@wkap.nl Permissions for books publishcd in the United States of Amcrica: pcrrnissions@wkap.com Printed on acid-free paper Dedicated to ourlamilies Contents Contents vii List ofFigures List ofTables Acknowledgements Preface IX xiii xv xvii Chapter 1: Product Development Process: An Introduction I The Evolution ofProduct Development The Importance ofProduct Development Sequential Product Development Simultaneous/lntegrated Product Development Generic Product Development Process Product Development Categories Case Studies Chapter 2: Modular Design I Modularity Types Modular Systems Characteristics Modular Systems Development Modeling Product Development Process using Design Structure Matrix Modularity Advantages 18 20 45 45 47 51 73 83 Contents viii Chapter 3: Design for Modularity Needs Analysis Produet Requirements Analysis Produet/Coneept Analysis Produet/Coneept Integration 85 87 99 101 105 Chapter 4: Deeomposition analysis of a Four-Gear speed redueer design: DFMo ease study 123 Problem Deseription Appendix A: Engineering Design Speeifieations Chapter 5: Design for Manufaeture and Assembly DFMA Methodology Case Study: DFA Analysis ofa Fog Lamp Design Geometrie and Parametrie Design Design for Manufaeture Strueture for a Template-based System Appendix A: Crankshaft Parametrie File Strueture Appendix B: Formulation used for Material Removal Appendix C: SampIe Proeess Plan Chapter 6: Flexible and Modular Cell Design Traditional Manufaeturing Systems-An Overview Cellular Manufaetuimg Systems Cellular Manufacturing Systems Design 123 141 143 144 155 165 168 173 179 182 184 189 190 192 194 Referenees 215 Index 221 List of Figures Figure Figure 1.1 Figure 1.2 Figure 1.3 Figure 1.4 Figure 1.5 Figure 1.6 Figure 1.7 Figure 1.8 Figure 1.9 Figure 1.10 Figure 1.11 Figure 1.12 Figure 1.13 Figure 1.14 Figure 1.15 Figure 1.16 Figure 1.17 Figure 1.18 Figure 1.19 Figure 1.20 Figure 1.21 Figure 1.22 Figure 1.23 Figure 1.24 Figure 1.25 Figure 1.26 Design for Modularity Life Cycle Sequential Product Development SimultaneouslIntegrated Product Development Product Development Process Needs Recognition Parametrie Analysis Plot Matrix Analysis Establishing Design Specifications Needs-Metrics Matrix Concept Generation Concept Selection Detail Design Single-Use Camera Single-use Camera Needs Interpretation Single-use Camera Matrix Analysis Needs Prioritization Survey Sunroof SunroofNeeds-Metrics Matrix Sunroof Competitive Benchmarking Sunroof Initial Specifications Paper Clip Paper Clip Function Paper Clip Detailed Functions Paper Clips - Market Study Paper Clips - Patent Material Design Seetions ofPaper Clip Clip Concept AI xix 9 11 12 13 14 16 20 22 22 24 25 26 27 27 28 29 29 30 30 31 31 x Figure 1.27 Figure 1.28 Figure 1.29 Figure 1.30 Figure 1.31 Figure 1.32 Figure 1.33 Figure 1.34 Figure 1.35 Figure 1.36 Figure 1.37 Figure 1.38 Figure 1.39 Figure 1.40 Figure 1.41 Figure 1.42 Figure 1.43 Figure 1.44 Figure 2.1 Figure 2.2 Figure 2.3 Figure 2.4 Figure 2.5 Figure 2.6 Figure 2.7 Figure 2.8 Figure 2.9 Figure 2.10 Figure 2.11 Figure 2.12 Figure 2.13 Figure 2.14 Figure 2.15 Figure 2.16 Figure 2.17 Figure 2.18 Figure 2.19 Figure 2.20 Figure 2.21 Figure 2.22 Figure 3.1 Figure 3.2 List o[ Figures Clip Concept A2 Clip Concept BI Clip Concept B2 Clip Concept B3 Clip Concept B4 Clip Concept Cl Clip Concept C2 Paper Clip Conceptual Design Connecting Rod Piston-Connecting Rod- Crankshaft Assembly Connecting Rod Design Feature Names Connecting Rod Design Details Partial Cross Section ofConnecting Rod and Crank Pin Journal Connecting Rod Virtual Prototype SampIe Crankshaft Template Crankshaft Generic Process Plan - Partial Machine selection procedure Machine layout - Partial Function and Module Types Component-Swapping Modularity Component-Sharing Modularity Fabricate-to-Fit Modularity Bus Modularity PC Assembly Diagram Structural Decomposition ofa VehicIe 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 Polycode Structure Hybrid Structure Part-Machine Incidence Matrix Information Dependency Types DSM Matrix Lower Triangular DSM Block Triangular DSM Decoupling to Speed Design Coupling to Improve Quality Overview of the Proposed Design Environment Design for Modularity 31 32 32 32 32 32 32 34 35 35 37 38 39 39 40 41 43 44 47 49 49 50 50 52 52 53 54 55 56 56 59 59 60 61 73 74 78 79 81 82 85 87 List 01 Figures 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 3.11 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 4.14 Figure 4.15 Figure 4.16 Figure 4.17 Figure 4.18 Figure 4.19 Figure 5.1 Figure 5.2 Figure 5.3 Figure 5.4 Figure 5.5 Figure 5.6 Figure 5.7 Figure 5.8 Figure 5.9 Figure 5.10 Figure 5.11 Figure 5.12 Figure 5.13 Figure 5.14 Figure 5.15 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 Basic structure of a genetic algorithm System Diagram Four-Gear Speed Reducer Physical Decomposition ofPump System Overall Function ofthe Speed Reducer Components' Functions System-Level Specification Hierarchy Structure Functional Similarity Matrix Physical Similarity Matrix Combined Similarity Matrix Functional Modules Physical Modules Combined Modules GA response for two-modules solution Grouping for a two modules GA response for a three-modules solution Grouping for a three-group solution Grouping for a four-module solution Summary results ofthe GA run Scope of DFMA Traditional Process vs Concurrent Engineering Process The Subtract and Operate Procedure Paper Clip Example DFMA Functional Criteria Flowchart Original Arm Bracket Assembly DFMA-Designed Arm Bracket Assembly Design for Manual Assembly Worksheet a and ß symmetry Sampie analysis of size and thickness of parts Manual Handling-Estimated Times (seconds) Manual Insertion-Estimated Times (seconds) Exploded View ofFog Lamp (current design) Assembly Sequence ofCurrent Fog Lamp Design Functionality Tables for Fog Lamp Design xi 88 89 94 102 102 104 104 106 111 123 127 127 128 128 130 132 133 133 134 134 135 136 137 138 138 139 139 144 145 147 147 148 149 149 150 151 151 152 153 155 156 160 XIl Figure 5.16 Figure 5.17 Figure 5.18 Figure 5.19 Figure 5.20 Figure 5.22 Figure 5.23 Figure 5.25 Figure 5.26 Figure 5.27 Figure 5.28 Figure 5.29 Figure 5.30 Figure 5.31 Figure 6.1 Figure 6.2 Figure 6.3 List 0/ Figures Exploded View ofFog Lamp (proposed design) Alternative Design Alternative Design Alternative Design Geometrie Modeling Classification CAPP Characteristics Integrated Product Design and Process Planning Surfaces that Require Machining General Crank Dimensions Fillet Radii Oil Hole Coordinate System Counterweight Dimensions Lightening Hole Dimensions Balance Hole Dimensions The Three Kinds ofTraditional Manufacturing Systems Layouts ofManned and Unmanned Cells The Dendrogram Constructed for Sampie Parts 162 163 163 164 165 172 173 177 179 179 180 180 181 181 190 192 209 208 Chapter6 Toollife: Equations deve10ped in this section will ensure that the toollife 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 folIows: L ßpm * ß *(J'tm * TMdpm *Y pe ~ T4 * NT,m c Vm,c,t p where: TMDpm = Total time required to meet annual demand for part p on machine type m TL, = Totallifetime of tool type t NT'me = Number oftools oftype t assigned to machine type m in cell c 1, if part p is processed on machine type m ßpm = 0, otherwise if tool type t is required by part p otherwise 1, if tool type t is required by machine type m (J'tm =0 , y = pe otherwise 1, if part p is assigned to cell c 0, 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 cel! This constraint is formulated as folIows: Ldp*Ype~ICe Vc p where: ICe = Maximum number of parts allowed in cell c dp = Total number of part p demanded annually 1, if part p is assigned to cell c Y = pe 0, otherwise Flexible and Modular Cell Design 209 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 acelI, the following constraints are proposed: gc apg *Ypc = Xgc where: 1, if group g is assigned to cell c X gc = Y = pe a 0, otherwise 1, if part p is assigned to cell c 0, otherwise = pg I, if part p is a member of group g 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: X gc E (0,1) Vgc Ypc E (0,1) Vp,c NMmc ?: and Integer Vmc NFfmc ?: and Integer Vf,m,c NTtme ?: and Integer Vt,m,c 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 210 Chapter Ta bi e 6.7 Disagreemcnl Mcasurcs b etwccn A Il Parts Pa" Vi I I 0.00 • 060 0.98 0(.0 1.00 0.6X ) 1.00 Pari S 10 11 13 I' 11 0.86 0.73 0,9( 0.8\ O~ 0>19 100 0.7 12 1.00 0.00 0.90 0.'1 1.00 0.63 0.94 0.66 092 07 051 0'5 071 0,'(, 0.S8 ) 0.60 0.90 0.00 0.7' 0.62 1.00 0.6\ 0.69 084 0.92 100 o SO 0.85 0.9) 0.77 0.98 0'\ 0.74 000 084 060 094 0.51 100 O.71, 0.41 OS) 0.70 044 1.00 S 060 100 0.62 0.8 0.0Il 097 0.7 0.71 076 077 100 o R8 089 100 0.82 • 1.00 0.63 1.00 0.60 0.97 000 100 059 100 067 0.6) 078 0.7' 051 1.00 0.68 094 0.6\ 09 076 100 000 082 075 094 088 07 OW 0.97 05' S 08( 066 06' 0.51 071 059 0.82 0.00 100 07S 075 0.73 0.92 0.8' 100 076 100 075 100 0.00 o 6~ 100 ~ 10 0.% 0.78 0.92 076 017 0.7 09' 075 0.68 11 0."5 0.51 1./)0 0.43 1.00 063 088 075 I 00 12 0.88 065 0.80 0.55 0.88 078 07 0(,\ 087 0.61 078 DM, 0'1 1.00 049 0.00 092 on O,l!il 0.75 0.\9 ~ 000 on 074 05' 100 1065 o,n 07.1 000 0.97 05S~' 11 089 071 0.85 0.10 IO R9 099 0.R7 i 0.91 Q,l!il 0.74 0.51 0.00 i 0.86 I' 1.00 0.36 093 0.44 1.00 0.51 0.97 0.63 00 0.75 054 0.17 o R 000 093 15 0.14 088 011 100 082 1.00 0.5 0.78 OA9 0.\9 1.00 0.66 0.97 0.93 0.00 Using the proposed formulation and by settingp (required number ofpart families) to be four, parts and their associated families are as GI (1,3,5), G2(2,4,6,8,ll,14), G3(7, 9,l O,l5) , and G4(I2,13) The dissimilarity values are also used to set up the dendrogram ofthis example, shown in Figure 6.3 066 0.65 Th reshold V.IJj"II O ~ 059 r ! i 056 055 -l I r- - - r- I -,- J- I i ; 0.51 _ : i I I ,i 049 11 044 0.43 I - I 11 I 11 li i OJ61r 14 11 G2 ~ -' 15 GJ Figure 6.3 The Dendrogram Constructed für Sampie Parts 11 10 i!3 5~ ' Gl Flexible and Modular Cell Design 211 For the threshold assignment of 0.60, the four families are as follows: Gl(2,4,6,8,11,14), G2(7,9,1O,15), G3(l,3,5), and G4(l2,13) Table 6.8 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 toollife 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 I 42,000 24,000 35,000 41,000 22,000 20,750 30,000 22,460 27,000 10 11 32,000 12 26,000 30,490 13 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 CMt TLt (min) I 2538 2576 2526 2436 2562 2334 2454 2154 2244 490 444 430 427 488 413 412 414 442 Table Annual Demand for Various Parts (d) , Part Type I - 10 , 11 12 13 14 -_._ - - - - - - - 15 ~ - Tool Type d, 1728 2000 2145 1729 1948 2263 2226 2236 2160 1777 1758 1824 2089 1929 2308 _-_._ ~~~ - 212 Chapter Table 6.10 Machine Reliability (R) Macbine Type R,,(%) 93 95 94 89 75 85 95 94 97 85 82 85 91 I 10 11 12 13 Table 6.11 Cell Configurahon Part Number I - 12 13 Family Number 1,4 Cell Number I 2 3 11 14 10 15 213 Flexible and Modular Cell Design Table 6.12 Number of Machine Types and 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pp 58-64, November 1983 Index Action statements, l3 Anderberg's equation, 196 Assembly worksheet, 151 Association coefficients, 194 Attractive requirements, 89, 90 Auxiliary functions, 48, 103 Binaryvariable, 61~63, 106, 194, 196,198,210 Boothroyd-Dewhurst method, 150 Cellular manufacturing, 191, 193, 194 Classification and coding, 58, 194 Clustering, 60, 61, 64, 68- 72, 194 Coding, 58, 59, 178, 195, 196 Computer-controlled configuration, 189 Computer-integrated manufacturing, 189,193 Concept analysis, 86, 10 Concept generation, l3, 126 Concept integration, 87, 105 Concept selection, 14, 126 Continuous variables, 196, 198 Correlation coefficients, 194 Crossover, 112, 1l3, 116, 117, 119 Customer loyalty, 88 Customer needs, 2, 9-11, 18, 19,8789, 91, 94-99, 101 Customerrequirements, 19,57,83, 84, 90, 92- 99 Customer satisfaction, 11, 15, 88-92, 107 Decomposition analysis, 86, 123 Dendrogram, 60, 210, 211 Design efficiency, 146, 149, 154, 157, 167 Design for functionality, 85 Design for manual assembly, 151 Design for manufacture, 86,145, 169, 176 Design for manufacture and assembly (DFMA),17 design for manufacturing and assembly (DFMA), 179 Design for modularity, 85-87, 123 Design Structure Matrix, 73,74, 82, 216 Distance coefficients, 194 Dutta's equation, 195 Expected requirements, 90, 91 222 Feature-based design, 167 Fitness Function, 119 Flexible manufacturing, 189, 191, 193 Flow shop, 190 Force flow diagrams, 147 Function flow diagram, 103-105, 135 Functional criteria, 149 Functionality flowchart, 148, 157 General functional requirements, 99101, 106, 107, 126, 131, 132 General functional requirements' weights, 126 General Functional requirements' weights, 10 I Generative process planning, 172 Genetic Algorithms, 110 Geometric and parametric design, 166 Global database, 175, 176 Group technology, 58, 70, 86, 172, 176,191 Hamming metric, 194, 195, 199 Hybrid structure, 59, 60, 174 Integer program, 196 Intracell material handling, 196, 202, 206 Jaccard's coefficient, 195 Job shop, 190 Kano's model, 89, 90 Knowledge-based system, 167 Linear disagreement index, 196, 198, 199 Manned and unmanned cells, 193 Manufacturing cells production, 189 Modularity, xviii, xix, 45, 46,48-51, 57,83-85,144,169,179 Monocode structure, 59 Must-be requirements, 89, 90 Mutation, 112, 114, 116, 1l7, 120 Needs analysis, 7-9, 86, 87, 100, 124, 131 Index Nominal variable, 196, 198 Operational functional requirements, 99,100,126 Optimization, 56, 217 Ordinal variables, 10, 196, 198, 199 Parametric data, 176, 178, 179 Partitioning, 78 Performance requirements, 89, 90 Physical characteristics, 51, 105, 106 Planning matrix, 94 Polycode structure, 59 Primary functions, 103 Probabilistic coefficients, 194 Process analysis, 86 Process planning, 17,98, 144, 170174,176,178 Product analysis, 86 Product concept analysis, 101, 126 Product design, xviii, 2, 17, 19, 45, 57,82,85,86,98, 105, 144, 145, 150,167,170,174,190 Product features, 2, 86, 91-97, 155 Product functional decomposition, 101,103,127 Product physical decomposition, 10 I, 102, 127 Product requirements analysis, 99, 125 Production planning, 4, 17,40,58, 98, 179 Project shop, 190 Quality, 1-3,5, 14,84,98, 144, 146, 155,165,168,169,179,194 Quality function deployment, 93, 95, 97 Requirement analysis, 92, 106 Requirements analysis, 86 Rule-based systems, 173 Self-aligning, 151, 155 Serviceability, 131 Similarity index, 107, 108, 132 Spoken requirements, 90, 91 223 Index Subtract and operate procedure (SOP), 147, 148 System-level specifications, 105-107, 129, 130, 132 Tearing,80 The house of quality, 93-96, 98 Tolerance, 165, 169, 171, 178, 179, 187 Tooling, 145, 166, 171, 176 Unexpected requirements, 90-92 Unspoken requirements, 90, 91 Variant design, 58, 169 Variant process planning, 86, 172 Z-axis assembly, 155 ... a new methodology for modular design The roadmap of this methodology is shown in the following figure: Design Goncept (Re)Formulation Design for Modularity (DFMo) -+ Design for Assembly (DFA)... Analysis Results for the Existing and the Proposed Design Using 161 DFMA Methodology Analysis Results for the Existing Design and Alternative Design 1162 Analysis Results for the Existing Design and... of a product The concept of modularity can provide the necessary foundation for organizations to design products that can respond rapidly to market needs and allow the changes in product design