Design syntheisis : Intergrated product and manufacturing system design

Integrated Product and

Manufacturing System Design

Graeme Britton

Seppo Torvinen

Design Synthesis:

ISBN-13: 978-1-4398-8164-4

9 781439 881644

9 0 0 0 0

K13843

Manufacturing and industrial EnginEEring

The biggest challenge in any marketplace is uncertainty. The major changes

taking place in world economies, politics, and demographics have raised

market uncertainty to its highest level in the past 50 years. However, with

new markets opening up in emerging and developing economies, the oppor￾tunities have never been better. To compete in this challenging atmosphere,

product design/redesign and manufacturing must be integrated to produce

better quality products faster and cheaper. Design Synthesis: Integrated

Product and Manufacturing System Design provides a conceptual frame￾work and methodologies to do just that.

The book explains how to integrate innovative product design with the design

of a batch manufacturing system. It covers the technical and social aspects

of integration, presents research and best practices, and embeds integration

within a framework of sustainable development. It covers the two methods

for achieving design synthesis: integration and harmonisation. Product, man￾ufacturing system, and social system architectures are integrated (united

or combined to form a whole that is greater than the sum of the parts). The

concurrent processes to design the architectures are harmonised (made

compatible or coincident with one another).

Wide in scope, the book supplies a multi-disciplinary perspective and an

extensive discussion on how to maintain integrity during the design process.

The authors present research and practices that are difficult or almost

impossible to find. They describe the different types of system lifecycles and

include guidelines on how to select the appropriate lifecycle for a specific

design situation.

Integrated Product and

Manufacturing System Design

Design Synthesis:

Britton

• Torvinen

K13843_Cover_mech.indd All Pages 9/16/13 9:23 AM

Integrated Product and

Manufacturing System Design

Design Synthesis:

CRC Press is an imprint of the

Taylor & Francis Group, an informa business

Boca Raton London New York

Integrated Product and

Manufacturing System Design

Graeme Britton

Seppo Torvinen

Design Synthesis:

CRC Press

Taylor & Francis Group

6000 Broken Sound Parkway NW, Suite 300

Boca Raton, FL 33487-2742

© 2014 by Taylor & Francis Group, LLC

CRC Press is an imprint of Taylor & Francis Group, an Informa business

No claim to original U.S. Government works

Printed on acid-free paper

Version Date: 20130628

International Standard Book Number-13: 978-1-4398-8164-4 (Hardback)

This book contains information obtained from authentic and highly regarded sources. Reasonable efforts

have been made to publish reliable data and information, but the author and publisher cannot assume

responsibility for the validity of all materials or the consequences of their use. The authors and publishers

have attempted to trace the copyright holders of all material reproduced in this publication and apologize to

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Library of Congress Cataloging‑in‑Publication Data

Britton, Graeme Arthur.

Design synthesis : integrated product and manufacturing system design / Graeme

Arthur Britton, Seppo Torvinen.

pages cm

Includes bibliographical references and index.

ISBN 978-1-4398-8164-4 (hardback)

1. Production engineering--Textbooks. 2. Product design--Textbooks. I. Torvinen,

Seppo J. II. Title. III. Title: Integrated product and manufacturing system design.

TS176.B75 2013

670--dc23 2013017993

Visit the Taylor & Francis Web site at

http://www.taylorandfrancis.com

and the CRC Press Web site at

http://www.crcpress.com

© 2008 Taylor & Francis Group, LLC v

Contents

List of Illustrations.................................................................................................xi

List of Tables ..........................................................................................................xv

Preface.................................................................................................................. xvii

Acknowledgements ............................................................................................ xix

The Authors ......................................................................................................... xxi

Section I Foundation

1. Introduction.....................................................................................................3

What This Book Is About................................................................................3

Who This Book Is For......................................................................................4

Improving Your Learning ..............................................................................5

About Concept Maps.......................................................................................6

Introduction to Global Manufacturing.........................................................8

Book Outline................................................................................................... 10

Exercises and Problems................................................................................. 13

References ....................................................................................................... 13

2. Designing System Architectures............................................................... 15

Introduction.................................................................................................... 15

Basic Concepts................................................................................................ 17

System Philosophy......................................................................................... 19

Describing Systems........................................................................................25

Describing Boundaries..................................................................................27

Describing Environments.............................................................................29

Designing System Architectures ................................................................. 31

Verifying System Architectures................................................................... 31

Exercises and Problems.................................................................................33

References .......................................................................................................34

3. Product Design.............................................................................................. 37

Introduction.................................................................................................... 37

Design as a Personal Activity ......................................................................39

Inspiration.................................................................................................. 41

Identification.............................................................................................. 41

Conceptualisation .....................................................................................42

Exploration/Refinement...........................................................................43

Definition/Modelling...............................................................................43

Communication.........................................................................................43

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© 2008 Taylor & Francis Group, LLC

Production..................................................................................................43

Design as a Phase...........................................................................................44

Types of Design Projects...............................................................................45

Design of Product Architectures .................................................................47

Design Standardisation.................................................................................49

Design and Manufacture..............................................................................50

Exercises and Problems.................................................................................54

References .......................................................................................................54

4. Manufacturing System Design..................................................................57

Introduction....................................................................................................57

Project Manufacturing ..................................................................................58

Jobbing Manufacturing................................................................................. 61

Batch Manufacturing..................................................................................... 61

Mass Manufacturing..................................................................................... 62

Part Manufacturing Cells: Group Technology ..........................................64

Between Cells ............................................................................................ 70

Within Cells ...............................................................................................71

Assembly and Test Cells ...............................................................................71

Cells............................................................................................................. 74

Stations ....................................................................................................... 76

Global Manufacturing................................................................................... 76

Exercises and Problems.................................................................................79

References .......................................................................................................79

Section II Context

Prologue to Section II.................................................................................... 81

References .......................................................................................................82

5. Ethics ...............................................................................................................83

What Is Morality?...........................................................................................83

Experimentalist Ethics ..................................................................................84

Ethical Aspects of Professional Life............................................................86

Wilful Blindness ............................................................................................89

Ethical Guidelines for the Professional ...................................................... 91

General Ethical Principles (What You Should Do)............................... 91

Moral Virtues (Who You Should Be)......................................................92

Ethics and Values in Business......................................................................93

Exercises and Problems.................................................................................95

References .......................................................................................................96

6. Aesthetic Context..........................................................................................99

Introduction....................................................................................................99

The Nature of Aesthetic Experience ......................................................... 100

Contents vii

© 2008 Taylor & Francis Group, LLC

Aesthetic Function....................................................................................... 103

Environmental Aesthetics .......................................................................... 106

Aesthetics of Product Design..................................................................... 107

Aesthetic Guidelines for Regenerative Development............................. 109

Exercises and Problems............................................................................... 110

References ..................................................................................................... 110

7. Social Context.............................................................................................. 111

An Ecological Perspective........................................................................... 111

Maladaptive Responses to Turbulence ..................................................... 113

Adaptive Responses to Turbulence ........................................................... 115

Social Guidelines for Regenerative Development................................... 117

Exercises and Problems............................................................................... 118

References ..................................................................................................... 118

8. Technological Context ............................................................................... 121

Innovation..................................................................................................... 121

Limits to Business Development ...............................................................125

Global Risk Management ........................................................................... 127

Technical Guidelines for Regenerative Development ............................ 128

Exercises and Problems............................................................................... 129

References ..................................................................................................... 129

9. Environmental Context ............................................................................. 131

Environmental Morality ............................................................................. 131

Limits to Growth.......................................................................................... 132

Nurturing the Environment....................................................................... 135

Environmental Guidelines for Regenerative Development................... 137

Exercises and Problems............................................................................... 138

References ..................................................................................................... 138

10. Economic and Political Context............................................................... 141

Introduction.................................................................................................. 141

Banking and Financial Markets ................................................................ 143

The Capitalist Economy.............................................................................. 147

Income Inequality........................................................................................ 151

Global Politics............................................................................................... 152

Guidelines for Regenerative Development .............................................. 154

Exercises and Problems............................................................................... 155

References ..................................................................................................... 155

Postscript to Section II................................................................................. 156

The Uniqueness of Moral, Aesthetic and Ecological Experiences ... 156

An Idealised Design for Regenerative Development......................... 157

Money and Banking........................................................................... 158

The Global Economy.......................................................................... 158

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© 2008 Taylor & Francis Group, LLC

Inequality ............................................................................................ 159

The Global Political System (Heinberg 2011, Stiglitz 2007) .......... 159

SMMCs................................................................................................. 160

References ..................................................................................................... 160

Section III Synthesis—Technologies

11. Life Cycle Analysis .................................................................................... 163

Introduction.................................................................................................. 163

Development Life Cycles for Industrial and Consumer Products ....... 166

Development Life Cycle for a Manufacturing System ........................... 169

Choosing a Life Cycle.................................................................................. 170

Intersecting Life Cycles............................................................................... 173

Specifying Life Cycles and Reviews ......................................................... 176

Using Life Cycles for Sustainability Studies............................................ 179

Exercises and Problems............................................................................... 180

References ..................................................................................................... 181

12. Product and Manufacturing System Architecture Integration......... 183

Introduction.................................................................................................. 183

Product Platforms ........................................................................................ 183

Modular Product Family Architectures ................................................... 186

Configuration ............................................................................................... 191

MPFA Generating Principles...................................................................... 192

The Ideal Manufacturing System .............................................................. 193

Illustrative Modular Design Example....................................................... 195

Design Integration Process......................................................................... 201

Analysis .................................................................................................... 201

Conceptual Product Design and Manufacturing Concept............... 201

Embodiment Design and Preliminary Manufacturing System

Design....................................................................................................... 202

Exercises and Problems............................................................................... 202

References .....................................................................................................203

13. Modular Configuration .............................................................................205

Configuration Matrices ...............................................................................205

Process for Creating Configuration Matrices ..........................................209

Configuration Maintenance ....................................................................... 211

Case Study: Ponsse ...................................................................................... 212

The Problem............................................................................................. 212

Configuration Matrices Solution........................................................... 217

Results....................................................................................................... 219

Exercises and Problems...............................................................................220

Reference .......................................................................................................220

Contents ix

© 2008 Taylor & Francis Group, LLC

Section IV Synthesis—People

14. The Socio-Technical Systems Approach................................................223

Introduction..................................................................................................223

Substantive Components .......................................................................223

Open System............................................................................................225

Two Subsystems: Technological and Social ........................................225

Work Roles ....................................................................................................226

Analysing the Technological System ........................................................230

Analysing the Social System ...................................................................... 232

Designing the Work Relationship Structure............................................ 232

Individual Level ......................................................................................234

Group Level .............................................................................................235

Managing the System-Environment Relationship.................................. 237

Boundary Management ......................................................................... 237

Open Systems Planning.........................................................................238

Implementing Socio-Technical Systems ...................................................238

Project Initiation and Approval ............................................................238

System Analysis ...................................................................................... 241

Design....................................................................................................... 241

Transition Planning ................................................................................ 241

Implementation and Evaluation ........................................................... 242

Exercises and Problems............................................................................... 242

References ..................................................................................................... 242

15. Organising People for Manufacturing................................................... 245

Introduction.................................................................................................. 245

Interactive Planning .................................................................................... 247

Mess Formulation ................................................................................... 247

Ends Planning ......................................................................................... 249

Means Planning ...................................................................................... 251

Resource Planning.................................................................................. 251

Implementation and Control of the Means Plan................................ 251

Modern Socio-Technical Work Group Design......................................... 252

Organisational Design (Structure) ....................................................... 252

Organisational Design (Vertical Teams)..............................................255

Organisation Design (Horizontal Teams)............................................258

Dealing with Product Demand Variability..............................................258

Exercises and Problems...............................................................................260

References .....................................................................................................260

16. Organising People for Design ................................................................. 261

Introduction.................................................................................................. 261

The Design Team ......................................................................................... 261

Chief Designer......................................................................................... 261

Chief Co-Designer................................................................................... 262

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© 2008 Taylor & Francis Group, LLC

Designer....................................................................................................263

Team Leader.............................................................................................263

Client.........................................................................................................263

Inventor.....................................................................................................264

Critic..........................................................................................................264

Librarian...................................................................................................265

Design Team Coordination and Integration............................................265

Product and Manufacturing Design Team Cross-Linking....................266

Team Management ......................................................................................268

Project Management.................................................................................... 269

Risk Management........................................................................................ 270

Organisational Integration.........................................................................272

Lightweight Team Structure..................................................................272

Heavyweight Team Structure ............................................................... 273

Autonomous Team Structure ................................................................ 273

Global Design Teams................................................................................... 274

Exercises and Problems............................................................................... 275

References ..................................................................................................... 275

17. Design Management..................................................................................277

Introduction..................................................................................................277

Socialisation.............................................................................................277

Externalisation......................................................................................... 278

Combination ............................................................................................ 279

Internalisation ......................................................................................... 279

Tacit Experience Management................................................................... 281

Critically Reflective Practice....................................................................... 282

Managing Concept Integrity......................................................................283

Interface Management............................................................................283

Design Integration Management..........................................................285

Design Scarce Resource Management ................................................. 287

Configuration Management.......................................................................288

Configuration Specification and Planning..........................................290

Configuration Change Management ................................................... 292

Technical Performance Tracking ............................................................... 292

Exercises and Problems............................................................................... 293

References ..................................................................................................... 293

Glossary............................................................................................................... 295

Appendix A: Reliability and Safety Methods .............................................305

Appendix B: Testing.......................................................................................... 311

Appendix C: Phase and Review Definitions for Product

Manufacturing System Intersecting Cycles......................... 315

Appendix D: Throughput Lead Time Analysis...........................................333

© 2008 Taylor & Francis Group, LLC xi

List of Illustrations

Figure 1.1 What this book is about....................................................................4

Figure 1.2 What is a concept map?....................................................................7

Figure 1.3 Concept map of the book............................................................... 11

Figure 2.1 Concept map of Chapter 2. ............................................................ 16

Figure 2.2 Illustration of centres and system of centres. .............................22

Figure 2.3 Illustration of unfolding. ............................................................... 24

Figure 2.4 General model of an open system. ...............................................25

Figure 2.5 Types of systems. ............................................................................27

Figure 2.6 Components of a connection.........................................................29

Figure 3.1 Concept map of Chapter 3. ............................................................38

Figure 3.2 Design as a personal activity.........................................................40

Figure 3.3 Engineer-to-order cycle.................................................................. 51

Figure 3.4 Design-to-order cycle. .................................................................... 52

Figure 3.5 Make-to-order cycle........................................................................ 52

Figure 3.6 Assemble-to-order cycle.................................................................53

Figure 3.7 Deliver-to-order cycle.....................................................................54

Figure 4.1 Types of manufacture.....................................................................58

Figure 4.2 Concept map of Chapter 4.............................................................59

Figure 4.3 Branched groups.............................................................................73

Figure 4.4 P-Q chart example........................................................................... 74

Figure 6.1 The nature of aesthetic experience. ............................................ 101

Figure 6.2 Range of aesthetic experiences. .................................................. 103

Figure 6.3 Emu in the sky............................................................................... 107

Figure 9.1 Rehabilitated industrial drain at Bishan Park, Singapore....... 138

Figure 10.1 How fractional reserve banking creates virtual money........ 144

Figure 11.1 Concept map for Chapter 11. ..................................................... 164

xii List of Illustrations

© 2008 Taylor & Francis Group, LLC

Figure 11.2 Generic life cycle of a system. ................................................... 165

Figure 11.3 Waterfall life cycle....................................................................... 167

Figure 11.4 Parallel life cycle.......................................................................... 167

Figure 11.5 Incremental life cycle.................................................................. 168

Figure 11.6 Iterative life cycle......................................................................... 168

Figure 11.7 Evolutionary life cycle. ............................................................... 169

Figure 11.8 Manufacturing system life cycle............................................... 170

Figure 11.9 Harmonising hardware and software cycles.......................... 174

Figure 11.10 Harmonising product and manufacturing system cycles. ..... 175

Figure 11.11 Product and manufacturing system intersecting cycles..... 175

Figure 12.1 Concept map for Chapter 12. .................................................... 184

Figure 12.2 Illustrative modular product family architecture.................. 186

Figure 12.3 Generic ways to assemble modules. ........................................ 191

Figure 12.4 MPFA generating principles...................................................... 192

Figure 12.5 Basic manufacturing unit. ......................................................... 193

Figure 12.6 Ideal manufacturing system—a network of BMUs. .............. 194

Figure 12.7 Formation of factories—some possibilities............................. 196

Figure 12.8 Possible table arrangements...................................................... 196

Figure 12.9 Two possible colour schemes. ................................................... 198

Figure 12.10 Straight fillers. ........................................................................... 199

Figure 12.11 Right-angle fillers...................................................................... 199

Figure 13.1 Function cross-linking through interaction matrices............ 210

Figure 13.2 Ponsse forestry machines. ......................................................... 213

Figure 13.3 Ergo 8w......................................................................................... 214

Figure 13.4 Ergo and Elk in action................................................................ 214

Figure 13.5 The family of harvester heads circa 2004. .............................. 215

Figure 13.6 Ponsse’s latest harvester heads H8 and H6 from the new

harvester head range. ................................................................. 215

Figure 13.7 Functional modular product structure.................................... 216

Figure 14.1 Concept map for Chapter 14...................................................... 224

List of Illustrations xiii

© 2008 Taylor & Francis Group, LLC

Figure 14.2 Definition of a work role. ...........................................................227

Figure 14.3 Concept of work relationship structure...................................229

Figure 14.4 Concept of unit operation. .........................................................230

Figure 14.5 Illustration of three connected unit operations...................... 231

Figure 14.6 Process for implementing socio-technical systems................ 239

Figure 14.7 Layout of a zinc die-casting department................................. 240

Figure 15.1 Concept map for Chapter 15...................................................... 246

Figure 15.2 Operations/support organisational structure. .......................255

Figure 15.3 Example organisational structure for a factory......................256

Figure 15.4 Boards for Supervisor A and the factory manager. ............... 257

Figure 15.5 Horizontal teams.........................................................................259

Figure 16.1 Concept map for Chapter 16...................................................... 262

Figure 16.2 Vertical integration of design teams. .......................................266

Figure 16.3 Horizontal coordination of design teams. .............................. 267

Figure 16.4 Product and manufacturing teams cross-linking.................. 267

Figure 17.1 Concept map for Chapter 17....................................................... 278

Figure 17.2 Externalisation through metaphor, analogy and model. ...... 279

Figure 17.3 N2 diagram format. .....................................................................284

Figure 17.4 Collaborative design using a master model. ...........................286

Figure 17.5 Evolution of design and design documentation.....................289

Figure A.1 Application of WCA. ...................................................................306

Figure A.2 Example of a sneak label.............................................................308

Figure D.1 Table construction........................................................................334

Figure D.2 Manufacturing product structure.............................................334

Figure D.3 Lead time Gantt chart. ................................................................335

Figure D.4 Order cycle for 7-week delivery expectation. ..........................335

Figure D.5 Order cycle for 5-week delivery expectation...........................336

Figure D.6 Minimum lead time for make-to-order.................................... 337