Methods in product design : New strategies in reengineering

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Industrial Engineering

As industries adopt consumer-focused product development strategies, they should

offer broader product ranges in shorter design times and the processes that can

manufacture in arbitrary lot sizes. In addition, they would need to apply state-of￾the-art methods and tools to easily conduct early product design and development

trade-off analysis among competing objectives. Methods in Product Design: New

Strategies in Reengineering supplies insights into the methods and techniques that

enable implementing a consumer-focused product design philosophy by integrating

design and development capabilities with intelligent computer-based systems.

The book defines customer-focused design and discusses ways to assess changing

demands and sources, and delves into what is needed to successfully manufacture

goods in a demanding market. It reviews proven methods for assessing customer

need. Then, after showing how changing needs impact the reengineering of products,

it explains how change can be efficiently achieved. It details how IT advances and

technology support customer-focused product development, discusses cutting￾edge mass customization principles that maximize cost-effective production, and

illustrates how to implement effective predictive maintenance policies.

Features

• Demonstrates successful methods of sustainable design

• Examines how changing customer needs impact the reengineering of

products and how this is accomplished in a timely, efficient, and cost￾effective manner

• Details how advances in information systems and technology support

customer-focused product development

• Discusses cutting-edge mass customization principles to maximize

cost-effective production of new and reengineered goods

• Illustrates how to implement effective maintenance policies

Methods in Product Design: New Strategies in Reengineering provides

methods, state-of-the-art technologies, and new strategies for customer-focused

product design and development that allow organizations to quickly respond to the

demanding global marketplace.

ISBN: 978-1-4398-0832-0

9 781439 808320

90000

K10411

www.crcpress.com

Methods in

Product Design

New Strategies in Reengineering

Edited by Ali K. Kamrani • Maryam Azimi

Abdulrahman M. Al-Ahmari

Methods in Product Design Kamrani Azimi Al-Ahmari

K10411 cvr mech.indd 1 5/1/13 11:03 AM

Methods in

Product Design

New Strategies in Reengineering

Engineering and Management Innovation

Series Editors

Hamid R. Parsaei and Ali K. Kamrani

RECENTLY PUBLISHED

Methods in Product Design: New Strategies in Reengineering

Ali K. Kamrani, Maryam Azimi, and Abdulrahman M. Al-Ahmari

Systems Engineering Tools and Methods

Ali K. Kamrani and Maryam Azimi

Optimization in Medicine and Biology

Gino J. Lim and Eva K. Lee

Facility Logistics: Approaches and Solutions to

Next Generation Challenges

Maher Lahmar

Methods in

Product Design

New Strategies in Reengineering

Edited by

Ali K. Kamrani

Maryam Azimi

Abdulrahman M. Al-Ahmari

CRC Press

Taylor & Francis Group

6000 Broken Sound Parkway NW, Suite 300

Boca Raton, FL 33487-2742

© 2013 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

Version Date: 20130422

International Standard Book Number-13: 978-1-4398-0833-7 (eBook - PDF)

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© 2010 Taylor & Francis Group, LLC

To my aunt, Fakhrie

—Maryam Azimi

To our students

—Ali K. Kamrani

—Abdulrahman Al-Ahmari

vii

© 2010 Taylor & Francis Group, LLC

Contents

Preface............................................................................................................ix

Editor Bios .....................................................................................................xi

Contributors List..........................................................................................xiii

1 Sustainable Design.................................................................................1

PRATHEEP AYYAMPERUMAL, RANJIT VINU, IBRAHIM ZEID,

SAGAR KAMARTHI, AND TUCKER J. MARION

2 Cellular Manufacturing Systems..........................................................27

YAOWU ZHANG

3 An Overview of Computer-Aided Design.............................................53

ALI K. KAMRANI, PHD, PE

4 Selection of Parameters for CAD-VR Data Translation.......................75

ABDULAZIZ M. EL-TAMIMI, EMAD S. ABOUEL NASR,

AND MUSTUFA H. ABIDI

5 A Semi-Integration System of CAD and Inspection Planning of

Standard Manufactured Features.......................................................109

EMAD S. ABOUEL NASR, ABDULRAHMAN AL-AHMARI,

AND OSAMA ABDULHAMEED

6 Tumor Geometrical Deformation Modeling ......................................141

MARYAM AZIMI, ALI K. KAMRANI, AND EMAD SAMIR ABDELGHANY

7 Product Variety and Manufacturing Complexity ..............................165

ALI K. KAMRANI, PHD, PE

8 A Simulation-Based Methodology for Manufacturing Complexity

Analysis ..............................................................................................185

ALI K. KAMRANI, ARUN ADAT, AND MARYAM AZIMI

viii  ◾  Contents

© 2010 Taylor & Francis Group, LLC

9 Optimizing Supply Chain Network Design.......................................217

MOHAMMED HUSSEIN HASSAN AND

HAITHAM ABBAS AHMED MAHMOUD

10 Shutdown Maintenance Scope of Work Assessment Model

(SWAM): Model for Reducing Shutdown Maintenance Costs and

the Loss of Production at Continuous Process Industries..................249

ADEL AL-SHAYEA

11 Machine Failure Time Detection through Product Defects...............275

HAZEM J. SMADI

ix

© 2010 Taylor & Francis Group, LLC

Preface

The current marketplace is undergoing an accelerated pace of change that challenges

corporations to apply new techniques to respond rapidly to this ever-developing

environment. At the center of this change is a new generation of customers. As

the industry adopts a consumer focus in its product development strategy, it must

offer broader product ranges, shorter model lifetimes, and the required ability to

process products in less time and costs. A consumer-focused product design must

simultaneously meet the conflicting objectives of consumer and manufacturer. It is

based on premises that (a) changing customer requirements dictate varied product

features, (b) the structure of products and processes must be aligned with dynamic

product features, and (c) manufacturing productivity requires managing conflict￾ing objectives due to these structural alignments.

Organizations now fail or succeed based upon their ability to respond quickly to

changing customer demands and to utilize new technological innovations. In such

an environment, the advantage goes to the firm that can offer greater varieties of

new products with higher performance and more overall appeal. In order to compete

in this fast-paced global market, organizations need to produce products that can

be easily configured to offer distinctive capabilities compared to the competition.

Furthermore, organizations need to develop new methods and techniques to react

rapidly to required changes and to shorten the product development cycle, which

will enable them to gain more economic competitiveness. This edited book is a col￾lection of methods and state-of-the-art technologies in new strategies for customer￾focused product design and development.

Chapter 1 by Ayyamperumal et al. introduces the concepts of sustainable design,

how to quantify and calculate environmental impact metrics, and the commercially

available tools that help a design engineers to create sustainability designs. It also

provides the knowledge needed to use sustainability models and tools to explore

trade-offs between eco-friendliness and cost. As one of the most important applica￾tions of group technology in manufacturing, cellular manufacturing seeks to deliver

high productivity and flexibility for manufacturing different product varieties. Cell

formation of part families and machine cells is the critical element in designing an

efficient cellular manufacturing system. In Chapter 2, Zhang provides an advanced

x  ◾  Preface

© 2010 Taylor & Francis Group, LLC

survey of methods for CMS design. As an advanced tool, CAD has been used for

design of complex systems. Chapter 3 by Kamrani presents an overview discussion

on Computer-Aided Design (CAD) and feature representation methodologies. CAD

and the supporting methods are used to facilitate integrated engineering design pro￾cess. El-Tamimi et al. present a method for the parameter selection for CAD-VR

data translation. To select the appropriate set of parameters, Design of Experiments

(DOE) techniques are applied. Based on the statistical analysis of the selected param￾eters, a set of guidelines is developed for parameters selection during the conversion

process. This is presented in Chapter 4. In Chapter 5, Nasr et al. propose a proposed

framework of the integrated system for CAD and Computer-Aided Inspection (CAI).

CAIP is based on the Automatic Features Extraction Module (AFEM), Computer￾Aided Inspection Planning Module (CAIPM), and Coordinate Measuring Machine

Module (CMMM). A case study is also presented to demonstrate the capability of

the integrated system. Geometric modeling is used for design of complex shapes such

as tumors. Chapter 6 by Azimi et al. presents results of an ongoing research in the

development a three-dimensional (3D) model for tumor deformation predication

during radiation treatment. MATLAB® software and rapid prototyping technology

are used for modeling and validation of the predicated geometrical models. Product

variety and its impact on manufacturing complexity is presented in Chapter 7.

In this chapter, Kamrani provides an overview of different methods for measuring

the degree of variety and complexity as proposed by other researchers. Chapter 8

continues the discussion on variety and manufacturing complexity by providing a

new methodology. This chapter by Kamrani et al. presents a sample case study for

analyzing manufacturing complexity due to increased product variety. A cost model

is developed that captures the impact of increased inventory and the storage cost of

subassemblies due to increased product variants. This is accomplished by generating a

mixed model assembly sequence that aims to minimize the variation of subassembly

inventories of the production span. Hassan et al. focus on the logistics issues, includ￾ing the classification of the supply chain based on logistics networks. In Chapter 9,

mathematical modeling of a dynamic SCN is developed, including a proposed solu￾tion. A case study on dynamic supply chains from a ready-mixed concrete (RMC)

industry is presented. Chapters 10 and 11 are based on the maintenance planning.

Maintenance is defined as the combination of activities and actions that are required

to control and supervise a system to perform the intended functions. In Chapter 10,

Al-Shayea proposes alternative methods for reducing maintenance and cost due

to shut down and loss of productivity. In Chapter 11, Smadi develops a five-step

methodology for preventive maintenance based on product nonconformances and

quality. A case study is also presented in this chapter.

We would like to thank our authors and reviewers that participated in this

project. We would also like to thank Auerbach for publishing this edited book,

and express our appreciation for the opportunity given by our friend, the late

Ray O’Conner, for enabling us to fulfill our vision in implementing this project.

xi

© 2010 Taylor & Francis Group, LLC

Editor Bios

Ali K. Kamrani is an associate professor of industrial engineering at the University

of Houston, where he is founding director of the Design and Free Form Fabrication

Laboratory. He received his BS in electrical engineering in 1984, master’s in electrical

engineering in 1985, master’s in computer science and engineering mathematics in

1987, and PhD in industrial engineering in 1991, all from the University of Louisville,

Louisville, Kentucky. His research has been motivated by the fundamental applica￾tion of systems engineering and its application in advanced design and development

of complex systems.

Maryam Azimi is a software project manager at Lenovo Corporation. She received

her PhD in industrial engineering from the University of Houston in 2011. Her

research interests are systems engineering, data mining in health care, Lean Sigma

Six, and project management.

Abdulrahman Al-Ahmari is a professor of industrial engineering at King Saud

University, Saudi Arabia, where he serves as dean of the Advanced Manufacturing

Institute. He received his PhD (manufacturing systems engineering) in 1998 from

the University of Sheffield, UK. His research interests are in analysis and design of

manufacturing systems, computer integrated manufacturing (CIM), optimization

of manufacturing operations, applications of simulation optimization, FMS, DOE,

and cellular manufacturing systems.

xiii

© 2010 Taylor & Francis Group, LLC

Contributors List

Chapter 1

Pratheep Ayyamperumal

Mechanical Engineer

Boston, Massachusetts

Ranjit Vinu

Boston, Massachusetts

Ibrahim Zeid

Department of Mechanical and

Industrial Engineering

Northeastern University

Boston, Massachusetts

Sagar Kamarthi

Department of Mechanical and

Industrial Engineering

Northeastern University

Boston, Massachusetts

Tucker J. Marion

Entrepreneurship and Innovation Group

D’Amore–McKim School of Business

Northeastern University

Boston, Massachusetts

Chapter 2

Yaowu Zhang

Corporate R&D engineer

Powell Industries, Inc.

Houston, Texas

Chapter 3

Ali K. Kamrani

Industrial Engineering

University of Houston, Houston, Texas

Graduate Program Studies

Chapter 4

Mustufa H. Abidi

Industrial Engineering Department

College of Engineering

King Saud University,

Riyadh, Saudi Arabia

Abdulaziz M. El-Tamimi

Industrial Engineering Department

College of Engineering

King Saud University

Riyadh, Saudi Arabia

Emad S. Abouel Nasr

Industrial Engineering Department

College of Engineering

King Saud University

Riyadh, Saudi Arabia

and

Faculty of Engineering

Mechanical Engineering Department

Helwan University

Cairo, Egypt