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You areto devisea solutionvia a productdesignto theproblemofbulk wastecreated
by plastic1,2 and3 litre milk bottles.Theideais to shredor granulate
thematerialso
thati1canbe lransponed
in a morccompactstateandavailablefor easier
rcprccesslng.
Theproductshouldfit thescenarioofajunior schoolthatis promotingrecycling,
on cunentlyavailablesolutions,
v/1. Undertakeproductandproccssresearch
producea briefreportandlist ofthe presenlsolutionscapability,costand
supplysource.
From
this rccommend
thebestexistingsolutionwith costs.(10%)
/
y'2. Analysethecomponent
partsandproducean analysisandlist ofthe key parts
you wouldneedin designingyourown machine.
Compilea panslist with supplierdetailsfor themaincomponents
ofyour
(15%)
desisn.
/
ur. Createa 3D CAD modelof yoursolutionwith a pansIist,someitemsmaybe
representational.
butthc uscofsupplierbasedCAI) modclswouldbe an
advantage.
Designa safeandsecuresurroundIbr yourmachine.(55%)
4. Explainhow yourmachincwill t'unctionandthekey rcasons
for this
(10%)
methodology.
5, Writea briefreporton theroleofPDM andhow i1couldcnhance
thedesign
proccssyou haveundertaken.
(10%)
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Figure
I isol,r
the tsest
'"',1*Tffi:ll'fi""j:il"ii
FfaCtiCgS
practices
engineering
on concurent
Lgaqln
Of
g
Conrpanies
phsesoi product
development.
*J:JJJ:*;il:J:l#"*fi;
thatoccwbe$veen
orphysicalproducts
The btueprht for a winning design thoseactivitiesThedomahofvirtual
rnayseemobvious:Assmbletheplay-product developmentor \?D (the
iswheredigitaldefsdtions
e!s;agreeoDthepoduct's capabilities shadedbox)
io win customeracceptafte;focuson of a productand its ploductionand
processes
arcdeveloped
productionandmairtenance maintenance
schedule,
Although the term'toncurnt
doit ltith CAD/CAM.Howcosts:and
engineering"givestheimpressionthat
ever,it is far ftom thatsimple.
In this section,we reflecton ihe everyfhi4 happensat the sarnetime '
key findiDgsftom theEeJtPrdcr'ceJ during productdevelopmentthis is
n C4rlC4,41andillusu'ateEDS' ap- not alwaysthecase.
proschtoimplernentingbestpractices. Sornetaskswithina development
phasedo occu in pa$Iel, for example.produclionplanningand!oo1-
. - --.-
'
E Product
DeVeiOpfnent
.PfOOeSS OVefVieW
ingdevelopmenr
duringrtreproducphase,
tion development
MoreenF
phasis
isplaced
ontheearlyparticipo--
Berorewederveinrotheimprementa*#TH:X|j:*T"fft::
cuatoMER,a tionissues,let'sconsidertheqr:estioo:ftont phases:Foduct conceptor de[vTEiE8T8...
Flgure
1.
ProductDevelopment
ProcessModel
l/PD
Virtual ProductDevlobrnenia I
The
validation.
velopment
andconcept
to
aequfemenas
useof goodcustomer
focustheirworkis mandatory'
Wlat doeshappenwith concurrcnt engineedngis betteraud faster
decision-makiDg
througtlthecommurucationand trainingof teammembelsandtheirfocusonmaking"witrningdecisions."
This is, at thecore,a
processfor shadngtechricllclowledgeamongthemembenof the developmentteam.Teaft membe$exchansewhatthevknowabouttheca_
pabilitiesofhtemalfacoryprocesses,
supplier
makrialsbehrvequiprneDr.
ior or assemblviechnioue:i.
The end
resuls arecomDressed
cvclesfor the
rnainacaivities,
as show! in the diagfin,andhigherqualitydefinitionsof
the Droductand ks Dmduction,nd
andtechnology.
Theconcepts
ofa viitual product
and\?D or VirtualProductDevelop
mntprovidesolutionsto fastto market, productquality and production
Understanding
theprocesses
usedby
leam
a
tluoughthevadousphases
of a
prcductdevelopment
projectprovides
the basisfor improvements
in cycle
I Focus:
time.Concurentengineeringis
ddven
by decision-making
amongtheteam's
Organizations
memben.
Unde$fanding
how good
and Processes
decisionsale madeby the tearnCentralto any discussionof vifiual regardingform,function,naterialsor
productsaadtheconcurrent
engineer- fiDishof apartorasserDbly-isesseDingEamsthatdevelopthemalepeoPle
tial to improvingthe productivityof
andhowtheyworklogedEr'
Through_ teamsandthe enterprise.
out tbjs section,you will seethe emTrainingin bestpractices
andteam
phasiso[how Peoplework abovethe protocolsstimulatesthe gro$th ,nd
tecbnologiestley use This is as it
accept4nce
of reamsin a productdeshouldbe.PeterMadcs
foundmughly velopmentproject.Teambuildingis
equal emphasison peopleard PIo- essential
to creatingateam-based
culsupport
processes.
Today'sview of Droductdevel_ cessescomparedtotechnologywithinture, Company mamgementmust
adopta new leadership
role to mate
opEerthigl ightstleinterdependence thecornpanieshestudied'
pe$nanent
thecultural
charyes
if funcamongthe tfueekey elemenls!o!cd
tionalbafiersbetween
teammembers
earlier:people(andcultule),processes
arcto beremoved.
Wepromotethe
Demingprinciple
of "plan{o-check-act"as a key !o
helpieamswork togther,betterard
faster.Continuousimprovemensof
theirwo* flow ard how theyapply
tecbnologyarethebasesfor competi!ivegainsin cycletirnea.1dthequaliry
ofthedesigns,
tieproductionprocesses
andtepairor maintenance
Focedures
for theproductsunderdevelopment.
POINTS OF INTEFEST
5 Focus:Enabling
Techno!ogies
Withouteffectiveuseoftechflology,it
wou.ldbeimpossibleto crealemanyof
theploductsavailabletoday.
For instance,new pagersfrom
Motorolacouldnotbeproducedwithout aulomatedassemblylines. The
cyclesevideDtin
shon developmeDt
this organizationarcenabledby srategicuseofECAD/ECAE andCAD/
intun, are
CAM tEc,bn-o,logi9r,
Th.e-sg,
suppgrtgd!y focusedB&D inqgits
integatedcirowncoletechnologies:
processing.
cuits andsignal
Morcover,with the help of technology,Apple ComputersimultaleouslyirEoducedsi1newMacinlosh
computers,all aheadof schedule,includirg the successfi.PowerBook.
in
EDs playeda role h this success,
additionto Unigraphicsbei.ogtheprifiIary CAD/CAM tool. Our imaging,
dalamanagement
andnetwork technologiesallowedApple to distribute
up-to-the-minuteproduct documentationwoildwideto makeit happen.
Technologyfor
lndividuals
Irdividualmembers
of pmductdevelperfornfwotasksrthose
opmen!teara
thatarc specficto their pofessional
discipline,suchas a tool designeror
andthosetldt arepartof
saessanalyst,
the teafl's worlq suchas desigr reviewsor Eade-offstudies.
Sharodviow
processes
of theteamarldtheen,
terprise
. build the techdcal and Fojecr
ski s of d]eiDdividual
.be available,on demard, anywheretheildividual wo.ks
prcvidedetails
Thefollowingsections
on how the individual'swo*ing
environmentis establishedand
supported.
Holt Vlew
Flgure2. CommunicailonsNetworkltlodel
The working envfonment ptovidedfor anindividualmustsatisfJthe
followhg criteria:
. containallthetoolsanddataneeded
to conducttechnicalandadminis. minimizenon-value-added
tasks,
suchasdataconve$ionsor tlans-
Communication
is enlancedin a
numbei of ways,the most obvious
being fhe useof nework to pemit
'\/irtual collocation"of tearn members.Sharingcomputingsessions,
or
computetconferencing,
permitsteam
membersto shareUnigraphicssessionsfor interactive
designreviewsor
11
for day{o-dayevaluations
of prcduct
designsor manufacturing
opemtions.
Severalconferencingtools are
availabletoday.While someareploprietaryto a specificapplicationor
softwarevendor,thetoolswe recommendandimplementto suppo.t"virtual rneetings"tbrcughconfercncing
arebasedon two basicmles:(1) they
shouldbe buried in the computing
ini:asftcturearrd(2)d1eyshouldwork
thmughextensions!o existingopen
Team Synchronization
Through Technology
Flgure3.
Model
Tean/Sync
Standards
ar.eessential
for theconnecdecidingform andfunctionwith
tivity to integratethe businessfuncan emphasison doing what's
tionsthatdeate,useordisfibutethese
bestfor thecustomernotwhaCs
data Theyincludebothstandards
for
convenientfor enginering."
thedataandstandards
for thetransac2.) ''Theuseof integatedsolid
tionsbehreenbusinessfunctions.
and sudacemodelhg to allow
hoduct development
teamscrebettercommurdcations
between
atedataolvarioustJ.pes,
for example,
functions."
CAD/CAM models;NC, CMM and
3.) "CAD/CAM for nt shape
rcbot prcgrams;bills of material;
marufacturingprocesses."
schedules;
andtech:oicaldocuments.
Let'sexamineeachmorecloseiy,
Foranyolganizationto integmtesev- bearingh mird tlnr theyaddrcssthe
eral or all businessfunctionsto de- issuesof !ople, thei pmcesses
and
velopandFoducea product,it must thetechlologiestheyuse,
firstdetermine
howinformationisrep-
icCiirirdirg,salis:iveryondith6 i6 - rcsented-forexample,
paf6, iira!:
in drevaluechaia.
netictape,bits and b]1es-rnd then
Let's examjnethe enterpdse's determinehow it is coFmudcatdto
tecbnologneedsfrom thevierpoint
ohers,This is a major task.Simply
of datathat are distibuted ftom the installinga Detworkandurgingengito o&er !e!fs ard suppliers
to shareCA_Ddata
Foductdevelopmeltprocegs
poifis in the enfelprise.Key comec- anda bill of mablial isn't enough.
tioff forwell-executedresponsivepro- Thebenefitsof integrationat he
ductior".aldlogistics.are
these:
e erpriselevelboildownio improved
. rnatlriat plalrlilg dataOiIs of
rcsponsivenessalld accountability
matelialandproductstuctures)
amongthebusiness
functions,which
. procurement
data(supplierceniarefocusedon gettinga newpmduct
fication requircments,puchase
into tIrc handsof the end user.This
odeNforprolotypes,
andsofolth)
tIanslates!o eadjerproductionand
. costandscheduledataGi-direcrcalizationof custometrevenues!o
tionalflow)
recoupthealevelopment
investrnent.
. trchdcalpublications
(operations
andrepal manuals,sewicebulleI Form and
tins andothers)
.Foduction pla$ing dara(fabriFunction: Creating
cation and assemblyplans,ina Winning Design
procedures,
specdon
test plans,
ConsultantPeterMarks sunmedup
packagingplans)
pmcticesfor product
thebest-in-class
. regulatorydata(producttestdata,
form and function designwith rhe
standarddrawilgs)
followingthrcepoints:
. elecEonicmail
l.) "A disciplinedprocssfor
Flgure4.
Disciplined Processes
The first factoris understanding
dle
workto beperformedanddeveloping
disciplinewithi! rhe organizarion's
day-to-dayactivitiesto accomplish
it.
Successfi
]l teaftingtoaccomplishcoDcunent engineedngdoesn'toccur
withoutsomereengineering
of developmentactivitiesto stea.'dinetask-s
and measureresults.A fu1l prcduct
life cycleview is neededto focusthe
reengineering
to ddvethe benefitsto
theproductandcustomers.
Thismeans
'toncept to production,""cradle to
g?ve," 'tustomer to cashcycle," or
whateveryou chooseto call it.
For efficiency, some staddards
mustbe in placewithin the ploduct
development
process!o makeit easier
for teammembefl !o wo* togefier
and communicatetheir collective
decisionsabout product form aDd
function.
of techniques
' Standardization
project
particularly
withh a
a large
one,ruDthegamutfromleamneetirE
Fotocol to tle modelingandshadng
of CAD/CAM Foduct desig! data.
Realistically,no organizationwill arrive at a single,univeFally adopted
processfor productdevelopment.
ways be good
reasons!o adapt
d eve lo p m e n t
processes
to suP
pon specialcircumstances.
But
a prcductdevelopment team
must have the
basic skills and
disciplineto focus on valueaddedwo* and
to usethetoolsal
handmosteffectively to achieve
p er fotm an ce ,
qualiry,costandscheduletargets.
Two techniqueswe rccommend
Io oul clientsdlathelpstandardize
the
non-CAD/CAMaspects
of thedevel(l)
opmertcycleare qualirytunction
deployment(QFD) and (2) Focess
modelingof which severaltypesare
applicable.
techQFDprovidesan ana.lysis
niquedu! pemits the team!o effectively captug, assessand use customer preferenceard competitive
tueasules
dmughoutitsdecision-makprocesses.
ing
hocess reengineering
depends
onalanguage!o exprcsscutlent stateandfutureprocesses,
generalizedas the AS-IS and TO-BE (o!
"COULD-BE) srates,Simple data
flow diagraE$work well. More sophisricatedmodeling tools such as
IDEF or STRADISareuscdby systemslnalystr.A process
management
iool
prograrEmed
softwarE canbe
to
monitorand-{egulate
teamfunctions
CAD/CAM as a Language
The secondkey factorcentenon the
useof CAD/CAMdataasacornmunicationmediumwithin a prcductdevelopmeDtteam,to andftom suppte$, and thrcughoutt-hercst of the
enterprise.Dataana.lysis
andmodeling areneededto definewhatdataare
critica-lto productdefilition. Again,
thenotionof thefulI productlife cycle
figures prominently.Figue 5 maps
the integrationof Foject direction,
work flows, \?D technologiesand
dataagainstthefour highlevel stages
of aprcductlife cycld concept,development,productionandsupport.
The informationthatcanbe createdandslfied arnongteammemben
6nd thrcughoutthe enterprise-bodl
real anq vifiu9l-jl very large,and
successbjlges on the way the data
CAlo. Conpuer-Ald6d
l.dBt alD.6lon
CAo = Compul.r.ABld
cAE Comput9.Aldd
CAM Compdgr-Aided
CAPFr complt6FAided
Prcc6$ PLannlno
ClM. C@pu6r Int6sr;ied
MRP= Maiedal of Manuta.lu ns
Fosouc6 PlMning
Virtual ProductDeveloDmentI 15
elements
andconfolling archiEcnrre
are established
and implemented.
Moving into more robust ussfor
CAD/C4M technologyis just partof
the solutionto inter- and intra-team
communications,
.^n-r
-!-
scopeof inJonnation
that is ahvaysqeated
duringpoduct developmentbecomesevidentwhenyou exaninetherequircments
of
lhe full producr life
cycle, Regardlessof
"concurency," the
gm\rthofdatafollowsa
sedalprocess:product
Flgur6. MasterModel6nd BTPS
requirementsgenerate
prelirninarydesignlayoutsandanaly- scriptionof all infolmationnededto
ses;lay-olltsgeoeratedefail designs; buildandmaintainoneend-itempart,
detaileddesigr,sgenerateprcduction assemblyor finished prcduct The
plansandanalysismodelslandsoon. mastrermodel provides the digital
A high degreeof goduct design mockups,detailedlayout6,assembly
datarcuseis ruandatory
to achievethe modelsandbill of material,andpre
kindsof designcycle time and sup- vides the foundationfor all CAD/
plier lead-timereductionsneededfor
CAtr4/CAEdataexchangewirhin a
today'sshorlerdevelopmentproject teamalldto tlle restof theeoterprise.
cycles.Datastandardization
Think of the BTP as a Fojecr
andhow
it is createdand managedwithin a folder containingCAD/CAM models, Focessplans,inspectionplans,
concudedt
englneeriigteampays
divibill-of-materialdata,analysismodels
dendstbmughoutthe product'sIife
cycle-not just duringdevelopment. andresults,andcostmodels-generSupplie$,parftenandmanufacture$ ally, whateveryou needto releasea
sharedleinifonnation
andbenefihof a designfor in-housepfoducdon.
consistent,completeand robustdeThe BTP hasa companion,the
scriptionof tie productusingCAD/ buy'to-package.
As its narneimplies,
the buy{o-packageis usedfor purCAM tecnnology.
chasedparts,toolsor assemblies.
LTplemenrarion
of lhesetechrwo things:[l) comniquesrequires
[itment to widespreadadoptronof a
singleCAD/CAM slandcrdand lcommiEnentto standlrdsfor model_
solids
feaure-based
ing lechnjques.
manage
nol 2-D v/ireframe...dala
information
exchanges
of
ment...and
amongteammemb$,to and ftom
partdercompanies
andwith suppliers
Thesearc no! optional Pars of the
is impaircd
soludon.CornrnuDjcation
eachspeaktheirown
if teammembers
language.
whrt arethebenefiEwhenimplementedtogether?Tbe mastermodel
putstle disciplirc in dreProductdesign and analysisprocessto consistendydescribeaproducl andtheBTP
process
derBndsthatall mem'
release
teamcon'
cross-functional
be$ ofthe
tibute andconcuron lhe {inal outpul
_- _ - _beforgasuppliet ol in-housemarlu_ facn:ringbeginsprocessinga work
order.Agrin. communicationamong
teammembersandacrosstheorgaoi'
zxdon is lhe objecdve CAD/CAM
becomes(parto0 thelanguage.
partmanufacnt. PanmdA$ombLV
ing. Standards
Models
for modeling
cutte$, fil1etsor
.Analrsis
Fesulls
dndModeLs
md Maklns
Packasiis
'Finishins,
blends
are
.Manuiidufins
rsmsnb
Pro(esSequ
neededfor costeffective CAD/
Buy-To"Package
Figure7. Bulld-To-Package,
CAM usefolnet
shapedesigns.
prctoD?ing-to createroughPattems, Fullyconstrained
3-Dpanmetricmodfor example-thepafi modelmustbe elirg systensdo not providetheabilaccuratein every detail, and the ity !o tweak geometryto meet the
modelingprocessesassociatedwith goduct's requirementswithout unils creatronandmodificationmustbe duesEessonthemodelingsystemand
flexible,
enduser.
that'ivork
Themodelingprocesses
The only completesolutionis a
dllo?es
for 2-D layoutswili not supportthe modelingsystemtllatprovides
feaof
3-D
net
sirape
wirefrarne
and
solid,
oftaditional
hig! fidelity needs
! Meeting Fast
to Market and
Cost Objectives
Time-based
competitionis,by now,a
familiar concept.Removingtimedelaysarldcostsfromcriticalpathactivities is the basisfor continuousimProdlct
Fovementin manufactudng.
developmentis no differenl We'll
look closer at the opportunitiesfor
timesavirgsreportedin theBerlPrdcticesin CAD/CAMstndy.Tllenwe')l
address
thebiggestbottleneckofallthefansition to production.
Partnerand Supplir
lntegration
dictaleindividuand\,vorkprocesses
alizedtrainingturdsupportprograrls.
Evenif thetechnologyis tutorial,
the applicationof tle techmlogyro
tean's protheproductdevelopment
cesses
is notself{eaching.Tlainingin
the properandstandardized
or sanctionedtecbniques
of a sofMaretoolto
help createa Foduct designor a descdptionof a produclionprocessis
essential.
lt mustbeplarneddghtalong
with techrclogyselectiondurirg probeforethetecbnolcessreengineeriDg
is
implemented.
ogy
then]
systemsandfully paramelerize
for rapid edililg into new featurebasedsolidmodeldesig . This flexibility protectsour custonel'sinvestmentin legacydatawhile openingit
up to newuses,AIld that savestime
andmoneyin criticalpatl taskssuch
astie redesigrof existingtoolingor
machinesto prcducea new or modrfredpartor assembly.
nce
Perforrna
toolsin place,
Puttingstate-of-the-art
or Feparinglegacydatafor reuse,is
only half dle batde.The productdeteall needsto leamhowto
velopment
effectivelyusethem,whichcatrbe atr
lt is amazing
evenbiggercha.llenge.
howlitdeattentionis given!o Eaining
How CAD/CAM
Fastsr
Communicatgs
As we'vc discussedin detail in the
pEcedingsection,CAD/CAM technologyprovidesanothernedium for
witlin adevelopment
communication
teamor to the rest of the enterprise.
Thatwas'ddhcussionofscience-ft
. .math
of.the
descripdon
ofa.product.
prosrams."
support
nainins
and
\alueofcAD/cAMrechnorogy.
Hisry realisric
imases
orprodorindividualparts
uc6,subassemblies
:*tf:':trtrffi,:ffi;i
waretooi.Thereaesevemlhomwhrch
a$dongoingsuppofiiltheuseofeven to choose;however,is this of value
simpledesi8ltoolsor of technologies otherthaDfor "Eetty picflres"?
teams
The answe! is, 'Yes, withoul
within aproductdevelopme$t
question."
workdayprocesses
But laitring cannotbe takenat
Among the earliestpioneefi in
Thettpe ofEainingusedat
theuseofCAD/CAMald solidsmodfacevalue.
manufacturer
rconecompanywillnotdeliverthesame elilg, an aerospace
quoted
portedto us thatsupplierc
15
rcsultsat another.Comparycultue
Virtual ProductDevelopmenlE'19
productdesignerhasbeenovercome
throughthe converyence
of 3-D art
andCADsoftwaresysterns.
But the.e
isoneconditiontoachievetimereduction \{ithin the developmeot
process
whenusinga CA.IDsystem:Thedafa
rt qeatesmustbeusableby dreCAD/
CAM systemasthebasisforpackaging desip andtoolhg.
Iaading CAID systemssupporr
thisrequircment.
PurelyCAD,based,
"concepualdesign" systemsrcally
aren'twhattlrcyproclaim!o be.Only
fteeform,3-D surfacingCAID systemsshouldbereJerred
to asconcep-
tual desigrsystems.
Rapidprotorrping
(Rp)tecbnolo_
gies*and therearemany,eachwith a
different strength_prcvialearother
tangeofoptions.Themostobviousis
themanufacnne
of physicalpa..tsfor
.louch"evaluations
ofform orfit wifi
otherparts.
SomeRp systemscreatelowstrengthplasticparts,or waxpattems,
to allow prototl?esto be castfiom
metals.New systems
dueshortlywill
permitlow-cost,deskop production
of molds.
__ . T9 !"1p..9irr cusromersdecide
whichRPsystemmeetstheirappiicationlequtments,we provideeducationa.lconsultingandsemina$featuringin-house
EDSandGeneralMotors
\Bxpedence
in all cofijrnerciallyavailablesystems.
As \re reviewedin fie
previoussection,thisis dredomainof
'het shape"partdevelopment.
All the
'
- modelingac.u.racy
andflexibility issuesdiscussed
tlere alsoapplyto Rp.
Within machjhetole&nce,,,youget
out whatyouput in.,'
Transition to Production
Did youeverEiponthetbrestrcldof a
cloorway,evenafteryou knewit was
therc?Manufacturers
experiencethis
asweil. It's lonwn as "fallitg down
duringthe transition"to the production of a new or modified product.
This is oneof thetime andcosttraps
not takense.iouslyenoughby some
nlmlufactule$.
Theacidtestfor a rnanufactursr
of how effectivea concurentengi-
needrgprocessreally wasoccun as
to full-rateprotheproductis released
duction.IJ productsare orderedlrto
Foduction\tith known designProblems, or if productionand maintehavenot beenvalinalce prccesses
isn't
dated,thenFoduct development
finished. All product deveiopmeDt
teameffortsshouldbefocusedon the
evenflEltransitionof theirworkintoa
productthat is producedwithoutftrltherchanges.
ProductprotoqTesandtestcycles
arcstill neededwith concurrenten81neeringard CAD/CAM technologY,
Tecbnologyenablersshouldeasethis
validationsiep.Simulationof Product
function can be performeddrough
alr,lydigitd mockupsandkinematics
sis.Simulationof assembly,ilsPeccar be
don andfabricationprocesses
verificatio4
using
NC
accomplished
inspertion,factoryopcrationsandro_
boticsritnulationsoftiwarer', - - Thel(eysto success
ir theransi_
(1)
the
tion are to validsle desigrand
beforeProloq?es
itsrelatedprocesses
arcbuilt, anddrco(2) to testandcorrect tbe prolotypesbefore releasilg
theproductto thefactory.
mustbeprotectedfrom "ercsion"due
downsizingorcalamity,
toretircments,
omcasualsnooping,
ard safeguardedft
unlawful disclosure or outright
esPronage.
tends
Withoutit, theorganizalion
to forgetornotre-leamwhatit already
knows,in the larger sense,aboutits
Withit,thecompetitioncould
business.
arebasing
In somecases,orrrcustomers
wholefamiliesof newp(oductson design
knowledgeretainedfor useil KBE sysvia Unigraphics
temsandarticulated
applications.
modelsandassociated
Engineering
KBEDesignBy Fiule3:An
ApproachThatWorks
Morethana few of oul cnstome$are
engineering
usi$g hrowledge-based
(KBE) toolssuchas ICAD to create
"designby nies" andexpertsystems
They
for trueengineeirgautomation.
areexaminingthe expertloowledge
aireadyin placein theirorganizations
and addingempidcallclowledgeio
the next generationof product
developmentsupportsystemsusng
formalized KBE methods.Shofier
designcycletimeson mission-critical
elements
oftheproductarcthebenefit.
Other customerspre-engioeef
completgfanilies of endproductsus_
ing IGE toolsandUnigraphicsand
VirtualProduct Developmentf, 21
thenoeate"smaflcatalogues"
forfi eld
engineers
to usewith thebcustomers
to createhighlycustomized
products.
Thisallowsthefieldengineer
to qeate
a quotefor a customFoduct, with
high confidence
that the engineering
behhd it works, and then coDflrm
pdceard deliverywirh thehomeoffice within hoursof therequeslThe
quoteprocessandthe basicdesigns
arelinkedby thesamefurctionaldesigll,assembly
aDdconfiguationrules,
a real Foductiviry breaktlroughfor
"engineered
sales"scenados.
KBE softwaletools accomplish
rw-oobjecriveswhen uied welt: (1)
The lhowlcdge captureprocessfocuseson competitiveedgeor highdsk designissuel,and(2) theknowledgerEuseprocessshorienscritical
pothdesigntaslathrcug} design-byrulesapplicalions.lnsomecases,our
customers
are basingwholefamilies
products
ofnew
o! designknowledg
retainedfor usein KBE systemsand
articulatedviaUnigraphics
modelsand
associated
apptcations.We call this
'lenerativemodelitg," Ou! customerscallit "missioncritical."
Wlut kild of designtasks are
candidates
forKBE?Usageisdive$e.
Applicationsrud the gamutof autG
matedgeomefydeationfor specific
detailsof a paft to the designand
documeDtation
of completeproduct
familieswell beyond"just pafis."
KBEtoolsareidealfor repeatable
designprocsses
wherethegoveming
decisionyariablesatemorecomplex
dnn packagingor shapedefinition,
thercbymakingtheoutcomeverydif,
feEntftom caseto case.
22ElVirtualPyoductDevetoprnent
rcs,iterative"design-analysis-rede_
sigt" loopscan be shonenedif not
entirclyeliminated.
Parametricdesignsyste&sdon,t
excel at "family of products"sihrationsfor thefollowingason:To cleate a basemodel,it would haveto
contail everypossiblegeome!.icfeatl]le and .eiatedconstraint,thereby
makingit too cosdyto maintainover
the life of the productfamily. The
complexityand editingcostswouid
kiu it.
program.Deciwithinauserlanglage
We rccommendLBE tools for
govems
which apdesigntask The sion complexiry
complex le-based
ktowledgebasesale easlerto maul- proactrrc use.
tainoverthelife oftheproductandcan
be reusedfor otheiproductfamilies
Thecostof startup,includingtraimg
in KBE methodsandknowledgebase
mayappearhigher,but
maintenance,
froEItleassembled
thepaybackcomes
knowledgeaIId accessafforded the
rest of the organizationon following
Projects.
Lastly,KBE toolsmakeexcelle
if setupas"designadviso$."
teachers
Thisis onewaythattheknowledgeof
enginee$can be
older,exprieDced
wi*l theyounger
preserved
andsharEd
membersof tie productdevelopment
team,
OtherApproaches
suchas
Cana CADuserlanguage,
(GRaphics
InterCRIP
Unigraphics
I i!uage),Peractine.hogiimfriry
Yes,butfor
functiotr?
formthesame
simplerdesig!t!sl(s.Forexarnple,the
writer sirrtedhis CAD/CAM career
a6 a desigpengineer,$iting FORTRANandGRIProutircsto automate
repetitive designprocesses-which
werebasedonbestengileelhg practicesfor tool andfDduredesignfor our
application.
ButthereisaFacticallimit to this
approach.Programmalntenance
of a lqlowlcatchesup to theexpense
edgebasewhen the designproblem
becomesmodelatelycompiex.Thefe
is nohardandfastguideoDhowmany
rules can be efficiently contahed
funclionaliryneededwithin thePDM
solution.
to PDM
Selectionofan approach
is generallydrivenby thefollowilg:
. projectsizeandduntion
projectwith a
'A l0-person,firlly collocated
two-weekdeadlinelooksvastlyffierent in
thana multi-year
termsof PDM requirements
pro$amwith teamsin five locadevelopment
tions,100certifiedsuppliersandtbreeglobally
partners."
manufacturing
dispersed
I Data
Managernent:
OneSizeDoes
Not Fit All .
Virtual ProductDevelopmentI 23
PDM soluriodslpssesdisfibutionof
informationandreliability of all conA lGperson,fully collocatedFoject
nectionsbetween
sitesandtearDs,
The
withatwo-weekdeadlirclooksvasdy dwationof thedevelopment
prcgam
differentin tems of PDM rcquirc- demands
stabilityandlongevityof all
mentsthana multi-yerdevelopment areasof drcPDM solutionidatabase
Fogramwith teaDtsin five locatioDs, eDgircs,sedetsandnetworks.
100 certifiedsuppliersand rhree
globally dispersedmaDufactudng
pafiErs.
Teamand Enterprise
ProcessRgquiroments
Ihe srnallprojectteamrlay only
needsuppoltfortop{owrdesi$and
As shownin Figureg, tle high_level
CAD/CAM datarelease.Its collabo- view of a pDM
solutioDvariesderadveworking.elvironmenr
is largdy
pendingupon your pe$peative.A
provKeoDycollocabonlrcgadlessof
aam,comprised
ofitrdividuals,needs
the life expeclancyof the producl
noioilymaccesdariandmanipulate
vely simPledata marugementwill
desi$r andproductstrdcturebutalso
slunce.
0ccooadinate
the statusof theirwork
Thelargeprogram,on he other with others,
usingdesi$ andprocess
.
ha.ud,alsodcpendso! PDM !o plodata.
vide-paJtof the comnunicationard
Theeotcl'prisepDMvjew,which
synchrodzationDeldedfor success. is
similarto the company_wide
view
The arshitectulcof the lalgc team's
of atr MRp o! accountilg system,
Proiect Size and Duration
soresses
overallcoordinationanddis_
h'ibutionof inforoation. This is also
whereloDglife histodcal design
recordslogicallyreside.
Produqt Characteristics:
Complexity and Lifa
Expectanay
Early iqplemenron of 3-D CAD/
CAM in aercspace
took two different
approaches
!omodelirganddatarlanagemcnt.
Oneschoolof thoughtemll_
latcd&etaditionalengineering
d!awingprdcticeofLssemblies
andpartson
the samedmix;iiig;This co;plcared
the relcasprocessto maiufacftrlirlg
ir dunyirlstlnces.Theotherapproach
createdwhat are known a6 ..monodetail"models,whereassembly
modelswerecreatedfiomE Dypartmodels. Asscmblymodethg developed
ftom themoncdetailconceptThisis
probablythc.mostwidely
implernented
approachto rhodeling complex
PIOdUCtS.
lntgFcompsnycoordination
Historicaldsignrecords
Distributsdstafor productlon
andproductmaint6nenc
Coordination
of dosignprocsss
with pertnrsandsuppli6rs
Internalcheck-out
and release
MastsrmodlendBTPmansgemont
Univ6rsaldetaaccss,
productstructurernanagement
and "dsignin context"
Figu.e8. High.LevelPDMReqllrements
Successfulmanagenrentof the
dataassociaEdwith complexproducts re{uircs two things: (1) dronodetailmodelillgand(2) designusi[g
asserhblymanagementtechniques,
suchas prcduct strocturc-based
de_
sign,Thesetchniquesprovideseveralbeneflts.
First,bill of materialdatafor use
in MRP systemsis readilygenerated
and can be importedas neededto
supportredesignplojects.Second,
associativitybetweenindividualmodels andsub-modelscan be managed
across
severaleDdassemblies
andstill
support"designin conrext."Third,rhe
sizesof individuelmodelscar1bekept
small,thercbyimprovingCAD/CAM
systempedonnfirce.Lastly, archive/
restorprocedrresarcimproved.
Thesebenefitsapplywell toProd
When
uctswithasLolllifeexpectanqJ.
suchas
apptedto longlileproducis,
big machincs,aircraftor hmsporta
tion equipnent.the benelilscom-
pound.\\4ry is this?
Highly complex, long-life
productsLrndfgo chimgesover tlme,
The use ol mono detail design
pncticesmakesitcasief tu rellselegacy
design data in new designs. Thc
discip!ft imposedbytop-dow'lldesign
rcchniquesimproles the efticiency of
a development leam working on a
ReengineeredProduct
Data Distribution and
Vaultlrlg Processes
Producl data rcleaseJnd control prcceduresare a high priorii) in any pro
cessreengineeringprojcct lbcusedon
product delelopmcnl.The benelils
comeftom improveddatalntegnry;
strearnlinedmodel
check-inandcheckout; updating,reYiev and approval;
andreleaseptocesses.
The counterpointto rcengineering theseprocessesis that llaining
mustbeprovidedto all productdevelophent teamsto ensurethey know
how to effectivelyusedrcir product
ilatarnanagement
system"
Legacy Design
Informationi Reu9e,
Format and Location
In aneadiersectioD,we reviewedtle
issuesrelatedto legacyproductirJormation.A PDM solutionmustmanage any legacy inJormationthat is
identifiedasnecessary
for fte product
team's
use.
This infordevelopment
maiioncanbelocatedin a widerange
of arcaswidrin dr entcrprise.
Determinirgtherightwaytofin4 catalogue
and,if needed,
convertit io a standad
datra
fomat is all partof tle pla dng
processfor PDM implementation.
ot Data
Productdeveiopmentinformationis
madeup of manypossibledatat!?es.
BesidesCAD/CAM, thereare cost,
documentation,prccessplans and
Foject notes-just to list a few. A
onlyCAD/
PDMsolutionthatmanages
not
effective.
information
is
CAM
lISpecial
Considerationsfor
Long-Life,Gomplex
Products
thatarcso unlikeconsumerproducts
or elecfonicsir the natue of what
they crealeas opposedto ttre complexitiesof theirproductdevelopmen!
WIat specialconsidemlionsdo
poseonourconceptof
theseindustries
a virtual product development
envircnment?
PrcCeSSeS.
Standardsand
Interoperability
Theforemostrequircment
ofcomplex
isrobuslstable simplycosttoomuch,andconve$ion
productmanufachrers
mere some of legacydat measuredrn tens of
forinfomration,
standards
of activeor recendyactive
car tolentepedodict ans- thousands
companies
ladonsbetweendissirnilarCAD sys- parr modelsis staggering.Stability
of datastandffdsare
temsusingIGES,DXF ordirccttmns_ and robustness
laiors,thecomplexproductmallufac- absolutelynecessaryfor successful
turelsliterallylive or diebasedonthe partnelships,as well as to supPo(
toproductsin theyear2020
upgrades
massiveamountsof infomalion
h 1990.
movedwithin aDdbetweenthehinter- that weredesigned
to andftom suPplinalorganizations,
ers,andto andftomkeycustomen.To
of an aircnft
quotea rcpresentative
engine manufacturer,"Translators
don't addvalue."
Synchronizationof data forms
usingSTEPis dledreamof theaerospsceanddefeNeprimds,aulomotive
andsuppliersto eithei
manufactuers,
Robust
industry-many supportbotb.
descriPlions and
product
'Teamedtoday,gonetomonow"
intqoperability of dissimilarCAD/
CAM and analysissystenNare the might beonewayto expressthesituationwitd! compadesthatcan'tp!e_
goalsofiDdustryfuldedwo*atPDES
dle 'tr'ttua.l dict whotleir teamitgpaftIersmighl
Iic. To thesecompanies,
enterplrse"will not occuruntil sta4_ be on 6e next military aiJcaft conSTEParcwidelyadopted tracto! a newcodunercialhelicopter'
dardssuchas
appea!to be "shot_
Thercasonis clfir onceYouun_ Thesesometimes
cycles gun mafiiages"ftom an information
thenatureofbusmess
derstand
defenseandauto_ systemsor CAD/CAM penpective
in lalgeaerospace,
Thefirs! courseof actionin these
withj.n
ParheNhips
motivecompanies.
is to acioPta comlnon
a$angements
and amongtheseindustriesare increasingdaily, wiih thefallout in the designsystemfo( the principlecontracton andtop-tiersuppliers!1&ile
technicalcommunitybeingthe rn nthis approachworks,it causesaddiagementdirective:"Make oul CAD/
tional stesson supplierswho ca$ot
CAM systemtdk to tleiis."
thesizeoftheinvest- afford a new higlFe d systemThis
Considering
rcflectsbackto theprines,whoincur
mentsin tectnologyandlegacyinforto providedifferadditionaloverhead
mation,adoptingaparEter'ssystemjustfied
for
entCAD/CAMdatafomutsto suPPlY
uDlessil is financially
reasons-is out of the ques- thet vendorswith designinformaconb:act
andretrain- tion. Eventually, the need for
tion,Softwarcconversion
teams intemperabilitybetweendifferent
hg of fie prcductdevelopment
of complexprod'The foremostrequircment
is robust,stablestandards
uctmanufacturers
the
. .Tothesecompanies,
for information.
'virtualenterprise'
will not occuruntil standmdssuchasS'[EParev/idelyadopted."
other technology.Standards,once
again,are the solution.The lack of
tlem is theproblefl!
on a particularvendor'sworkstation
alsohingesontheircorlorationofall
the X.11 standard
"intrinsics"elsewherctomakeitwo.t.Intercperability
betlveen
unitsof a 'lirtual company"
demandsattentionto the tecbnical
detlils of computingpladorms,networkprotocolsaodbandwidth,
e-mail
and
systems,
softwareavailability secunty systems,
definitionof a Foduct;regulationsor
contracts
maystill stipulatepape.bluepdnts or 2-D digital dra$/ingsas the
"mastet''productdefinition.
Even thoughat least five U.S.
airftammanufacnrers
Oaledonfusthand kaowledge)are pursuing 100
percentdigitaly defined aircraft or
helicopters,
drawingswill continueto
be extlactedand colfinunicatedas
partof theproductdefinitionor con-
E Breaking
Down Barriers
"TruebelieveN"in hepowerofCAD/
CAMinpmductdevelopmearcftustratedby tle barien to widespread
adoptionof sharcdproducr
dara.These
canbe encountercd
within their own
companyor at a supplier'sengineering office,
WIat a.rethe barrie$?How can
theybeovercofiE?
We've observedseveral,all
equallydifficult.Theremaybeothers,
butthesearetheonesmostfrequently
Any
-encounleled. candoomtheconstructionof avirtualproductdevelopmentenviro llent:
. maoagemelltindifference and
cultllle
tract
paircd
documeDtation.
This
witlr
.
Ths Path to th6 Future ls
Iackofrcsources
tie cha.nging
configurationsand the
Long
. poordesignpractices
2S to sGyeal sewicelives of.r-he
. no visiblebenefits
Anotherphenomenon
ofdreseindusproductscompound
thecomplexiryof
The main causeof thesebaniersis
triesis leDgthydevelopment
timelines
thei Foduct modelingard product lackof awareness
of thebusiness
bencoupledwith requirements
for techdaiamanagement
requEements.
efii ttratflowsftomcreatingandusing
nologicallyoutdaredengineering
Muchof whatwe observein fast sharcd
delivembles.
Rapidadoptionof new
Foduct data throughoutthe
moving, "leapfrog" companies(to enterpdse.
genmodelingoranalyicaltecturiques
borow atelmftomtheDesignInsight
To overcome
dresebalriers,demfiIst
in
the
mission-critie$lly occu$
snrdy)is not practical,or achievable, onstration
ofthebenefitscoupledwith
cal arcasof prcductdesign,suchas
within theselargecompalisunless
theeducationofdecisionrnal<ers
and
aiicraftshapedefinitionforGdarevamandated
fiom thetop of theorgani- end
lsers
must
becompleted.
sion.But it may takeyea$ for dlese
zation.Practicaldemonst-ations
ofnew
to adoptanddesameorganizations
productdevelopmenttechniquesor
ploy 3-D solidsmodelsasthemaster
applicationsof CAD/CAM technol,
23 g Virtual ProduatDeveloprnent
Pilot Proiects
Practice.
- teamanaiiiterpailpoitciiinanci
r a
- tiriie-ardqualiry-dliven
market.
Fa-
29
VirtualProductD../elopmentF
POINTS OF INTEREST
Understandiog
VirtualTeams:Thethreeaspectsof good
& Comquaerimg
Tirne anclSpaae:
Virtua! Tearns
a!'!d F{ow to
Create T'hern
Today'sgeogaphicallydispersed
yer
linted productdevelopmenttearnsr_re
the logicaistateof evolutionfor con
currenteneineeringpncticcsandcomputing technology.The bestpractices
of leadingcompaniesin datashring
and team integration are reviewed in
earlierscctionsofthisdocument.
Let's
tbcus now on the crealion of virtual
teams.We'vc done it q,itb our cusIomers;you can,1oo.
Thc thrceaspects
ol-goodproduct
dcvclopmenfpoint to the time rd
spacesolutionof virtualteans:
. People: communicdion wihin
the tcam and to the rest of the
entcrylrise
. Piocesiii: ownerstripandunder,
standing of the overall developmentprocess;
disciplinein cary-
to traln lhem.
Team Training
Just as any professionalspofi has
coaches
andstrafegiessotoodoesa
productderlopmenrteamhave its
ownintemrl "guruJ' and"stonetab
lcts."Theonly truly effectiveway to
brjnge\rerYone
in a leamup to speed
onthedey{o-day
useof tcchnology
is
rng lt out
.Technology: substitution for
proximitv of face-to,face work
sltualons; caplrres and sbares
design and m.nufacturing intenl
The key io a vifiual rean is good
cornmunication-between peopleand
It isbestto trainateemtogelherbeMeencomputeN.Processdiscipline
evenbetterif trahing in the applicaand use of tecbnologyare lermed by
tion ofits toolsispaltofteambuilding
lhe tearru,
,nd familiadzationasa newprojectis
First, infrasn-ucturemusr be in
launched.
PilotFojectsmakeexcelplace.or nothingelsewill happeD.
By
lent oppor0nitiesfor leamiq andre
fiis, we mean a st nd,lrd setof eng!
inforcement.
neering pfactices and sorlwLarctools,
and stirdard, "open" networks con
Virtual ProductDevlopmontE 31