Concurrent Engineering and Lean Manufactuer

Concurrent engineering is one of the most important techniques for engineering design teams. Concurrent Engineering Software from TeamSET provides an integrated New Product Introduction toolkit for use by concurrent engineering teams. The toolkit consists of:

• Design for Assembly
• Manufacturing Analysis
• Design to Target Cost
• FMEA
• QFD
• Controlled Concept Convergence

These are all tools that contribute towards efficient New Product Introduction ( NPI ) and Lean Manufacture.

DFA is a simple, structured analysis technique which gives design teams the information they need to reduce product costs by simplifying product structure and optimising manufacturing processes

Typical benefits

• Average parts count reduction - 46%
• Average assembly cost reduction - 47%
• Product cost reduction - 15%
• Reduction in parts related costs
• Assembly tooling cost reduced
• Product introduction lead time reduced
• Product reliability improved

DFA used as part of an integrated approach encourages the design of products that can be produced at minimum cost and maximum quality and reliability. It gives the best results when used by multi-disciplined New Product Introduction ( NPI ) teams.

QFD is a detailed planning technique used to translate the 'voice of the customer' into company specifications at each major stage of the Product Introduction Process.

Some of the benefits of QFD are:-

• Products meet customer expectations better.
• Reduced lead times through fewer design changes and focus on key features.
• Design traceability.
• Improved communication within organisation and with customer.

FMEA is another key tool. It is a simple, structured analysis technique which gives design teams the information they need to improve product quality and reduce cost by:

• Increasing product reliability
• ensuring the design is robust
• reducing the number of engineering changes
• correcting design errors before production starts

Failure Modes and Effects Analysis is standard practice in the automotive industry. Its use is increasing rapidly in a wide range of other industries to produce more reliable products with less wasted cost.

Failure Modes and Effects Analysis gives optimum results when used with the other TeamSET tools: QFD, DFA, MA, DTC. It is most effective when used by multi-disciplined New Product Introduction ( NPI ) teams.

Design to Target Cost (DTC) is the managed process of monitoring and controlling manufacturing cost to a fixed cost target set at the product specification stage. The responsibility for attaining the target cost resides with the project team.

There is always a tendancy for costs to drift up during the development phase. The reasons for this vary, but unless the costs are monitored on a regular basis throughout the project, they can easily get to a level where drastic and traumatic action is needed to recover the situation. With DTC we compare our current best estimates of costs against targets set at the beginning of the project. This is done on a regular basis, perhaps once a week or once every two weeks, and corrective action initiated before the problems become too great. This regular correction ensures that the product is delivered to cost.

Concept Convergence is a simple, structured technique for comparing and selecting solutions for a set of requirements. The technique can be used for:-

• Evaluating alternative concept designs.
• Identifying strengths and weaknesses in relation to a set of requirements.
• Identifying ideas which have the highest potential.

It is important that all the tools are applied as a team exercise, with input and involvement from all the major stakeholders. This ensures that all aspects of the product design are considered from different points of view.

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