1st Edition
Design Synthesis Integrated Product and Manufacturing System Design
The biggest challenge in any marketplace is uncertainty. The major changes taking place in world economies, politics, and demographics has raised market uncertainty to its highest level in the past 50 years. However, with new markets opening up in emerging and developing economies, the opportunities 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 framework 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, manufacturing 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.
FOUNDATION
Introduction
What this Book is About
Who this Book is For
Improving Your Learning
About Concept Maps
Introduction to Global Manufacturing
Book Outline
Exercises and Problems
References
Designing System Architectures
Introduction
Basic Concepts
System Philosophy
Describing Systems
Describing Boundaries
Describing Environments
Designing System Architectures
Verifying System Architectures
Exercises and Problems
References
Product Design
Introduction
Design as a Personal Activity
Design as a Phase
Types of Design Projects
Design of Product Architectures
Design Standardisation
Design and Manufacture
Exercises and Problems
References
Manufacturing System Design
Introduction
Project Manufacture
Jobbing Manufacture
Batch Manufacture
Mass Manufacture
Part Manufacturing Cells: Group Technology
Assembly Cells
Global Manufacturing
Exercises and Problems
References
CONTEXT
Prologue to Part II
References
Ethics
What is Morality?
Experimentalist Ethics
Ethical Aspects of Professional Life
Ethics and Values in Business
Exercises and Problems
References
Aesthetic Context
Introduction
The Nature of Aesthetic Experience
Aesthetic Function
Environmental Aesthetics
Aesthetics of Product Design
Aesthetic Guidelines for Regenerative Development
Exercises and Problems
References
Social Context
An Ecological Perspective
Maladaptive Responses to Turbulence
Adaptive Responses to Turbulence
Social Guidelines for Regenerative Development
Exercises and Problems
References
Technological Context
Innovation
Limits to Business Development
Global Risk Management
Technical Guidelines for Regenerative Development
Exercises and Problems
References
Environmental Context
Environmental Morality
Limits to Growth
Nurturing the Environment
Environmental Guidelines for Regenerative Development
Exercises and Problems
References
Economic and Political Context
Introduction
Banking and Financial Markets
The Capitalist Economy
Income Inequality
10.5 Global Politics
Politico-Economic Guidelines for Regenerative Development
Exercises and Problems
References
Postscript to Part II
References
SYNTHESIS - TECHNOLOGIES
Lifecycle Analysis
Introduction
Development Lifecycles for Industrial and Consumer Products
Development Lifecycles for a Manufacturing System
Choosing a Lifecycle
Intersecting Lifecycles
Specifying Lifecycles and Reviews
Using Lifecycles for Sustainability Studies
Exercises and Problems
References
Product and Manufacturing System Architecture Integration
Introduction
Product Platforms
Modular Product Family Architectures
The Ideal Manufacturing System
Illustrative Modular Design Example
Design Integration Process
Exercises and Problems
References
Modular Configuration
Configuration Matrices
Process for Creating Configuration Matrices
Configuration Maintenance
Case Study: Ponsse
Exercises and Problems
References
SYNTHESIS - PEOPLE
The Socio-Technical Systems Approach
Introduction
Work Roles
Analysing the Technological System
Analysing the Social System
Designing the Work Relationship Structure
Managing the System Environment Relationship
Implementing Socio-Technical Systems
Exercises and Problems
References
Organising People for Manufacturing
Introduction
Interactive Planning
Modern Socio-Technical Work Group Design
Organisational Design (Structure)
Organisational Design (Vertical Teams)
Organisational Design (Horizontal Teams)
Dealing with Product Demand Variability
Exercises and Problems
References
Organising People for Design
Introduction
The Design Team
Design Team Coordination and Integration
Product and Manufacturing Design Team Cross-Linking
Team Management
Organisational Integration
Global Design Teams
Exercises and Problems
References
Design Management
Introduction
Tacit Experience Management
Critically Reflective Practice
Managing Concept Integrity
Configuration Management
Exercises and Problems
References
Glossary of Terms
Appendices
Appendix A: Design Analysis Techniques
Appendix B: Testing
Appendix C: Phase and Review Definitions for Product-Manufacturing Intersecting Cycles
Appendix D: Throughput Time Analysis
Biography
Graeme Britton (DEng., PhD., BE.(hons), C.Eng, FIMechE, Snr.MSME) is Professor and Vice President of Vocational and Technical Education at Raffles University System, a unit of Raffles Education Corporation, Singapore. He has been involved in improving the manufacturing effectiveness of SME's since the 1970's. He is an expert in the design of management and computer-aided systems for engineering companies using systems methodologies and General Graph Theoretic Methods. He has published over a 100 refereed articles on CAD, CAM, CAPP, and manufacturing systems. Graeme has over 30 years experience conducting applied research in industry, including company-specific projects, national projects, and international collaborative research projects. His current research interests are sustainable development and the education and training of engineers.
Seppa Torvinen is a Professor of Production Engineering at Tampere University of Technology, Finland. His areas of interest and expertise are Production Systems Design, Demand Driven Supply Networks, Industrial information systems, Sustainability and Socio technical Systems Design.
"The book is about a relevant issue for competitive manufacturing: the integration of product design and manufacturing system design. ... The book provides both a conceptual framework and methodologies for the integrated design of product, manufacturing and social system architectures, and for the harmonisation of the concurrent processes needed to design the architectures. ... For the contents and the style of presentation, as well as some new critical perspectives, I recommend the book to senior undergraduate students and even to postgraduate engineers and managers. I think that the book is also a good starting point to reflect on the research needs for approaches and methodologies specifically designed to support the product and the manufacturing system life cycle in small and medium enterprises. In this concern, young researchers may find the book a nice reading in order to stimulate further investigation."
—Marco Macchi, in Production Planning & Control, 2016, Vol. 27, No. 4, 343
