All Rights Reserved by Tsuyoshi Koga, Univ. of Tokyo, 2005. Email: [email protected] 1 Manufacturing Systems Engineering lab. Manufacturing

All Rights Reserved by Tsuyoshi Koga, Univ. of Tokyo, 2005. Email: [email protected] 1

Manufacturing SystemsEngineering lab.


- Information Technology for Design Simulation -- Information Technology for Design Simulation -

http://www.msel.t.u-tokyo.ac.jp/http://www.msel.t.u-tokyo.ac.jp/

Top

Failure Model

Design Process

Product Design

Production Design

Cross-Sectional Failure

Database

Prototype System

Conclusion

An Integrated Management System of Product Failure Information

on Design and Production Stage

Tsuyoshi Koga and Kazuhiro Aoyama

University of Tokyo School of Engineering

Design and Integration Seminar 2005 Pre-workshop 15:30 ～ 16:50 2005/11/21 at Osaka University





http://www.msel.t.u-tokyo.ac.jp/http://www.msel.t.u-tokyo.ac.jp/Background

Eradication of product failure is one of the dreams of manufacture.

– Product failures are causing loss costs.

on design stage on production stage even if products were in

the market

– Product failures are increasing.

！！

Burr by cuttingBurr by cuttingSpread burrSpread burr

Operator

Press Machine

Forming OperationForming OperationDesign failure(Overturn check)

Production Failure(Press operation)

050

100150200250300350400450500

1991

年度

1992

年度

1993

年度

1994

年度

1995

年度

1996

年度

1997

年度

1998

年度

1999

年度

2000

年度

リコ

ール

件数

（件

）

Increasing

Management System of Failure Information is highly desired

Num

ber

of R

ecal

ls

Failure in market(Automotive Recalls)





http://www.msel.t.u-tokyo.ac.jp/http://www.msel.t.u-tokyo.ac.jp/Problems

Representation, Access and Share of Failure Information using Information System of Design and Production is required

However, QCD (Quality, Cost, Delivery) Requirement is getting more and more inclement.

Today, Information Access and Share between Engineers have been achieved by Information System of Design and Production.

ProcessShortenings

Test LessDevelopment

Lack of Desk Examination and Validation

Efforts for Failure Reduction

Huge numberof Documents

QC process chart

Design / ProcessFMEA Sheet

Failure Cases

Check List

Design Don'ts

Problems are still remain

Lateral Spread is difficult

Isolated

Very hard to be referred

Kaizen-activities

Bottom-upimprovement

Japanese companyis very good at

Dried Rag

PDM (Product Data Management)

EAI (Enterprise Application Integration)

PLM (Product Lifecycle Management)





http://www.msel.t.u-tokyo.ac.jp/http://www.msel.t.u-tokyo.ac.jp/Purposes

Realization of Representation, Access and Share of Failure Informationusing Information System of Design and Production

(1) Model of Failure Causality across Product and Production

(2) Multi-stage Design Method to reduce failures

DesignDesign ProductionProduction OperationOperationT

roub

le C

ost

Tro

uble

Cos

t

LowLowCostCost

HighHighCostCost

•Today nearly half of failures have causality between design and production. •Integration of Product Failure Model and Production Failure Model is required.

•Decisions of early design stage have huge impacts on detailed design stage.•Failure factors should be eliminated from initial design stage.

1 5 315

13

59

4117

15

32

317

Vehicle Recalls that hascausality across Designand Production (45%)Detailed purposes

To achieve this goal,

Goal

All Rights Reserved by Tsuyoshi Koga, Univ. of Tokyo, 2005. Email: [email protected]

- Information Technology for Design Simulation - Information Technology for Design Simulation --

(3) IPPF Model(Integrated Product-Production-

Failure Model)

(1) Product Behavior (2) Production Process

RequiredBehavior

ProductInfo.

ManufacturedQuality

ProductionProcess

Computer Integrated Product and Production Information system that provides cross-sectional failure information from initial design stage.

ProductionEngineer B

Overview

Designer B

Designer A

Design Review Room

ProductionEngineer B

Designers can know how it is going to make and

what is going on in the production process.

Production engineers can know why this component is required and

how it is going to work on entire product life cycle.

They can share in this room the causality of product failure between product and production.






Top

Failure Model

Design Process

Product Design

Production Design


Database

Prototype System

Conclusion

Scenario

ConclusionConclusion

Prototype SystemPrototype System

Cross-Sectional Failure DatabaseCross-Sectional Failure Database

ProductDesignProductDesign

ProductionDesign

ProductionDesign

Failure ModelFailure Model

Design ProcessDesign Process

Model of Failure Causality across Product and Production

Formulation of Design Processto reduce product failure

Failure reduction methodon Product Design

Failure Reduction methodon Production Process Design

Acquirement of Cross-SectionalFailure by Database





http://www.msel.t.u-tokyo.ac.jp/http://www.msel.t.u-tokyo.ac.jp/Definition of Product Failure

Usually, product failure is defined as loss of product functions.

(JIS Z 8115)

Unified-description-model of product function does not exist.

[Tomiyama 1997]

So I focused on Product Behavior.（ Product function = subjective recognition)

　　　　

Required Behavior

ProductBehavior

Unexpected / HazardousBehavior is generated

Required Behavioris not achieved

（ a ）（ b ）

Definition of Product Failure（ a ） Loss of Required Behavior

or（ b ） Generation of unexpected

(Hazardous) Behavior





http://www.msel.t.u-tokyo.ac.jp/http://www.msel.t.u-tokyo.ac.jp/An example actual failure case

！！

Engineers must realizeand prevent these failures

Failures can be modeled by Causal Chainsbetween causes and results

Production Process

Product andRequiredBehavior

②GarageOperation

②Cavitations

②When the user operated this automobile in a garage, Cavitations in PS Pump is generated.

③LoadIncrement

③Cavitations cause incrementation of Rotation Load.

④Engine Speedwill increase

④Rotating Speed of Engine will increase by stall prevention control

⑤SuddenAcceleration

⑤Suddenly automobile will accelerate at garage operation

⑥InjuryAccident

⑥Hazardous situation (e.g. Injury Accident) could happen

Chassis Assembling 1 Chassis Assembling 2

①Air Contamination

①PS (Power Steering) Oil contains air by the process change of Chassis Assembling.

①Escape into The Market

Transfer Machine

Steering & Suspension Assembling

SuddenAcceleration

Process ChangeOf Chassis Assembling

Stall PreventionControl

Results

Causes


- Information Technology for Design Simulation - Information Technology for Design Simulation --Model of Failure Mechanism

QualityPropagation

ManufacturedQuality Generation

Causal ChainInside Product

Chain ofScenes

QualityStateProductBehavior

・ Operation（Worker, Equipment, Condition）

・ Intermediate Product(Partly-finished Product)

・ Quality Propagation

・ Production BOM

・ Assembling Connection

・Manufactured State

・Manufactured State Change

・ Quality Propagation inside Product

・ Components

・ Topological Structure

・ Attributes

・ Element State

・ Element Action

・ Interactions

・Whole Product Scene

・Whole Product Event

・ Environmental Load

・ Hazardous Situations and Actions

RequiredBehavior

ProductStructure/Behavior

Manu-facturedQuality

ProductionProcess

ManufacturedProduct

Product InformationRequiredBehavior Model

Production Process Model

Failure Mechanism

Press line

Computer comprehensive Computer comprehensive Model is requiredModel is required

→→Petri-NetPetri-Net


- Information Technology for Design Simulation - Information Technology for Design Simulation --Production process model

QualityPropagation



Chain ofScenes





・ Production BOM





・ Components


・ Attributes

・ Element State

・ Element Action

・ Interactions





RequiredBehavior



ProductionProcess

ManufacturedProduct



Failure Mechanism


QualityPropagation


Quality




・ Production BOM





ProductionProcess

ManufacturedProduct







Definition of Production Process

Model of Production Process

Definition of Each Element

Element of ManufacturedProduct

ManufacturedEntity

Assembling Connection between Entities

Interface betweenManufactured

Entities

Symbol Name Definition　◇ Operation can act on Manufactured Product and change its manufactured state　◇ Manufacturing Product can be modeled as Manufactured Entities and Interfaces　◇ Production Process can be represented as sequences of operations

Attribute of Entities andInterfaces generated by Production Process

Attribute

ManufacturedState

ManufacturedState Change

Quality of Manufactured Productin Production Process(Place)

Change of Quality State(Transition)

IntermediatePart

Intermediate Part or Assemblyin Production Process(Place)

OperationOperation generates Attribute of Manufactured Product(Transiton)

Manu-factured

Entity

Manu-factured

State

Manu-factured

State

Manu-factured

State Change

IntermediatePart

(Output)

Operation

Attribute Value of Attribute

Value of Attribute

IntermediatePart

(Input)

ProductionProcess

Manufactured Product

Condition






Description of Failure in Production Stage

3 types of production failure　 (1) Defect of Product (e.g. Additive Defect)　 (2) Defect of Operation (e.g. Miss Operation)　 (3) Causal Chain inside Product

2 Types of Operations　 (1) Assembling Operation: Generate Interface Quality　 (2) Manufacturing Operation: Generate Entity Quality

Production ProcessProduction Process

hoodpanel

Press Formed

Coil Cut

Forming press

Wrinkle

falsetrue

Height8mm

Forming press

Height4mm

Height<6mmThen true

ProductProduct

Correspondence between Entityand Intermediate Product

Symbol

ManufacturedEntity A

ManufacturedEntity B

IntermediateProduct A

Operationab

IntermediateProduct AB

IntermediateProduct B

Factor of Product and Production Process

Assembling Operation

Causal Chain inside Manufacturing Product

ManufacturedEntity

QualityState 1

QualityState2

StateChange

Attribute Value aValue b f(a,b,c)

ManufacturedEntity

QualityState 3

Attribute Value c

Test Arc

plasticstrainCompleted

UnevenMaterial

Wrinkled Sheetwrinkle

wrinkle

SeparatedConnect

weld


- Information Technology for Design Simulation - Information Technology for Design Simulation --Product structure and behavior model

QualityPropagation



Chain ofScenes





・ Production BOM





・ Components


・ Attributes

・ Element State

・ Element Action

・ Interactions





RequiredBehavior



ProductionProcess

ManufacturedProduct



Failure Mechanism


ProductBehavior

・ Components


・ Attributes

・ Element State

・ Element Action

・ Interactions


Product Information






Definition of Product Behavior and Structure

Model of Product Behavior and Structure


Element of ProductDesignEntity

Interactions (Connection, Signal/Material/Energy Flow) between Entities

InteractionBetween

Design Entities

Symbol Name DefinitionBehavior of Product Element is represented as network of States and Actions　◇ Product Structure is represented as Design Entity and Interactions　◇ State means the value area of Attribute　◇ Action means the change of Attribute　◇ Product Behavior Token means entity state at given moment

Attribute Value of EntityAnd InterfaceAttribute

State

Action

Recognition of area of Attribute Value(Place)

Attribute Change betweenStates(Transition)Air Cont-

amination

cavitate

ResistanceAmplify

RotationalResistance

0.1(N/m) 0.3(N/m)

Engine

Idle upcontrol

PS Pump

IdlingUp

Idling

(N/m)0.10.3

Revolution(rpm)5001200

<Example of description model>

ProductBehavior Token

State of Entity at givenmoment





http://www.msel.t.u-tokyo.ac.jp/http://www.msel.t.u-tokyo.ac.jp/Model of Component Failure

pressure

depressure

Strain Unstrain

deteriorate

NormalOil

Splash

Rotation Ignition

Oil attatch

leak

Failure State

Failure Action

Test Arc

SynchronousArc

Legend Symbol

Pump DrivingBelt

High Pressured Piping

Clamp of HighPressured Piping

Pump

Arrangement of PowerSteering System

Component failure can be represented by product model.　◇ Component state that derives product failure = Failure State. 　◇ Component action that derives product failure = Failure Action.

Failure states and actions propagate inside product.

Power Steering PumpDriving Belt

High PressuredPiping

Clamp of High Pressured Piping

Power SteeringPump

Line Pressure High Pressure

Example


- Information Technology for Design Simulation - Information Technology for Design Simulation --Required behavior model

QualityPropagation



Chain ofScenes





・ Production BOM





・ Components


・ Attributes

・ Element State

・ Element Action

・ Interactions





RequiredBehavior



ProductionProcess

ManufacturedProduct



Failure Mechanism

Chain ofScenes





RequiredBehavior

RequiredBehavior Model






Definition of Required Behavior

Model of Required Behavior


Required Whole ProductState (Place)

Required Whole ProductAction (Transition)Event

Scene

Hazard Scene

Hazard Event

Unintended or HazardousScene (Place)

Unintended or HazardousEvent (Transition)

Symbol Name DefinitionRequired Behavior means the whole Product Behavior that fulfils its function　　◇ Network of Scenes and Events　　◇ Scenes and events have environmental attributes.　　◇ Required Behavior Token means the whole Product State at given moment

Physical Attribute　 dust / splash / snow / dirt / torque fluctuations / displacement/twisting...etc.

Chemical Attribute　 brine damage / ozone / ...etc.

Operational Attribute　 operation time, speed, Load / switching time / rotation speed...etc.

Fully Turning

Average SpeedTime

Rotation SpeedRotation Torque

full rotate

GarageOperation

Injury AccidentFully Turning

suddenaccelerate

full rotate

rotate back

[Example]Environmental Attribute


- Information Technology for Design Simulation - Information Technology for Design Simulation --Integration between product and production

QualityPropagation



Chain ofScenes





・ Production BOM





・ Components


・ Attributes

・ Element State

・ Element Action

・ Interactions





RequiredBehavior



ProductionProcess

ManufacturedProduct



Failure Mechanism

State






Design Engineer Production Engineer

Dynamicspring

Rubber Insulation

Static spring

Hysteresis

Sulfur mixing ratio

Color

Correspondence between design attributesand manufactured attributes

Mapping between Design State and Manufactured State

Mapping between Design State and Manufactured State

Design State must be achieved by Manufactured State　◇ Designers assign Entity State in order to realize Required Behavior　◇ Production Engineers grasp its quality as Manufactured State　◇ Mapping Function of functional attributes and manufactured attributes can be defined.

DesignedState

FunctionalAttributes

ManufacturedState

ManufacturedAttributes

Translated Attribute

Rubber Insulation

MappingFunction

Dynamic springStatic spring

Hysteresis





http://www.msel.t.u-tokyo.ac.jp/http://www.msel.t.u-tokyo.ac.jp/Example of Failure Model

Garage Operation

Injury Accident

Fully Turning

AirContaining

cavitate

ResistanceAmplify PS Pump

NoAir

AirContainingboil

Air bleed

OilFilled

air bleed

more than5%

0.3(N/m) Rate ofAir Content

9%3%

ReleaseValve CloseEngine

idle upcontrol

PS Pump

Idlingup

sudden accelerate

full rotate

This model is Failure Causality across Product and Production

②GarageOperation

②Cavitations③Load

Increment④Rotation Speed

will increase

⑤SuddenAcceleration

①Air Contamination

⑥InjuryAccident

Product andRequiredBehavior

Chassis Assembling 1 Chassis Assembling 2

①Escape into The Market

Transfer Machine Steering & Suspension Assembling

Failure Case

RequiredBehavior



ProductionProcess

Rate ofAir Content

Failure model description






Top

Failure Model

Design Process

Product Design

Production Design


Database

Prototype System

Conclusion

Scenario





ProductionDesign

ProductionDesign












http://www.msel.t.u-tokyo.ac.jp/http://www.msel.t.u-tokyo.ac.jp/Design method for Failure Reduction

RequiredBehavior



ProductionProcess

Mechanism of Failure

Design Method

RequiredBehavior


Design Method 1 ： Input Required Behaviorand output Interactions

Propose InteractionDesign Algorithm


Design Method 2 ： Mapping between Design State and Manufactured Quality Concrete Example

ProductionProcess

Design Method 3 ： Input Required Qualityand output Sequence of Operations

Propose Quality Design Algorithmof Production Process


DesignMethod 3

DesignMethod 2

DesignMethod 1






RequirementDesign

Structure/Behavior Design

QualityDesign

ProductionProcess Design

Design Process

Mapping

Decom

position

ConceptualRequirement

ConceptualStructure

ConceptualQuality

ConceptualProcess

DetailedRequirement

1)RequirementDecomposition

a) Productdesign

c) QualityAssignment

e) QualityEmbodiment

DetailedStructure

2)StructureDecomposition

DetailedQuality

3)M-BOMDecomposition

DetailedProcess

4)ProcessDecomposition

b) BehaviorGeneration

d) StateGeneration

f) QualityGeneration






Top

Failure Model

Design Process

Product Design

Production Design


Database

Prototype System

Conclusion

Scenario





ProductionDesign

ProductionDesign





A product design method to reduce failure








Failure Reduction in Product Design Stage

What is Failure in Product Design Stage?　◇ Loss of Required Behavior　◇ Generation of Unintended (Hazardous) Behavior

What is Product Design?　◇ Translation from a functional concept (spec concept) into a solution concept　◇ Behavior Concept is required to consider product failure

Product Design in this research　◇ The output process of Product Components and Interactions by the input of Required Behavior

The Design Concept of GDT [Yoshikawa 1987]Functional

SpaceAttribute (Entity)

Space

A DesignerA Customer Product Attributes

Specifications

The Design Concept of this Research

Product Behavior Space

Components andInteraction Space

A DesignerProduct Components

and Interactions

Scenes (Product Behavior)

?

A Customer

A Product??

?

Design Method that can prevent the loss of Required Behavior or generation of

Unintended (Hazardous) Behavior from early design stage is required.





http://www.msel.t.u-tokyo.ac.jp/http://www.msel.t.u-tokyo.ac.jp/Indicator of Failure: Performance

Charging

Charged Ready

StapledEmpty

open

close

close

open

charge

fire

release

push& fire

Required Behavior G1

push

Charging

Charged Ready

Empty

open

close

close

open

charge

fire firefire

Miss Fire

Calculated Behavior G2

Definition of Performance

Comparison between G1 and G2

PerformanceValue of Required

Behavior＝ Lack of Scenesand Events－

StapledEmptyrelease

Ready

StapledXma Lack of Events

StapledXsa Lack of Scenes Xs Unintended Scenes Miss Fire

Ready

Empty

fire

Ready Miss Fire

charge

Xm Unintended Events

Unintended Scenesand Events－





http://www.msel.t.u-tokyo.ac.jp/http://www.msel.t.u-tokyo.ac.jp/Product Behavior Design

◆Product Behavior design = Component design + Interaction design　◇ Product Information consists of Component Behavior and Interactions between them.　◇ Product Information determines Product Behavior.　◇ From comparison between Required Behavior and Product Behavior, performance can be calculated.

Calculate

(A) Component Behavior

HousingOpened PushedClosedopen

close

release

push

MagazineUnitCharged Empty

charge

fire

(B) Interactions

HousingOpened

push

MagazineUnit

fire

(C) Product Information


close

release

push


charge

fire

Charging

Charged Ready

Stapled

Empty

push

release

open

close

close

open

charge

(D) Product Behavior

(Charged, Closed)

(Empty, Pushed)

(Empty, Closed)

(Empty, Opened)

(Charged, Opened)

＋

=





http://www.msel.t.u-tokyo.ac.jp/http://www.msel.t.u-tokyo.ac.jp/Interaction design method

From iteration cycles, system outputs Interactions that maximize Performance.

Opened PushedClosedopen close release push

Charged Emptycharge fire

(A) Importance of Interactions iw•Performance: 91.3

•Feasibility: 56%

•Classification: Xa

•Absent Action: {E1}

•Superfluous Action: {E2}

(G) Evaluation Result

Generate Interface Structure

(B)

CalculateBehavior

(D)

Feed BackLearning

(H)

(C) Product Information


close

release

push


charge

fire

(E) Product Behavior

Charging

Charged Ready

StapledEmpty

open

close

close

open

charge

release

chargepush&fire

E2

E1

(F)Comparison between

Required Behavior

◆ Especially, interaction design is difficult. ◆ Therefore, computational design assist method is required.



Calculated Product Behavior

Shape Attribute

Required Behavior Product Information

Design Example of Auto-Breaker

Input: Hazard Scene, Component failure,

Required Behavior

Output:Product Information that satisfies

Required Behavior and does not involve product failure






Top

Failure Model

Design Process

Product Design

Production Design


Database

Prototype System

Conclusion

Scenario





ProductionDesign

ProductionDesign






A design method of production process to reduce the failure






http://www.msel.t.u-tokyo.ac.jp/http://www.msel.t.u-tokyo.ac.jp/Reduction of production failure

◆What is quality problem in production?　◇ Generation of quality that derives Product Failure

◆What is production?　◇ Generation process of product attribute

◆What is production process design?　◇ Operation design 　◇ Sequence design of Operations

[Hitomi 90]

Design Method of Production Process that satisfy Required Quality is required.

Production Process of Vehicle

Forging

Melting

Melting

DieDie-casting

Coating Transfer

Chassis Assembling Assembling 2

STRG/SUSP Assembling

Engine Assembling

Finished Car

AssemblingCoating

Cutting Press Body Assembling

MachiningTRSM Assembling







ManufacturedEntity

QualityState 2

QualityState 1

QualityChange

QualityChange

IntermediateProduct 3

Operation 1

Operation 2

Operation 3


Space of Quality State

Computationalcalculation

Operation 1Operation 1 Operation 2Operation 2

Operation 3Operation 3 Operation 4Operation 4 Operation Operation ３３Operation 4Operation 4

Explanatory note

Marking

Firing Sequence

Marking1Marking1

Marking2Marking2 Marking3Marking3

Marking4Marking4 Marking5Marking5

◆Model of Production Process　◇ Production Process is represented as a sequence of Operations

　◇ Operation can change Quality State of Manufactured Entity

◆Behavior of Production Process　◇ From Production Process model, computer can calculate the behavior of production process

　◇ Marking5 means Quality Problem

　◇ Production Scenario of Quality Problem can be calculated

　◇ This model can be simulated by probability of Quality Change and actual performance of Operations 　　１． Per cent defectives 　　２． Contribution List of Failure Factors

Explanatory noteSynchronous Arc

Quality Problem



Operation 4


QualityState 1


QualityState 2


QualityState 2


QualityState 1


QualityState 1

Operation 2Operation 2

Operation 4Operation 4






Design Method of Production Quality

PS Pump

ValveOpened

NoAir

AirContaining

boil

PS PumpASSY

influx OilEmpty

OilFilled

Closed close

PS OilAssembled

close

bleed air

fill oil

STEP2Select final Quality State and

Scenario of Quality Generation

STEP3Output Sequence

of Operations

STEP1Calculate Space of

Quality State Change

Scenario of Quality Generationrequired

Quality State

◆Procedures　 STEP1 Calculate the Space of Quality State Change by combination of possible Operations　 STEP2 Select required Quality State and Scenario of Quality Generation　 STEP3 Output Sequence of Operations

◆Hierarchy Model of QualityQuality State of Assembly = Combination of Quality States of Components

OpenedEmpty

ClosedEmpty

ClosedFilled

Containing

ClosedFilled

Containing

ClosedFilled No Air

OpenedFilled No Air

OpenedFilled Containing


- Information Technology for Design Simulation - Information Technology for Design Simulation --Design Example (Auto-Breaker)

Design problem– How to produce this C

ontact ASSY that does not involve qualitical problem

Real Shape Arrangement of Contact ASSY

Contact ASSY

Manufacturing BOM of Contact ASSY


- Information Technology for Design Simulation - Information Technology for Design Simulation --1st Step: List up Conceivable Operations

①Brazing

③Form press

②Calk

ProducedShape

Formed

bend byform press

Disconnected Connected

connect bycaulk

Disconnected

Connected

connect bybraze

Three operations


- Information Technology for Design Simulation - Information Technology for Design Simulation --2nd Step: List up Conceivable failures

⑤Misalign by forming press

④Curve by brazing

Shape Formed

curveby braze

Curved

Produced

misalignby form press

Misaligned

Two possible failures of operations


- Information Technology for Design Simulation - Information Technology for Design Simulation --3rd Step: Calculate combined network

（ A) Product Structure

（ B) Conceivable Operations

（ C) Conceivable Failures

④

⑤

①

②

③

Combined Structure/Operation/Failures

④

⑤

①

②

③


- Information Technology for Design Simulation - Information Technology for Design Simulation --4th Step: Calculate Space of Quality State

Reachable Tree

Specify the scenario that does notinvolve failure quality

凡例FailureQuality

NormalQuality


- Information Technology for Design Simulation - Information Technology for Design Simulation --Result

Output is Production Process– Output means that failure reduction is achieved by the

production process of brazing, form press and caulk

Brazed

Pressed

Caulked

Contact

Contact Plate






Top

Failure Model

Design Process

Product Design

Production Design


Database

Prototype System

Conclusion

Scenario





ProductionDesign

ProductionDesign













Result of Auto-Breaker Design

<e>DetailedRequirement

<f>DetailedStructure

<g>DetailedQuality

<a>ConceptualRequirement

<b>ConceptualStructure

<c>ConceptualQuality

<d>ConceptualProduction

<h>DetailedProduction

RequirementDesign

Structure/Behavior Design

QualityDesign

ProductionProcess Design

Mapping

Decom

position


- Information Technology for Design Simulation - Information Technology for Design Simulation --Impact Analysis of Design Change (Production Process)

Product Behavior Product Structure Quality Information Production Process

Production ProcessProduct Behavior Product Structure Quality Information

Before Change

After Change

Brazing

Forming

Forming

Brazing

①

②

①

②

If production engineer want to reverse two operations, forming and brazing,Generated quality is changed and product state is changed. So product failure can be detected.



CausalDatabase

Knowledge Repository based on PPF Model

Product-Production-Failure (PPF) Information Model

interrupt

ContactPlate

TripFixed

Contactformpress

Mounted

mount

disconnect

Miss-trip LeverASSY

MissTrip

Contact

Lever ASSY

Connected

Trip

soldersolder dustgenerate

solder dust

ContactMelt

arc generateContact

Plate

formpress

Pressed

Produced

bendShapeFormed

Produced

ContactASSYConnected

Disconnected

connect

disconnect

interruptdownup

interrupt

Contact

TaxonomyDatabase

Unit ElementDatabase

Abstract

ConcreteCause Result

All

Part

Each Element Unit Entity or Operation

Provide Unified Terms and Expanded Search

Provide element vocabularyProvide Causal Knowledge

Causal Relationship






Top

Failure Model

Design Process

Product Design

Production Design


Database

Prototype System

Conclusion

Scenario





ProductionDesign

ProductionDesign













Required Behavior

Product Structure / Behavior

Production ProcessQuality Information of

Manufacturing Product

Prototype System

Architecture of information on proto-type system





http://www.msel.t.u-tokyo.ac.jp/http://www.msel.t.u-tokyo.ac.jp/Demonstration Movies

Movie1: Product-Production-Failure (PPF) Information ModelMovie2: Simulation of Production and BehaviorMovie3: Acquirement of Cross-Sectional Failure






Top

Failure Model

Design Process

Product Design

Production Design


Database

Prototype System

Conclusion

Scenario





ProductionDesign

ProductionDesign













Top

Failure Model

Design Process

Product Design

Production Design


Database

Prototype System

Conclusion

Conclusion

Model of Failure Causality across Product and Production is proposed.

– Cross sectional knowledge can be shared Product failure and behavior Quality change in manufacturing process

Design method to reduce failures by step-by-step decomposition is proposed.

– Reduction of product failure from early design stage– Development shortenings






Top

Failure Model

Design Process

Product Design

Production Design


Database

Prototype System

Conclusion

That's All. Thank You!