Concurrent Engineering

To our parents, Abolfazl Parsaei and Barat Atabaki,

William H. Sullivan and Kathleen A. Glasstone

Concurrent Engineering

Contemporary issues and modern design tools

Edited by

Hamid R. Parsaei Associate Professor

Center for Computer-aided Engineering University of Louisville

USA

and

William G. Sullivan Professor

Department of Industrial and Systems Engineering Virginia Polytechnic Institute and State University

USA

SPRINGER-SCIENCE+BUSINESS MEDIA, B.V

First edition 1993

© 1993 Springer Science+Business Media Dordrecht

Originally published by Chapman & Hali in 1993

Softcover reprint ofthe hardcover lst edition 1993

Typeset in 10/12 Times by Interprint Limited, Malta

ISBN 978-1-4613-6336-1 ISBN 978-1-4615-3062-6 (eBook)

DOI 10.1007/978-1-4615-3062-6

Apart from any fair dealing for the purposes of research or private study, or criticism or review, as permitted under the UK Copyright Designs and Patents Act, 1988, this publication may not be reproduced, stored, or transmitted, in any form or by any means, without the prior permission in writing of the publishers, or in the case of reprographic reproduction only in yaccordance with the terms of the licences issued by the Copyright Licensing Agency în the UK, or in accordance with the terms of licences issued by the appropriate Reproduction Rights Organization outside the UK. Enquîries concerning reproduction outside the terms stated here should be sent to the publishers at the London address printed on this page.

The publisher makes no representation, express or implied, wîth regard to the accuracy of the information contained in this book and cannot accept any legal responsîbility or liability for any errors or omissions that may be made.

A catalogue record for this book is available from the British Library

Library of Congress Cataloging-in-Publication data available

List of contributors Preface

Part One

Contents

ORGANIZATION ISSUES IN CONCURRENT ENGINEERING

ix xii

1

1. Principles of concurrent engineering 3 Hyeon H. 10, Hamid R. Parsaei and William G. Sullivan

2. Concurrent engineering's roots in the World War II era 24 M. Carl Ziemke and Mary S. Spann

3. Implementation: common failure modes and success factors 42 Stephen Evans

4. Overcoming barriers to the implementation of concurrent engineering Gary A. Maddux and William E. Souder

5. Improving interpersonal communications on multifunctional teams Michael E. Fotta and Ray A. Daley

6. Scheduling of concurrent manufacturing projects Adedeji B. Badiru

Part Two TOOLS AND TECHNIQUES OF CONCURRENT ENGINEERING

61

75

93

111

7. Models of design processes 113 Ali Bahrami and Cihan H. Dagli

8. A decision-based approach to concurrent design 127 F arrokh M is tree, Warren Smith and Bert Bras

9. Concurrent optimization of product design and manufacture 159 M asataka Yoshimura

10. Computer-based concurrent engineering systems 184 Michael 1. O'Flynn and M. Munir Ahmad

VI Contents

11. Multiattribute design optimization and concurrent engineer-mg 207 Deborah L. Thurston and Angela Locascio

12. Concurrent cell design and cell control system configuration 231 F. Frank Chen

13. A generalized methodology for evaluating manufacturability 248 Srinivasa R. Shankar and David G. Jansson

14. Evaluating product machinability for concurrent engineering 264 Dana S. N au, Guangming Zhang, Satyandra K. Gupta and Raghu R. Karinthi

15. Concurrent optimization of design and manufacturing toler-ances 280 Chun Zhang and Hsu-Pin (Ben) Wang

16. Design for human factors 297 Fariborz Tayyari

Part Three COST CONSIDERATIONS IN CONCURRENT ENGINEERING 327

17. Designing to cost 329 Mahendra S. Hundal

18. Economic design in concurrent engineering 352 James S. Noble

Part Four ARTIFICIAL INTELLIGENCE IN CONCURRENT ENGINEERING 373

19. Application of expert systems to engineering design 375 Gary P. Moynihan

20. A knowledge-based approach to design for manufacture using features 386 Eoin Molloy and J. Browne

21. Concurrent accumulation of knowledge: a view of concurrent engineering 402 Robert E. Douglas, Jr. and David C. Brown

22. Integrated knowledge systems for adaptive, concurrent design 413 Steven H. Kim

Contents Vll

23. Automating design for manufacturability through expert sys-tems approaches 426 A.R. Venkatachalam, Joseph M. Mellichamp and David M. Miller

24. Modeling the design process with Petri nets 447 Andrew Kusiak and Hsu-Hao Yang

25. Neuro-computing and concurrent engineering 465 Cihan H. Dagli, Pipatpong Poshyanonda, and Ali Bahrami

Index 487

Contributors M. Munir Ahmad, Department of Mechanical and Production Engin­eering, University of Limerick, Plassey Technology Park, Limerick, Ireland.

Adedeji B. Badiru, Director, Expert Systems Laboratory, Department of Industrial Engineering, The University of Oklahoma, 202 West Boyd, Suite 124, Norman, OK 73019-0631, USA.

Ali Bahrami, Department of Economics and Management, Rhode Island College, Providence, RI 02908, USA.

Bert Bars, Systems Design Laboratory, Department of Mechanical Engin­eering, College of Engineering, University of Houston, Houston, TX 77204-4792, USA.

David C. Brown, AI Research Group, Computer Science Department, Worcester Polytechnic Institute, Worcester, MA 01609, USA.

J. Browne, Computer Integrated Manufacturing Research Unit, University College, Galway, Ireland.

F. Frank Chen, Department of Engineering Management, College of Engin­eering, The University of Southwestern Louisiana, Lafayette, LA 70504-2250, USA.

Cihan H. Dagli, Intelligent System Center, Department of Engineering Management, University of Missouri-Rolla, Rolla, MO 65401-0249, USA.

Ray A. Daley, Concurrent Engineering Research Center, Drawer 2000, West Virginia University, Morgantown, WV 26506, USA.

Robert E. Douglas, AI Research Group, Computer Science Department, Worcester Polytechnic Institute, Worcester, MA 01609, USA.

Stephen Evans, The CIM Institute, Cranfield Institute of Technology, Cranfield, Bedford, MK43 OAL, USA.

Michael E. Fotta, Concurrent Engineering Research Center, Drawer 2000, West Virginia University, Morgantown, WV 26506, USA.

Satyandra K. Gupta, Department of Computer Science, University of Mary­land, College Park, MD 20742, USA.

Mahendra S. Hundal, Department of Mechanical Engineering, The Univer­sity of Vermont, Burlington, Vermont 05405, USA.

x Contributors

David G. Jansson, President, Sugar Tree Technology, 1035 Pearl Street, Boulder, CO 80302, USA.

Hyeon H. Jo, Department of Industrial Engineering, University of Louis­ville, Louisville, K Y 40292, USA.

Raghu R. Karinthi, Department of Computer Science, University of Mary­land, College Park, MD 20742, USA.

Steven H. Kim, Design Research Institute, 406 Engineering Theory Center, Cornell University, Ithaca, NY 14853, USA.

Andrew Kusiak, Intelligent Systems Laboratory, Department of Industrial Engineering, The University of Iowa, Iowa City, IA 52242, USA.

Angela Locascio, Decision Systems Laboratory, Department of General Engineering, 117 Transportation Building, University of Illinois at Urbana­Champaign, Urbana, IL 61801-2996, USA.

Gary A. Maddux, Director, Center for the Management of Science and Technology, University of Alabama in Huntsville, Huntsville, AL 35899, USA.

Joseph M. Mellichamp, Department of Management Science and Statistics, University of Alabama, Tuscaloosa, AL 35487, USA.

David M. Miller, Department of Management Science and Statistics, Uni­versity of Alabama, Tuscaloosa, AL 35487, USA.

Farrokh Mistree, School of Mechanical Engineering, College of Engineering, Georgia Institute of Technology, Atlanta, GA 30332-0405, USA.

Eoin Molloy, Computer Integrated Manufacturing Research Unit, Univer­sity College, Galway, Ireland.

Gary P. Moynihan, Department of Industrial Engineering, The University of Alabama, Box 870288, Tuscaloosa, AL 35487-0288, USA.

Dana S. Nau, Department of Computer Science, University of Maryland, College Park, MD 20742, USA.

James S. Noble, Department of Industrial Engineering, College of Engineer­ing, University of Washington, Seattle, WA 98195, USA.

Michael J. O'Flynn, Department of Mechanical and Production Engin­eering, University of Limerick, Plassey Technology Park, Limerick, Ireland. Hamid R. Parsaei, Department of Industrial Engineering, University of Louisville, Louisville, KY 40292, USA.

Pipatpong Poshyanonda, Intelligent Systems Center, Department of Engin­eering Management, University of Missouri-Rolla, Rolla, MO 64501-0249, USA.

Contributors Xl

Srinivasa R. Shankar, Institute for Innovation and Design in Engineering, Department of Mechanical Engineering, Texas A&M University, College Station, TX 77843-3123, USA.

Warren Smith, Systems Design Laboratory, Department of Mechanical Engineering, College of Engineering, University of Houston, Houston, TX 77204-4792, USA. William E. Souder, Center for the Management of Science and Technology, University of Alabama in Huntsville, Huntsville, AL 35899, USA.

Mary S. Spann, Center for the Management of Science and Technology, University of Alabama in Huntsville, Huntsville, AL 36899, USA.

William G. Sullivan, Department of Industrial and Systems Engineering, Virginia Polytechnic Institute, Blacksburg, V A 24061, USA.

Fariborz Tayyari, Department of Industrial Engineering, Bradley Univer­sity, Peoria, IL 61625, USA.

Deborah L. Thurston, Decision Systems Laboratory, Department of General Engineering, 117 Transportation Building, University of Illinois at Urbana­Champaign, Urbana, IL 61801-2996, USA.

A.R. Venkatachalam, Department of Management Science and Statistics, University of Alabama, Tuscaloosa, AL 35487, USA.

Hsu-Pin Wang, Department of Industrial Engineering, College of Engineer­ing, University of Iowa, 4130 Engineering Building, Iowa City, IA 52242, USA.

Hsu-Hao Yang, Intelligent Systems Laboratory, Department of Industrial Engineering, University of Iowa, Iowa City, IA 52242, USA.

Masataka Yoshimura, Department of Precision Engineering, Kyoto Univer­sity, Yoshida Honmachi, Sakyo-Ku, Kyoto 606-01, Japan.

Chun Zhang, Department of Industrial Engineering, College of Engineering, University ofIowa, 4130 Engineering Building, Iowa City, IA 52242, USA.

Guangming Zhang, Department of Computer Science, University of Mary­land, College Park, MD 20742, USA.

M. Carl Ziemke, Center for the Management of Science and Technology, University of Alabama in Huntsville, Huntsville, AL 36899, USA.

Preface

In the area of computer-integrated manufacturing (CIM), concurrent engin­eering (CE) has been recognized as the manufacturing philosophy for the 1990s. The mission of CE is to develop high quality products and bring them to the competitive global marketplace at a lower price and in significantly less time. However practicing the CE philosophy requires a large number of design tools during the design phase. This book explores a wide variety of CE topics, including popular tools for making CE a reality.

As technological tasks in the manufacturing environment have become progressively complicated, today's designers are faced not only with increas­ing complexity of product designs but also with a constantly increasing number of sophisticated design tools. Consequently, the entire design process has become very demanding. A large number of highly specialized design tools have to be developed to meet the technological needs of complex design tasks, such as design analysis for manufacturability, assem­blability, cost estimation and engineering analysis. Moreover, these design tools should be integrated into a CAD framework to provide a variety of functions and services to the design community.

Design decisions have to be made early in the product development cycle to have significant impacts on manufacturability, quality, cost, time-to­market, and thus on the ultimate success of the product in the marketplace. This implies that all the information pertaining to a product's life cycle should be used to augment the information for design decisions to achieve the optimized product design for manufacture. This is the underlying philosophy of CE, which entails the concurrent consideration of product design and all its related processes with an organization's manufacturing capabilities and future strategies.

The product development cycle begins with the conception of a need based on the market analysis and research and development (R&D) activ­ities. Conventionally, a series of sequential steps is followed to design the product, identify the process operations, fabricate the parts, assemble the components, and ship the product to the marketplace. Product designers are mainly concerned about their products' performance and functionality and rarely take the process design and/or manufacturing constraints into consideration. This traditional sequential path has not entailed much dialogue between design and downstream value-adding processes except a series of requests for engineering changes. It is true that the cost of

Preface Xlll

incorporating engineering changes increases significantly as the changes are made later in the product's life cycle. This implies that the product designer must be knowledgeable of important manufacturing implications of a design as early as possible along with the structural, functional, and aesthetic requirements.

The philosophy of CE is not entirely novel. Pioneers of the automobile industry, like Henry Ford and Ransom Olds, practiced to a certain extent the philosophy of concurrent engineering. These companies have grown into giant corporations with numerous departments each specialized in a task. This specialized separation contributed to the further development of special functions within the departments. It also caused some detrimental effect to the corporation as a whole, mainly spawned by the lack of communications among those departments. As a result, it now seems to be inevitable for those large corporate organizations to reverse their functional silos by building CE teams.

This book is an attempt to address the central issues associated with concurrent engineering. This volume consists of twenty-five reviewed articles which are grouped into four parts. Part One deals with organizational issues in concurrent engineering and presents six chapters covering various aspects of management's challenge in implementing concurrent engineering. Part Two offers ten chapters regarding proven tools and techniques of concurrent engineering. Part Three contains two chapters on the topic of designing for cost targets set in the marketplace. Current and future research directions of concurrent engineering that encompass artificial intelligence are considered in Part Four.

We are indebted to the following individuals: A. Soundararajan, Hyeon Ho Jo, Lakshmi Narayanan, Jian Dong, Sai S. Kolli, and Patricia Ostaszewski for their assistance and support to make this endeavor possible.

Hamid R. Parsaei William G. Sullivan