Function-based benchmarking to identify competitor-based lightweight design potentials

Abstract

The development of lightweight design solutions can have many reasons. Examples are resource efficiency (e.g. automotive industry, aerospace industry), the reduction of accelerated mass (e.g. transport) or comfort reasons (e.g. hand-held devices). The weight of a product is defined essentially in the early phase of product development. In the subsequent development phases, comparatively only minor weight savings can be achieved. Therefore, the integration of lightweight design methods into the early phase is advisable.One possibility of supporting the product developer in the early design phase is the use of benchmarking. However, product benchmarking is often based on components. The abstract description of a product as a whole of its functions offers the possibility of detachment from existing component structures. This strategy is subject to the Extended Target Weighing Approach (ETWA), which represents a function-based lightweight design method. After identifying functions that are associated with too high mass, costs and CO2 emissions, they are methodically transferred into new concept ideas that are lighter, cheaper and more ecological.The contribution discusses an adaption of the ETWA in order to identify competitor-based lightweight design potentials and to support the generation of concept ideas. Therefore, the existing ETWA is modified in order to be able to compare previously defined competitor products at functional level with the own product. Assuming that the benchmark product fulfils the same functions under the same requirements, a function portfolio, which is necessary for the ETWA, can be used to quickly classify the own product in competition and to derive competitor-based lightweight design potentials. However, this procedure needs to be adapted if the benchmark product fulfils functional requirements better or worse than the own product. The paper describes how the function portfolio can be systematically expanded to be able to make early assessments of the product’s lightweight design potential.