Specific Customer Requirements Research Articles

Product design by application of Taguchi's robust engineering using computer simulation

This article discusses the application of Taguchi's robust parameter design (RPD) approach in the design of a motor in a large electrical company in India. There used to be specific customer requirements related to temperature rise and low efficiency of the existing model of motor, which the organisation was unable to meet. Taguchi's parameter design approach was successfully applied to derive the optimum design. Orthogonal arrays were used to design the experiments with 13 control factors, each at 3 levels and 2 noise factors. The experimentation was carried out by a computer simulation and the data were analysed using signal-to-noise ratio method. From the analysis of variance along with main effect plots, the optimum factor level combination for the new product was reached. As per the optimum design, prototype was made and tested with respect to the customer requirements and was found to give satisfactory results for all performance characteristics. This approach has given the result in just 10 weeks' time, whereas the traditional design approach used to take 12 to 15 months to arrive at the optimum design values.

조선에서 대량 맞춤화의 영향

One of the goals of mass customization is to permit changes in the product to meet specific customer requirements without substantially impacting the cost or delivery schedule. In large assembly manufacturing industries, such as shipbuilding and commercial airplane production, customization takes place by changing components and/or modules, sometimes called interim products. Using shipbuilding as a case study, it is possible to study the impact of such changes using mass customization principles on the schedule. In large assembly manufacturing, mass customization changes would cause changes in engineering time and production time, based on the amount of change required by the customization. This work first proposes a structure for implementing mass customization in shipbuilding and then uses simulation of a simplified, theoretical shipbuilding process to evaluate the impacts of various levels of change on delivery performance.

Estimation and Optimization Cutting Conditions of Surface Roughness in Hard Turning Using Taguchi Approach and Artificial Neural Network

One of the most important requirements of part manufacturing is the surface quality. This is so because the most important part is meeting the specific requirements of customers. The surface roughness is a leading indicator of the quality of the machined surface Parts. In the present work in an experimental study to achieve by application of Taguchi method to investigate the effect of three parameters, which known as cutting speeds of (45, 90, and 135 m/min), feed rate of (0.1, 0.2, and 0.3 mm/rev), and cut depth of (0.05, 0.1, and 0.15 mm) on performance measure of surface roughness (Ra). Thus to determine the optimal levels and to analyze the cutting parameter’s effect on the surface finish values by employing different method of Orthogonal array, S/N ratio, analysis of variance (ANOVA). During our work two models for prediction have been used. The first one is known as the method of regression analysis, and the second is the method of Adaptive - Neural Network (ANN) relying on practical results. The achieved results show that the estimation and prediction ability of neural networks is better than the regression analysis. Experimental results confirmed with optimal levels of the machining parameters which are clarified by using Taguchi optimization method. Also, the indicated results of the Taguchi’s method show its ability to improve the process.

Impact of Customization on Delivery Schedules

Effective commercial shipbuilders utilize the principles of mass customization to achieve production efficiencies. This approach can allow new ship designs to satisfy specific customer requirements without substantially impacting the cost or delivery schedule. In part, this is achieved by maintaining learning curve benefits at individual workstations, where similar but nonidentical interim products are produced. The changes to an existing design when employing mass customization can be estimated in design and production effort required to implement the changes. Using a notional ship design and a notional shipyard production process, this study uses Monte Carlo simulation to evaluate the impacts of various levels of change on delivery performance.

Evaluation and decision of products conceptual design schemes based on customer requirements

Within the competitive market environment, understanding customer requirements is crucial for all corporations to obtain market share and survive competition. Only the products exactly meeting customer requirements can win in the market place. Therefore, customer requirements play a very important role in the evaluation and decision process of conceptual design schemes of products. In this paper, an evaluation and decision method based on customer requirements is presented. It utilizes the importance of customer requirements, the satisfaction degree of each evaluation metric to the specification, and an evaluation metric which models customer requirements to evaluate the satisfaction degree of each design scheme to specific customer requirements via the proposed BP neural networks. In the evaluation and decision process, fuzzy sets are used to describe the importance of customer requirements, the relationship between customer requirements and evaluation metrics, the satisfaction degree of each scheme to customer requirements, and the crisp set is used to describe the satisfaction degree of each metric to specifications. The effectiveness of the proposed method is demonstrated by an example of front suspension fork design of mountain bikes.

19.3: Invited Paper: Creative Integration of Christie MicroTiles in Tiled‐Display Applications

AbstractThree case studies are presented in which Christie MicroTiles were creatively integrated into digital signage, entertainment and broadcasting applications. By fulfilling specific customer requirements, Christie MicroTiles offer a high resolution, flexible display technology solution that seamlessly blends within the existing architectural design while providing the best viewing experience.

Spare parts logistics and installed base information

Many of the challenges in spare parts logistics emerge due to the combination of large service networks, and sporadic/slow-moving demand. Customer heterogeneity and stringent service deadlines entail further challenges. Meanwhile, high revenue rates in service operations motivate companies to invest and optimize the service logistics function. An important aspect of the spare parts logistics function is its ability to support customer-specific requirements with respect to service deadlines. To support customer specific operations, many companies are actively maintaining and utilizing installed base data during forecasting, planning and execution stages. In this paper, we highlight the potential economic value of installed base data for spare parts logistics. We also discuss various data quality issues that are associated with the use of installed base data and show that planning performance depends on the quality dimensions.

Sustainable value co-creation through mass customisation: a framework

Adopting sustainability considerations in businesses is no longer a choice for companies. Sustainable value co-creation by customers and producers collectively considering environmental and societal implications is essential to increase value to all stakeholders. Such opportunities are provided by mass customisation which involves producing individually customised products to meet specific customer requirements. During co-design, a key feature of mass customisation, customers and producers interactively determine the specifications of the product to meet customer needs, within the limits defined for the solution space. However, this co-creation of value (through co-design) in mass customisation has thus far been pursued without explicit consideration of environmental and societal implications, both important from a sustainability perspective. This paper presents an in-depth review of the mass customisation model and its potential as a platform for sustainable value co-creation. Approaches to integrate sustainable manufacturing practices for mass customisation, a preliminary model to optimise sustainable value co-creation and directions for further research are also discussed.

The impact of customer-specific requirements on supply chain management

The complexities of being a supplier to motorcar manufacturers, also known as original equipment manufacturers (OEMs), provide an array of challenges to component manufacturers. Customer-specific requirements (CSRs) add to the convolutions of a supplier’s quality management systems when producing components for the various motor manufacturers. The catalytic converter industry (CCI) forms part of the component supply chain in the motor industry. The CCI consists of a plethora of suppliers to produce the catalytic converter. This paper focuses on three of the five main suppliers, namely the ‘monolith substrate manufacturers’, the ‘coaters’, and the ‘canners’. Most OEMs required that critical and strategic suppliers should be ISO/TS 16949:2009 certified. ISO/TS 16949:2009 refers to an internationally recognised specification, specifically adapted for the motor industry. The specification indicates the minimum requirements and also makes provision for additional requirements known as CSRs that can be specified by the OEM.

Application of QFD in product development of a glass manufacturing company in Kazakhstan

PurposeThe purpose of this paper is to demonstrate how quality function deployment can be used to improve the quality of tinted glass produced by a glass manufacturing company in Kazakhstan.Design/methodology/approachData were collected using a combination of Delphi method, unstructured, and semi‐structured survey. Principal component and Pareto analysis were used to identify the ranking of customer wants needed to improve the acceptability of the product in the market.FindingsThe paper suggests that satisfying all customer needs require the deployment of all the technology and resources available to the company. It illustrates the possible courses of action company management can take based on prevailing market conditions.Research limitations/implicationsThe research shows the specific requirements of customers for tinted glass used in industrial settings. From supply chain perspective, downstream customer opinions were used to identify the desired product attributes.Practical implicationsSince no studies to date have been conducted on the glass manufacturing industry in the Central Asian region, this paper could help glass manufacturers in the region to improve their production practices.Originality/valueThe paper is of value to those glass producers interested in the glass manufacturing industry in Central Asia.

Supply chain integration systems by small engineering to order companies

Purpose – The purpose of this paper is to develop a model for overcoming the key barriers to the implementation of supply chain integration systems by small engineering to order (ETO) companies.Design/methodology/approach – Qualitative data from three in‐depth case studies are collected. The three case studies are small UK ETO companies, i.e. manufacturing companies that customise generic product types to meet specific customer requirements and only make these to order.Findings – The paper identifies three key barriers: management awareness of the benefits and implementation challenges of these systems, perceived risk to the business and to information security and intensity of skills needed for their successful implementation. The paper proposes an iterative model that aims at overcoming these barriers.Research limitations/implications – The authors apply the knowledge on technology adoption in the context of small ETO companies to explain the apparent lack of implementation of supply chain integration s...

Understanding business intelligence in the context of healthcare

In today's fast changing healthcare sector, decision makers are facing a growing demand for both clinical and administrative information in order to comply with legal and customer-specific requirements. The use of business intelligence (BI) is seen as a possible solution to this actual challenge. As the existing research about BI is primarily focused on the industrial sector, it is the aim of this contribution to translate and adapt the current findings for the healthcare context. For this purpose, different definitions of BI are examined and condensed in a framework. Furthermore, the sector-specific preconditions for the effective use and future role of BI are discussed.

Adaptive generic product structure modelling for design reuse in engineer-to-order products

In product lifecycle management, the efficiency of information reuse relies on the definition and management of equivalence information between various product data and structure representations. Equivalence information ensures the consistency and traceability of product information throughout the product lifecycle. The sales-delivery process of engineer-to-order (ETO) products presents a great potential for design reuse, i.e. the reuse of previously validated design solutions in the design of new product variants according to customer-specific requirements. A product family data model that focuses on the interdependencies of viewpoints on information will therefore improve the setup of design reuse mechanisms such as modularity. This paper describes the Adaptive Generic Product Structure (AGPS), a dynamic structure-based product family modelling approach that enables the systematic aggregation of product variants and their distinctive components. The purpose of the approach is to capitalize on the expanding component variety developed within previous product variants as early as the sales lead phase of the sales-delivery process, in order to reduce customer-driven design costs and shorten lead-times. An illustrative example based on the aerospace industry is presented.

Improving cost effectiveness in an existing product line using component product platforms1

Previously, we introduced a new method for improving commonality in a highly customised, low volume product line using component product platforms. The method provides a bottom-up platform approach to redesign family members originally developed one-at-a-time to meet specific customer requirements. In this paper, we extend the method with an activity-based costing (ABC) model to specifically capture the manufacturing costs in the product line, including the cost associated with implementing a platform strategy. The valve yoke example is revisited in this paper, the customised ABC model is defined, two design strategy alternatives are addressed, and the new method is used to determine which alternative is better at resolving the trade-off between commonality, total cost, and product performance. The proposed method shows promise for creating a product platform portfolio from a set of candidate component platforms that is most cost-effective within an existing product line. The proposed method allows for arbitrary leveraging as it does not rely solely on the traditional vertical, horizontal, or beachhead strategies advocated for the market segmentation grid, and this is especially beneficial when applied to an existing product line that was developed one-at-a-time time such that artefact designs are inconsistent from one to another.

Standardized infotainment software platform

Microsoft’s “MS Auto” is one of the open, standardized software platforms in the automotive infotainment sector that are currently under discussion. The software manufacturer describes how modular the basic software is and how flexibly it can be developed with OEMs and suppli- ers to meet specific customer requirements. The first of many service applications is scheduled to go to market this month: with “Live Search for Devices”, the user is able to access current information on so-called points of interest (POIs) live in the vehicle.

Machine configuration analysis using multi-instance modelling

The design practices used within small special purpose machine design companies often mean that they produce machines that are tailored for the specific requirements of a customer. This can lead to an unnecessarily large family of machines, supported with large sets of change parts. However, the resources are often not available to investigate the design fully and obtain an understanding of its functionality. This paper proposes an approach that offers both the ability to visualize and explore the space of feasible design solutions and the potential to rationalize designs.

A Method to Improve Platform Leveraging in a Market Segmentation Grid for an Existing Product Line

This paper describes a method for improving commonality in a highly customized low volume product line whose members were originally developed one at a time to meet specific customer requirements. Rather than focusing on redesign of the entire product line, which can often be cost prohibitive, the method is part of a strategy to redesign a limited set of component parts that have the highest potential for cost savings. The method involves a four-step methodology: (1) determine an optimal component solution for each member artifact of an existing market segment grid, (2) test the feasibility of using each optimal component as a platform for the other artifacts, (3) formulate an optimization problem around the feasibility statistics whose solution is a product platform portfolio, and (4) solve the optimization problem for the platform portfolio that can span the existing market segment grid most cost effectively. The proposed method is applied to an example involving the redesign of actuator mounting yokes for an existing set of valves that are used in nuclear power plants. The methodology shows promise for determining a product platform mix that maximizes cost effectiveness yet meets performance requirements.

Testing an Interrelationship Matrix-Based Method Designed for Assisting in e-Marketplace Selection

Over the past decade an extraordinary increase has been experienced in the practice of B2B online trading. Portals, hubs, brokerages, and in particular electronic marketplaces (e-marketplaces) have emerged as everyday channels for business trading. The decision process behind joining such an e-marketplace, and evaluating which particular ones offer the best mix of services for a particular business's requirements, is not a straightforward undertaking. There are a host of variants on offer, numerous different membership schemes, service ranges, functionality types, product ranges, and technology platforms in existence, so it can prove to be a very confusing process for any prospective company contemplating joining. In earlier work (Hopkins and Kehoe 2006) an interrelationship matrix-based method was developed for evaluating, and rating, the appropriateness of a range of services offered by e-marketplaces in comparison with specific customer requirements. The system was designed to be used not only for evaluating existing e-marketplaces, but also in assisting with the design of new ones, and was intended be of equal value to both buyers and sellers. This paper now describes how the developed system has been tested, in two case study environments, in order to gauge its suitability for e-marketplace evaluation at both component level and sector level.

Optimal process design of two-stage multiple responses grinding processes using desirability functions and metaheuristic technique

Two-stage grinding processes in mass-scale manufacturing unit are usually too complex to optimize, due to large number of interacting process variables, between and within the stages. Furthermore, statistical design of experiment techniques, such as factorial design, fractional factorial and response surface design by sequential experimentations, to determine the exact optimal process design for the overall interdependent two-stage system, are sometimes too difficult to implement, if not impossible. In this context, considering each stage in isolation and determining individual optimal conditions may not result in an optimal process design, when the entire two-stage system is considered. The aim of this study is to apply empirical modelling technique based on direct observations, for prediction of a two-stage grinding process behaviour having multiple response characteristics of continuous variables, and determine overall optimal process design to meet the specific customer requirements. In order to achieve the above goal, the study proposes an integrated approach using multivariate regression, desirability function, and metaheuristic search technique. Three different metaheuristic search techniques, viz. real-coded genetic algorithm, simulated annealing, and a modified Tabu search based on novel Mahalanobis multivariate distance approach to identify Tabu moves, are employed to determining near optimal path conditions for an industrial case study of two-stage CNC grinding (honing) optimization problem, having various process and variable constraints. Computational study results based on different metaheuristics, and applied on the same two-stage optimization problem, show that the modified Tabu search performs better and also offer opportunities to be extended for other multi-stage metal-cutting process optimization problems.

Exploiting the Order Book for Mass Customized Manufacturing Control Systems With Capacity Limitations

Customer specific requirements is one of the key drivers in a supply chain strategy based on mass customization. At the same time there are intense pressure on price and short delivery lead times providing a complex environment for managing the supply chain. The complexity can be reduced by introducing the concept of a customer order decoupling point (CODP). The CODP separates the supply chain into two key processes that can be categorized as make-to-order (MTO) and make-to-stock (MTS) and constitutes the two key building blocks of a system based on the mass customization concept. The dynamic properties of the MTS environment have been extensively researched using the automatic pipeline-, inventory-, and order-based production control system (APIOBPCS) archetype. In contrast to MTS systems, the customer facing MTO process, which is usually exposed to a more volatile demand stream suitable for an agile strategy, is less well investigated. Agility does, however, frequently not mean that infinite capacity is available but that there is some surplus capacity available and that the capacity can be adapted to the customer requirements in certain time frames. When the adaptation is not instant but requires some time to take effect the delay creates a dynamic backlog represented by the order book which affects the delivery lead time. Since controlling lead times is a key factor in providing reliable delivery promises an order book control logic is introduced. It is also shown that the new MTO model of the customer facing part of a mass customization system is an extension to the well established APIOBPCS framework