Early Product Development Research Articles

Exploration of Simulation-Driven Support Tools for Sustainable Product Development

Global society is encountering many challenges such as climate change, resource depletion, etc., which comes with a set of challenges and opportunities for businesses. Applied research in operational tools and methods that support sustainable product- and service systems innovation, aims to strengthen businesses to overcome these challenges. In recent years, several tools and methods have been developed in the sustainable product development field with focus on modelling and digitalization. This paper explores how sustainability has been integrated in modelling and simulation, and presents results from a literature review with the purpose of highlighting opportunities and challenges in the field. Furthermore, an initial model-based engineering support toolbox (MBE) is presented, with focus on support tools for socio-ecological sustainability integration in the early product development stages.

Method for Design of Human-industrial Robot Collaboration Workstations

In order to fully utilise a 3D simulation software capable of evaluating hand-guided human-industrial robot collaborative (HIRC) work tasks, there is a need of a HIRC design process for early production development stages. This paper proposes a HIRC design method that uses the possibilities of the demonstrator software in the HIRC workstation design process. The method is based on Pahl and Beitz's engineering design method; it interprets all their phases and activities into HIRC design-specific ones.

An Improved Method of Predicting Extinction Coefficients for the Determination of Protein Concentration.

Concentration determination is an important method of protein characterization required in the development of protein therapeutics. There are many known methods for determining the concentration of a protein solution, but the easiest to implement in a manufacturing setting is absorption spectroscopy in the ultraviolet region. For typical proteins composed of the standard amino acids, absorption at wavelengths near 280 nm is due to the three amino acid chromophores tryptophan, tyrosine, and phenylalanine in addition to a contribution from disulfide bonds. According to the Beer-Lambert law, absorbance is proportional to concentration and path length, with the proportionality constant being the extinction coefficient. Typically the extinction coefficient of proteins is experimentally determined by measuring a solution absorbance then experimentally determining the concentration, a measurement with some inherent variability depending on the method used. In this study, extinction coefficients were calculated based on the measured absorbance of model compounds of the four amino acid chromophores. These calculated values for an unfolded protein were then compared with an experimental concentration determination based on enzymatic digestion of proteins. The experimentally determined extinction coefficient for the native proteins was consistently found to be 1.05 times the calculated value for the unfolded proteins for a wide range of proteins with good accuracy and precision under well-controlled experimental conditions. The value of 1.05 times the calculated value was termed the predicted extinction coefficient. Statistical analysis shows that the differences between predicted and experimentally determined coefficients are scattered randomly, indicating no systematic bias between the values among the proteins measured. The predicted extinction coefficient was found to be accurate and not subject to the inherent variability of experimental methods. We propose the use of a predicted extinction coefficient for determining the protein concentration of therapeutic proteins starting from early development through the lifecycle of the product.LAY ABSTRACT: Knowing the concentration of a protein in a pharmaceutical solution is important to the drug's development and posology. There are many ways to determine the concentration, but the easiest one to use in a testing lab employs absorption spectroscopy. Absorbance of ultraviolet light by a protein solution is proportional to its concentration and path length; the proportionality constant is the extinction coefficient. The extinction coefficient of a protein therapeutic is usually determined experimentally during early product development and has some inherent method variability. In this study, extinction coefficients of several proteins were calculated based on the measured absorbance of model compounds. These calculated values for an unfolded protein were then compared with experimental concentration determinations based on enzymatic digestion of the proteins. The experimentally determined extinction coefficient for the native protein was 1.05 times the calculated value for the unfolded protein with good accuracy and precision under controlled experimental conditions, so the value of 1.05 times the calculated coefficient was called the predicted extinction coefficient. Comparison of predicted and measured extinction coefficients indicated that the predicted value was very close to the experimentally determined values for the proteins. The predicted extinction coefficient was accurate and removed the variability inherent in experimental methods.

Systematic Process Chain Creation for CFRP Structures in Early Product Development Stages

A planning method is presented which allows to systematically building process chains based on a preliminary design of composite structures. The method utilises the specific sequences of procedural steps that occur in the production of carbon fibre reinforced plastic (CFRP) structures, to build sub process chains for each component of the structure. Process restrictions are considered to evaluate the suitability of different production processes. To obtain the whole process chain of the structure, different joining methods are applied in addition to combine the components and its sub process chains. The results of the presented method are used in an overarching development procedure to investigate resulting impacts on the solution. Possible impacts could be the production costs or the material characteristics.

Molecular insights into the formation of drug-monoacyl phosphatidylcholine solid dispersions for oral delivery

Phospholipid-based formulations provide a key technology to formulate poorly water-soluble drugs. A recent interest has been in using phospholipids with a high content of monoacyl phosphatidylcholine (monoacyl PC) due to its ability to form mixed micelles of mono- and di-acylphospholipids upon aqueous dispersion. The present work focused on binary drug- monoacyl PC systems (at about equimolar ratio) with respect to screening of solid dispersion feasibility. It was tested whether or not a molecular rule of thumb can predict the desirable absence of drug crystallinity in the products. Subsequently, molecular simulations were performed to gain a better understanding of molecular association between drugs and monoacyl PC. Finally, the glass-forming ability (GFA) of pure drugs was considered with respect to solid dispersion formation. All products were obtained from a solvent-evaporation process and subsequent analysis of potential drug crystallinity was measured with X-ray powder diffraction and differential scanning calorimetry. Molecular simulations were making use of a Monte Carlo algorithm and molecular properties relevant for GFA were calculated. As a result, the dataset of 28 drugs confirmed an earlier proposed empirical rule that enthalpy of fusion and logP were important for solid dispersion formation, while some relevance was also evidenced for drug energies of frontal orbitals. Interestingly, the Monte Carlo simulations revealed several likely associations between drug and phospholipid rather than a well-defined single complex formation. However, drug-excipient interactions were still pivotal, since GFA of pure drug could not predict solid dispersion formation. These findings led to important molecular insights into binary solid dispersions of drug and monoacyl PC, which can guide formulators in early drug product development.

Product development in higher education marketing

Purpose – During the last 20 years or so the changing environment in which universities operate has meant that commensurately more emphasis has been placed on marketing principles. In light of this emphasis, it is perhaps a little surprising that relatively little attention has been directed towards the processes by which universities develop their products, and the extent to which module and programme development processes are market informed and customer oriented. The paper aims to discuss these issues. Design/methodology/approach – This paper adopts a case study methodology to examine early stage new product development (NPD) processes in UK higher education (HE) institutions. Findings – The findings reveal some potential shortcomings in the early stages or fuzzy front end of NPD in universities. In particular, there appears to be a lack of staff incentives, financial or otherwise, to innovate and introduce new ideas relating to module and programme development. Research limitations/implications – The issue of sample bias needs to be factored into however, given that these six institutions proactively engaged with this process possibly indicating a recognition or impetus on their part to learn how new programme development could be better understood. That the vast majority of the sample were teaching dominant institutions is also an interesting consideration as this will have an impact on the imperative to improve new programme development processes in an increasingly competitive HE environment. Practical implications – The paper discussed some of the implications for the corporate governance structures of universities and also emphasized the need for cultural change. In this respect, one of the biggest challenges facing universities is to break down or erode the barriers, which exist between academic and non-academic staff and create a “level playing field”. Originality/value – As the authors enter an era of higher student fees, the question of value for money combined with an associated increase in the expectations of university stakeholders, will have potentially quite marked implications for universities. Accordingly, the future viability of some degree programmes and, perhaps, even the long-term survival of some institutions may be dependent on the adoption of the sort of changes identified in this paper.

An investigation of low ergonomics risk awareness, among staffs at early product development phase in Malaysia automotive industries

Currently there are many automotive companies still unable to effectively prevent consequences of poor ergonomics in their manufacturing processes. This study purpose is to determine the surrounding factors that influence low ergonomics risk awareness among staffs at early product development phase in Malaysia automotive industry. In this study there are four variables, low ergonomic risk awareness, inappropriate method and tools, tight development schedule and lack of management support. The survey data were gathered from 245 respondents of local automotive companies in Malaysia. The data was analysed through multiple regression and moderated regression using the IBM SPSS software. Study results revealed that low ergonomic risk awareness has influenced by inappropriate method and tool, and tight development schedule. There were positive linear relationships between low ergonomic risk awareness and inappropriate method and tools, and tight development schedule. The more inappropriate method and tools applied; the lower their ergonomic risk awareness. The more tight development schedule is the lower ergonomic risk awareness. The relationship between low ergonomic risk awareness and inappropriate method and tools depends on staff's age, and education level. Furthermore the relationship between low ergonomic risk awareness and tight development schedule depends on staff's working experience and number of project involvement. The main contribution of this paper was identified the number of factors of low ergonomics risk awareness and offers better understanding on ergonomics among researchers and automotive manufacturer's employees during product development process.

CFD-Simulations in the Early Product Development

A growing range of products shifts the product development in focus. Especially the early design phase defines the costs and quality. Thus, to ensure the quality of the products, different concepts are designed and evaluated. A tool for the evaluation of the different designs is simulation due to being fast and cost efficient. But simulation in the early phase still remains a problem. This results of the basic and fast changing concepts, which take too much effort to be converted into a simulation model. To get around these circumstances, we propose a method for an online modelling in the design process. Instead of defining the simulation model at once, the method modificates the simulation model during simulation run time. Furthermore, the functionality is shown in a CFD simulation using the meshless Smoothing Hydrodynamics method. Using the GPU to achieve real-time simulation, the method allows a WYSIWYG design-simulation development helping to raise the quality of products.

Robust Design of Aero Engine Structures: Transferring form Error Data When Mapping Out Design Spaces for New Turbine Components

In aerospace modeling and simulation, nominal geometries are norm. However, it has been shown that form error, or irregular deviations in geometry, aggravates thermal stresses, which in turn reduces product life. While form error can be measured on manufactured products using 3D laser scanners, a simulation infrastructure is needed to analyze its effects on aerodynamic, structural and thermal performance. Moreover, in early product development phases, before manufacturing has begun, form error data is not available. This paper describes a method for including form error data in mainstream simulation activities. The suggested method works by creating parametric CAD-models to accommodate form error. There are two main benefits of this method. Firstly, it enables proactive robustness simulations where substantial design changes can be tested and evaluated. Secondly, it enables the mapping of data from previous products onto new designs, which means that robustness analyses can be performed in earlier design phases. To demonstrate this capability, a case study shows how a robust optimization scheme using genetic algorithms can improve product robustness to form error. The results show that form error have effects of the same order of magnitude as key design parameter changes. This finding underlines the importance of performing form error analyses in exploratory early design phases.

Prediction of mixed-mode cohesive fatigue strength of adhesively bonded structure using Mode I data

A cohesive zone model is presented for analyzing the fatigue life of an adhesive joint in the range of 104–106 load cycles. The parameters of the model are derived from Mode I double cantilever beam experiments. Fatigue experiments with adhesively joined components from the automotive industry are performed, and the results from the experiments are compared to the results of simulations. The error in the predicted fatigue strength is of the same order as the statistical deviation of the fatigue experiments, indicating that the simulation method produces acceptable predictions of the fatigue strength for applications in e.g. early product development.

A systematic adaptable platform architecture design methodology for early product development

ABSTRACTAdaptable product platforms, which express a platform's modular and scalable combinations, are well suited for representing the complex mechanical composition of series products. Current adaptable platform design methods, however, still have certain limitations, such as an insufficient basis for functional modules classification, unstable classified results due to experience-based thresholds, and limited scope because of a reliance on performance mathematical models. Given the hierarchical model of adaptable platform architecture, a two-stage methodology for adaptable platform design based on quantitative indices and fuzzy arithmetic is proposed in this paper. In the first stage, the variety index and change propagation class are applied to cluster the acquired modules into standardised and flexible ones using visualised fuzzy clustering. In the second stage, common and scalable indices based on product lifecycle factors are developed in order to subdivide the components within flexible modules into common and scalable types. Trapezoidal fuzzy arithmetic is introduced in these two stages to deal with the imprecise, approximate, or qualitative linguistic assessments. The proposed approach is demonstrated using the concrete spaying machine family as an exemplary product. Sensitivity analysis showed that the results were robust for the disturbance of design variables. Comparisons with other studies’ results point to a higher stability, lower requirements for basic data, and a general effectiveness of the proposed method.

Pig manure treatment with housefly (Musca domestica) rearing – an environmental life cycle assessment

The largest portion of a product’s environmental impacts and costs of manufacturing and use results from decisions taken in the conceptual design phase long before its market entry. To foster sustainable production patterns, applying life cycle assessment in the early product development stage is gaining importance. Following recent scientific studies on using dipteran fly species for waste management, this paper presents an assessment of two insect-based manure treatment systems. Considering the necessity of manure treatment in regions with concentrated animal operations, reducing excess manure volumes with the means of insects presents a potentially convenient method to combine waste reduction and nutrient recovery. An analytical comparison of rearing houseflies on fresh and pre-treated pig manure is reported with reference to agricultural land occupation, water and fossil depletion potential. Based on ex-ante modelled industrial scale rearing systems, the driving factors of performance and environmentally sensitive aspects of the rearing process have been assessed. Expressed per kg manure dry matter reduction, the estimated agricultural land occupation varied between 1.4 and 2.7 m2yr, fossil depletion potential ranged from 1.9 to 3.4 kgoil eq and the obtained water depletion potential was calculated from 36.4 to 65.6 m3. System improvement potential was identified for heating related energy usage and water consumption. The geographical context and the utility of the co-products, i.e. residue substrates and insect products, were determined as influential variables to the application potential of this novel manure treatment concept. The results of this study, applied at the earliest stages of the design of the process, assist evaluation of the feasibility of such a system and provide guidance for future research and development activities.

Directions for instilling economic and environmental sustainability across product supply chains

Although sustainability is a frequent topic in product development literature, the often segmented and narrow scope of prior works limits the potential benefits of the industrial application of methods, models, and tools developed by the research community. The work herein has the goal of coalescing relevant, recent work supporting the economic and environmental aspects of sustainability for early stage product development by focusing on the interfaces between product design and supply chain operations. This discussion is intended to highlight past accomplishments and to be a call for action to the research community for the development of integrated methods, models, and tools to support sustainability initiatives across product supply chains. A literature review spanning product design, manufacturing, and supply operations management reveals several near-term research needs, which are organized into four highly promising foci addressing product architecture engineering, assembly/disassembly operation modeling, manufacturing process modeling, and joint optimization of life cycle activities. Finally, potential avenues for future collaborative research are presented and discussed.

Large-Scale Needfinding: Methods of Increasing User-Generated Needs From Large Populations

Understanding user needs and preferences is increasingly recognized as a critical component of early stage product development. The large-scale needfinding methods in this series of studies attempt to overcome shortcomings with existing methods, particularly in environments with limited user access. The three studies evaluated three specific types of stimuli to help users describe higher quantities of needs. Users were trained on need statements and then asked to enter as many need statements and optional background stories as possible. One or more stimulus types were presented, including prompts (a type of thought exercise), shared needs, and shared context images. Topics used were general household areas including cooking, cleaning, and trip planning. The results show that users can articulate a large number of needs unaided, and users consistently increased need quantity after viewing a stimulus. A final study collected 1735 needs statements and 1246 stories from 402 individuals in 24 hr. Shared needs and images significantly increased need quantity over other types. User experience (and not expertise) was a significant factor for increasing quantity, but may not warrant exclusive use of high-experience users in practice.

Assessing sustainability and value of manufacturing processes: a case in the aerospace industry

In spite of the growing awareness and significance of accounting for sustainability aspects in product development, design decision support is still immature in this end compared to other decision support areas, such as product performance and manufacturability. This paper proposes a novel decision support method that combines qualitative sustainability assessment techniques with a quantitative analysis, without losing transparency and still covering a full sustainability perspective. The aim is to contribute to an understanding for how to enable value assessment of sustainability issues already in early product development situations. The method, named Sustainability Assessment and Value Evaluation, combines two qualitative sustainability assessment techniques with a quantitative Net Present Value analysis based on alternative future scenarios. A case study, related to the development of a new high-temperature aero-engine component, illustrates both how the sustainability assessment identifies hotspots and clarifies potential sustainability consequences for a new product technology, and how Net Present Value is used to assess alternative solution strategies based on the hotspot, to facilitate early stage decision-making in design. The paper argues that the method serves two main purposes: i) to make sustainability consequences more concrete and understandable during design concept selection activities, rather than to have an exact measurement, and ii) to simplify and prioritize, systematically asking what is important in the sustainability analysis, rather than to reduce the sustainability problem. The method allows undertaking the sustainability assessment in a more structured way than what happens today in preliminary design, through scenario building based on socio-ecological assessments, including back-casting to cover the longer time perspective. In addition, the Sustainability Assessment and Value Evaluation-method provided the design team of a means for displaying sustainability consequences on an equal basis with other decision support tool results.

Automatic product conceptual optimization based on object-oriented performance components and graph grammars

Compared with parameter uncertainty, model form uncertainty is difficult and expensive to alleviate due to limited design information at the early product development stage, but it may have significant impacts on performances of complex products. In this article, an optimal configuration of performance models based on graph grammars is presented to seek a solution for simultaneously resolving model form and parameter uncertainties at the product conceptual design stage. First, a hybrid performance component database is built using object-oriented modeling method taking account of the model evolution history; second, a function structure model is taken as the reference template to dynamically generate system models driven by graph grammars rules derived from product configuration and layout design and matching of component interface parameters with flows in the function structure model; third, a meta-model-based method is adopted to transform the performance component graph into mathematical models including the optimization objective function and associated constraints; fourth, an optimization procedure combined with performance simulation framework is invoked to solve the optimization problem. The final result is a solution that includes the optimal configuration of performance components and optimal design parameters, and thus, much larger design space than traditional mere optimization of design variables is explored. The method is tested by the optimal conceptual design of tank movement systems, and comparisons of deign results obtained by the proposed method and traditional optimization method are conducted to illustrate the efficacy of the method.

Tactile friction of topical formulations.

The tactile perception is essential for all types of topical formulations (cosmetic, pharmaceutical, medical device) and the possibility to predict the sensorial response by using instrumental methods instead of sensory testing would save time and cost at an early stage product development. Here, we report on an instrumental evaluation method using tactile friction measurements to estimate perceptual attributes of topical formulations. Friction was measured between an index finger and an artificial skin substrate after application of formulations using a force sensor. Both model formulations of liquid crystalline phase structures with significantly different tactile properties, as well as commercial pharmaceutical moisturizing creams being more tactile-similar, were investigated. Friction coefficients were calculated as the ratio of the friction force to the applied load. The structures of the model formulations and phase transitions as a result of water evaporation were identified using optical microscopy. The friction device could distinguish friction coefficients between the phase structures, as well as the commercial creams after spreading and absorption into the substrate. In addition, phase transitions resulting in alterations in the feel of the formulations could be detected. A correlation was established between skin hydration and friction coefficient, where hydrated skin gave rise to higher friction. Also a link between skin smoothening and finger friction was established for the commercial moisturizing creams, although further investigations are needed to analyse this and correlations with other sensorial attributes in more detail. The present investigation shows that tactile friction measurements have potential as an alternative or complement in the evaluation of perception of topical formulations.

Utilizing end User Input in Early Product Development

A critical component in the development of new products is the inclusion of input from future users. This input is invaluable in defining and understanding the technical/functional needs that the product must fulfill. This input also serves as a guide to less tangible, but often as important, attributes such as satisfaction, acceptability or aesthetics. Along with the functional needs, these play an important role in the ultimate success of a product. This is particularly true in the case of assistive products where functionality is critical but the treatment of non-functional needs can play a large role in a device's acceptability, the stigma associated with it and reducing rates of abandonment. This paper will review the product development challenges faced by producers of assistive technology products. It will then describe results from two early studies which may provide new approaches to meeting these challenges. The first is an investigation of the accuracy of user input when it is provided based on different representations of a design (such as sketches, renderings or models) that are commonly available at various stages of the design process. A better understanding of this input will allow designers to focus more on the components of it that are more likely to accurately represent users’ opinion of a finished product. The second is an investigation into the use of augmented reality to facilitate usability testing of design concepts.

Conceptualizing ReX for Aggregating End-of-life Strategies in Product Development

Efforts towards a circular economy are accelerating and gaining more attention. Since product's lifecycle is mostly determined during early product development phases, it is crucial to support those phases with explicit strategic directions. This paper examines the possibility to aggregate various definitions of end-of-life (EoL) strategies in a visually compelling way. We propose a taxonomy for communication between multidisciplinary product development teams using ReX, an abbreviation for alternative EoL strategies starting with prefix ‘Re’, such as reduce, reuse, repurpose, repair, remanufacture, recycle, and recover. We construct our taxonomy based on a) EU Waste Directive, b) a systematic literature review, and c) relevant theoretical constructs. Then we discuss whether ReX allows assessing potential EoL alternatives, and steering the product development efforts. Finally, we suggest ReX for supporting decision-making when several stakeholders are involved, common language is sought for, and significant EoL related decisions are made at the early phases.

Assessment of Energetic Leverage Effect Using a Virtual Prototype

The so-called energetic leverage effect describes the influence of manufacturing strategies on the energy balance in the use-phase of tribological components in technical products. The objective of the presented approach is to consider this effect in early phases of product engineering of construction and agriculture machinery with the help of a prospective life-cycle-assessment.In the approach a virtual prototype is developed. This enables a quantitative assessment of the use-phase of a product in early product development phase. The virtual prototype simulates the behavior of considered components, in this case gear wheels, and the effect on the energy consumption of the whole machine in its use-phase. In different simulation runs gear wheels with differences in surface quality, tribological characteristics but also in energy consumption during their production-phase resulting from different manufacturing strategies are compared. The life-cycle-assessment ensures that energy consumption of all life cycle phases is included and optimized.