Entire Product Development Process Research Articles

Measuring the Impact of Augmented Prototyping Systems in Co-Design Activities

In recent years, research reached a very high level of development and validation of augmented prototyping systems in support of collaborative design activities. However, there is still great scepticism in companies when it comes to integrating these new technologies within a consolidated working model. Among others, the main barrier to overcome concerns the lack of understanding of the impact of AR systems on the key objectives of a business, such as improving its efficiency and revenue. For this reason, this paper aims to quantify these indicators by observing the technological impact not on a single design session but on an entire product development process, during which the aspects related to its integration are also considered. Thanks to the collaboration with a design agency, it was possible to compare parameters such as the lead time, number of iterations, person-hours and costs between two similar and realistic projects in which only one was supported by projection-based AR technology.

An Improved Explicit Reference Modeling Methodology for Parametric Design

The use of formal methodologies for parametric modeling has been shown to significantly improve the robustness and reusability of feature-based CAD models, particularly in response to changes, which has implications in the entire product development process. One of these methodologies, explicit reference modeling, has been proven particularly effective in design scenarios involving complex geometry. However, certain design situations may lead to different interpretations of the methodology and the possibility of drastically different modeling alternatives at certain points in the process, some of which can become inefficient and hinder reusability. In this paper, we analyze the explicit reference modeling methodology through the lens of CAD quality and identify the key aspects that may lead to underperformance. We propose a new improved version of the methodology that maximizes model robustness and flexibility, while reducing regeneration time and intrinsic variability. Five modeling aspects are considered: the internal structure of functional geometries, subtractions, combination operations, replication features, and localized modifications. We validate our proposal through an empirical study in which 96 modeling paths for a parametric model were analyzed.

Business Operation Using Identification of Product in Context of Developing Countries Emphasizing Nepal

Purpose: With the emergence of Online Purchasing, Product Identification is an essential model that allows the seller to add a product to a decentralized platform such as Blockchain and allows buyers to purchase the product from the decentralized platform. Fraud products, counterfeiting, and duplication are the current marketplace's major problems. This aims to develop a system for verifying product identification with their information, ownership, and validity detail. Design/Methodology/Approach: The proposed system applies Extreme Programming (XP) to reduce the risk caused by the fixed-time project using new technology and thus the final project could be delivered in time. Solidity and metamask being new technologies were unstable and to adopt the changes, the agile development model was the best through ABI and the bytecode are deployed into the Ethereum Blockchain. Findings/Result: This system maintains the buyers, sellers, and product details in a decentralized blockchain platform. This research details the entire product development process from planning, analysis, design, implementation, and testing for systematic online purchasing. Verifying the product ownership and its information to get the original product is the major difficulty in this space, but this research systematically solves some of those problems. This signifies an improvement in the current centralized way of purchasing goods online, where the information remains as it is entered by the seller while listing the product in Nepal and developing countries context. Originality/Value: The study has produced a decentralized, reliable, secure, and third-party independent marketplace for buying and selling products for fraud free market. Paper Type: Research paper

Triple bottom line performance of manufacturing Industry: A value engineering approach

Circular economy is a growing area of research because it replaces the end-of-life concept and works towards cleaner production and sustainable development. Similarly, value engineering is a strategy for exploring non-valued added costs and performance of the entire product development process. In these regards, study proposes a value engineering methodology that integrates circular economy concepts to fulfill sustainable product development objectives. The article aims to implement value engineering and circular economy concepts and develop a cost-effective product with reduced power consumption, CO2 emissions and minimum wastage of raw material. The study reveals that product development costs were reduced by up to 23.91% and productivity of barrels per day increased by around 150%. Also, power consumption is reduced by 100 KVA, CO2 emissions by 1825.91 tons/year, water consumption by 96% and total electricity requirement are reduced to 25%. These results may improve social, economic and environmental performance of the organizations. The proposed methodology is applied in a case study of ABC barrel manufacturing organization with circular economy perspective. More studies may be carried out to generalize the findings of the proposed case study. However, these findings may be useful for researchers and industrialists in implementing value engineering and circular economy effectively.

Quality 4.0 and Cognitive Engineering Applied to Quality Management Systems: A Framework

In order to create high-quality products, quality engineering must be integrated across the entire product development process. To accomplish the ultimate goal, innovative approaches are required, and a Quality Management System-QMS is imperative to standardize all processes. All business areas depend on people and processes, but quality is especially dependent on them. A QMS can benefit from the application of Quality 4.0—Q4.0 and Cognitive Engineering—CE aspects to reduce the workload and cognitive capacity required from QMS specialists, using these technologies to tackle long-standing quality concerns and to re-optimize to deliver creative solutions. The decision to implement a QMS based on Q4.0 technologies is difficult to take due to the challenge that is to automatize dispersed activities. The purpose of this paper is to develop a framework that aids in the application of a Q4.0 QMS. The relationship between quality management practices and Industry 4.0 technologies that improve quality are deeply studied and connected with CE practices to develop an advanced framework, that makes it easier to overview all the dispersed activities within the manufacturing environment gathered as one, and simplify the application of new technologies to the QMS activities. The proposed framework was developed as result of this study.

Knowledge-Based Adaptation of Product and Process Design in Blisk Manufacturing

Abstract Early and efficient harmonization between product design and manufacturing represents one of the most challenging tasks in engineering. Concepts such as simultaneous engineering aim for a product creation process, which addresses both, functional requirements as well as requirements from production. However, existing concepts mostly focus on organizational tasks and heavily rely on the human factor for the exchange of complex information across different domains, organizations, or systems. Nowadays product and process design make use of advanced software tools such as computer-aided design, manufacturing, and engineering systems (CAD/CAM/CAE). Modern systems already provide seamless integration of both worlds in a single digital environment to ensure a continuous workflow. Yet, for the holistic harmonization between product and process design, the following aspects are missing: (i) the digital environment does not provide a complete and data consistent digital twin of the component; this applies especially to the process design and analysis environment, (ii) due to the lack of process and part condition data in the manufacturing environment, an adaptation of product and process design for a balanced functionality and manufacturability is hindered, and (iii) systematic long-term data analytics across different product and process designs with the ultimate goal to transfer knowledge from one product to the next and to accelerate the entire product development process is not considered. This paper presents an exploration concept which couples product design (CAD), process design (CAM), process simulation (CAE), and process adaptation in a single software system. The approach provides insights into correlations and dependencies between input parameters of product/process design and the process output. The insights potentially allow for a knowledge-based adaptation, tackling well-known optimization issues such as parameter choice or operation sequencing. First results are demonstrated using the example of a blade integrated disk (blisk) .

Early Robust Design—Its Effect on Parameter and Tolerance Optimization

The development of complex products with high quality in dynamic markets requires appropriate robust design and tolerancing workflows supporting the entire product development process. Despite the large number of methods and tools available for designers and tolerance engineers, there are hardly any consistent approaches that are applicable throughout all development stages. This is mainly due to the break between the primarily qualitative approaches for the concept stage and the quantitative parameter and tolerance design activities in subsequent stages. Motivated by this, this paper bridges the gap between these two different views by contrasting the used terminology and methods. Moreover, it studies the effects of early robust design decisions with a focus on Suh’s Axiomatic Design axioms on later parameter and tolerance optimization. Since most robust design activities in concept design can be ascribed to these axioms, this allows reliable statements about the specific benefits of early robust design decisions on the entire process considering variation in product development for the first time. The presented effects on the optimization of nominal design parameters and their tolerance values are shown by means of a case study based on ski bindings.

Is ResonantAcoustic Mixing® (RAM) a Game Changer for Manufacturing Solid Composite Rocket Propellants?

AbstractThis study is a structured literature review of published ResonantAcoustic® Mixing (RAM) literature, considering the benefits and constraints of using RAM. Focussing on how this will affect the future production of rubbery composite rocket propellants. The main benefits of RAM were found to be shorter mixing time, versatility of mixing and ability to mix higher viscosities than conventional mixers. Facilitating the next generation of composite propellants with improved performance and mechanical properties. Mixed in‐situ RAM overcomes viscosity limitations by removing the casting process and has safety and environmental benefits, but does need to be tested at larger production scales. The implications of RAM production on the energetics qualification process was considered. A new framework was discussed based on understanding the entire product development process including ingredient properties, manufacturing processes, and linking this to product performance; through adoption of a digital twin approach with in‐situ monitoring. Future R&D focuses on process and material control through a validated model of the mixing mechanisms, linked to material properties and output performance. Validation with scaled up comparative studies and continuous in‐situ monitoring. A full list is provided in the conclusions. Overall RAM offers numerous benefits to mixing existing and new materials with large savings in time, cost, improved safety and is more environmentally friendly.

Custom-made apparel manufacturing micro-enterprise owners’ perspectives on sustainability: how higher education can contribute

Purpose The purpose of this paper is to investigate custom-made apparel manufacturing micro-enterprise (CMME) owners’ perspectives of sustainability within their business practices throughout the entire product development process and determine how educational initiatives can promote a more environmentally conscious product development process. Design/methodology/approach A qualitative case study, using face-to-face interviews and observations of CMMEs at an incubation hub presents evidence of owners’ sustainability perspectives. Findings Although CMME owners disregard sustainability as a pro-environmental approach within the business context, attempts at pro-environmental subconscious behaviour and a deliberate non-environmental consciousness are evident in sourcing and manufacturing during the product development process. Research limitations/implications Because of the case study approach of four CMMEs in an IH, the findings may not be applicable to other small and micro-businesses. Despite this limitation, valuable insights emerged that show the current inaptness of the CMMEs to manage an environmentally sustainable business practice. Social implications To promote sustainable development goal 12, related to the clothing and textile industry, it is postulated that CMMEs should be supported to minimise their use of resources, thereby promoting environmental sustainability. Originality/value The findings of this study direct the development of higher education educational programmes featuring learning content on pro-environmental design and business practices for CMMEs.

Lightweight design in product development: a conceptual framework for continuous support in the development process

To get closer towards achieving the climate targets and the resulting reduction in CO2 emissions, one possible strategy is to consider lightweight activities across all industries. In product development, this means that lightweight design should be integrated at a very early stage, as this is the only way to achieve the highest lightweight potential. However, such an integration is very complex, since necessary lightweight activities cannot be applied sequentially or universally to all products. Even multiple usage of different lightweight design strategies is not sufficient to achieve a targeted lightweight design on the overall system level. Therefore, it is necessary to support the product developer in the application of lightweight design by providing a framework with necessary methods and processes as well as recommendations regarding their timing. The possibility to apply them individually to different systems and related problems has to be given.To develop such a framework, different projects with respect to lightweight design were analyzed and evaluated. The main focus was on the determination of lightweight design strategies that were applied in the projects and the subsequent derivation of requirements in order to raise further lightweight potential.Based on this analysis and evaluation, a conceptual framework was developed that focuses on the overall system to be optimized, which can be part of a previous generation, for example. Subsequently, the available lightweight activities and design strategies were linked with supporting tools and methods from knowledge management. Therefore, this conceptual framework provides continuous support for the product developer throughout the entire product development process in lightweight activities.

A Hybrid MADM Model for Product Design Evaluation and Improvement

Global warming and climate change are the most pressing issues in the world. This is the inevitable result of human beings pursuing a better quality of life and materials. If the green design concept is used in the design and manufacture of products, the impact of production on the environment will be greatly reduced. Because of this, green product design assessment and improvement activities play an important role in achieving the 2030 sustainable development goals. Product design is the forefront of the entire product development process, and it plays a very critical role. The purpose of this study is to develop a decision-making model for helping decision makers to evaluate and improve the performance of product design systematically. The model combines the design standard of the iF world design guide and multi-attribute decision-making methods. First, the DEMATEL-based analytic network process is used to establish the influential relationship and weights of attributes. Next, the VlseKriterijumska Optimizacija I Kompromisno with aspiration-level method is used to obtain the gap between each evaluation attribute and the aspiration level of each design. Finally, this evaluation result uses the influential network relationship map (INRM) to propose various improvement strategies with causal influence. This study uses products from a Taiwanese furniture design company as an empirical case, which is a leading brand and benchmark in Taiwan’s furniture industry. The research results show that the proposed model can help decision makers to choose the most appropriate design scheme (i.e., the design with the smallest gap from expectations); designers can also improve the gap between product design and expectations.

Virtual powertrain development

This article presents the new system of virtual powertrain development introduced at Porsche AG that incorporates all phases of the development process, as well as all components and simulation disciplines. The system enables a powertrain in its entirety to be designed and tested virtually. Most activities can be planned and budgeted at the beginning of the project, and interactions that occur are systematically taken into consideration. The hardware-driven development process used until now is completely transmitted to the digital world. Powertrain development is divided into thirteen digital powertrain systems (DPSs), which contain different components and disciplines and are developed throughout the entire product development process. For each DPS, tasks, links, time schedules, reporting scopes, and responsibilities are precisely defined. Finally, a digital vehicle prototype is built from several DPSs. The results are aggregated in several stages, ensuring that core statements are consistently incorporated at all assessment levels, from the individual component to the overall vehicle. Furthermore, this article discusses in detail DPSs that are especially important for battery electric vehicles. For most of the examples, the powertrain of the Porsche Taycan is used. The Driving Performance and Load Spectra DPS provide the necessary design parameters for a new drive system. In the Electric Motor DPS, active parts of the electric motor are designed and all structural components are verified. In the Transmission DPS, all gear set parts are designed and verified. In the Cooling, Lubrication and Actuation DPS, all temperatures are calculated and the lubrication circuit is designed. The Powertrain Dynamics DPS provides information on powertrain vibrations. The article closes with a look at future development trends. The aim is not just to design and verify components but also to completely virtualize function and software development. Therefore, this article presents a system for creating and using a virtual development environment and tracking the results.

Managing knowledge and parameter dependencies with MBSE in textile product development processes

Abstract Today’s mechanical engineering companies are confronted with challenges like new material technologies, shorter product life cycles, increasing interdisciplinarity of the various departments as well as product development across distributed company locations. In the context of lightweight design, Tailored Textiles offer promising potentials to reduce product weight and manufacturing costs. Tailored Textiles are textiles with integrated local reinforcements whose textile properties can be adapted locally during the production due to the textile structures, so that process steps and therefore time and costs can be reduced. However, the production-oriented design of Tailored Textiles is currently very complex. One reason for this is the large number of stakeholders that are involved in the process. In order to make this complexity manageable, it is necessary to develop a common understanding of the textile process chain and to improve communication between different stakeholders. Another major challenge is the identification and management of technical parameter dependencies over the entire product development process (PDP). The aim pursued by this work is to link the technical parameter level of different expert models with the process level of Tailored Textiles PDP, so that expert knowledge is externalized to other stakeholders In this context, Model-Based Systems Engineering (MBSE) is a promising approach. Through the formalized application of modeling, MBSE allows the process accompanying development of a system model, which enables the visualization of the parameter dependencies within the product development process. In this paper, a methodological approach is presented which initially involves modeling the PDP for Tailored Textiles in a product data management system (PDMS). The process is then linked to a MBSE modeling tool. In the modeling tool, the analyzed parameters and their dependencies are set up and visualized. Following this procedure, the feasibility of the design will be evaluated based on a use case.

Introduction of a maturity model for the assessment of the integration of the GPS system in companies

Abstract For more than 25 years, the aim of the Geometrical Product Specification (GPS) system has been to establish a consistent framework for specification and verification of geometrical properties ensuring the functional requirements placed on a product – unambiguously, completely and non-verbally. In order to get to know the system or to learn how to use it, it is common for selected employees, mostly designers or developers, to receive training courses lasting several days. The majority of the currently 150 existing individual standards are presented in an overview while the extensive symbol language is explained and applied to fictitious examples. Though, because of a lack of efficient teaching courses, it is almost impossible for the technical experts to use the GPS system in practice in its entirety. Furthermore, all far-reaching cuts in all product development processes, including the interfaces considering the internal and external customer supplier relationships, are still not understood sufficiently. There is no user-friendly procedure for integrating the GPS system into companies and assessing the progress of application, up to now. This paper describes the approach of a GPS integration based on a maturity model. The aim is to enable companies to integrate the GPS system into the entire product development process using agile methods and to develop themselves into learning organizations.

Literature-based identification of success-relevant influencing factors of distributed product development

Increasingly complex products and processes, tougher international competition and increasing customer requirements are some of the trends leading to the current organizational change. Companies are more and more conducting their development activities across locations and national borders. The aim is to optimally exploit the potential created by the changed environment and to gain an advantage over the competitors. Furthermore, companies are facing additional challenges, such as increased organizational effort, a lack of personal contact and the resulting communication delays. In order to be able to react flexibly to the changed boundary conditions, companies are increasingly trying to implement agile measures. The implementation of these measures and the addressing of the heterogeneity of the distributed development environments increase the complexity of the entire product development process. In order to successfully master this complexity in the transformation process, the question arises which influencing factors are decisively contributing to the success of distributed development processes. This contribution is therefore dedicated to the literature-based identification of the success-relevant influencing factors in distributed product development. In addition, the success-relevant influencing factors were assigned to the dimensions people, technology and organization to further be able to investigated what effect changing an influencing factor has on the dimensions and thus also on the influencing factors classified under them. Finally, the collection of success-relevant influencing factors indicates which influencing factors must be considered when adapting processes, methods and tools as part of the operation system of the product development process to the prevailing distributed development situation. Additionally, it must be considered that the transformation process can only be successful if the integrated consideration of the three dimensions technology, organization as well as the individual people affected by change as the center of product development is taken into account.

Planning and communicating prototype tests for the Nano Membrane Toilet: A critical review and proposed strategy.

Urban sanitation in growing cities of the Global South presents particular challenges. This led to the Bill & Melinda Gates Foundation's Reinvent The Toilet Challenge, which sparked the development of various non-sewered sanitation technologies like the Nano Membrane Toilet. Complex disruptive technologies like this entail an extensive product development process, including various types of prototype tests. While there is an abundance of literature discussing how to build prototypes, and the optimal number of tests, there has been little focus on how to plan and conduct tests, especially in a development endeavour of this complexity. Four approaches to testing are reviewed, and their strengths and weaknesses compared. A visualised testing strategy is proposed that encompasses the entire product development process and can be used to plan and communicate prototype tests for the Nano Membrane Toilet to ultimately achieve compliance with international standards.

Planning and communicating prototype tests for the Nano Membrane Toilet: A critical review and proposed visual tool

Urban sanitation in growing cities of the Global South presents particular challenges, like the speed of their growth, the high population density, and, often, the lack of existing wastewater infrastructure. This led to the Bill & Melinda Gates Foundation’s Reinvent The Toilet Challenge, a call to develop novel, non-sewered sanitation technologies, which sparked the development of various inventions, like the Nano Membrane Toilet. Complex technologies like this entail an extensive product development process, including various iterations of prototype tests. While there is an abundance of literature discussing how to build prototypes, and the optimal number of tests, there has been little focus on how to plan, communicate, and conduct tests, especially in a product development endeavour of this complexity. Multiple aspects of testing prototypes are reviewed. A visual test planning tool is proposed that encompasses the entire product development process and can be used to plan and communicate prototype tests for the Nano Membrane Toilet to ultimately achieve compliance with international standards.

Planning and communicating prototype tests for the Nano Membrane Toilet: A critical review and proposed strategy

Urban sanitation in growing cities of the Global South presents particular challenges. This led to the Bill & Melinda Gates Foundation's Reinvent The Toilet Challenge, which sparked the development of various non-sewered sanitation technologies like the Nano Membrane Toilet. Complex disruptive technologies like this entail an extensive product development process, including various types of prototype tests. While there is an abundance of literature discussing how to build prototypes, and the optimal number of tests, there has been little focus on how to plan and conduct tests, especially in a development endeavour of this complexity. Four approaches to testing are reviewed, and their strengths and weaknesses compared. A visualised testing strategy is proposed that encompasses the entire product development process and can be used to plan and communicate prototype tests for the Nano Membrane Toilet to ultimately achieve compliance with international standards.

Design for Additive Manufacturing and Advanced Development Methods Applied to an Innovative Multifunctional Fan

In an increasingly competitive business world, the “time to market” of products has become a key factor for business success. There are different techniques that anticipate design mistakes and launch products on the market in less time. Among the most used methodologies in the design and definition of the requirements, quality function deployment (QFD) and design for Six Sigma (DFSS) can be used. In the prototyping phase, it is possible to address the emerging technology of additive manufacturing. Today, three-dimensional printing is already used as a rapid prototyping technique. However, the real challenge that industry is facing is the use of these machineries for large-scale production of parts, now possible with new HP multi-fusion. The aim of this article is to study the entire product development process taking advantage of the most modern models and technologies for the final realization of a case study that involves the design and prototyping of an innovative multifunctional fan (lamp, aroma diffuser and fan) through the Multi Jet Fusion of HP. To begin with, issues related to the DFSS, the QFD and their application to identify the fan requirements are explored. Once the requirements have been defined, the modern CAD design systems and the CAE systems for the validation of the case study will be analyzed and applied. Finally, HP's Multi Jet Fusion methodology and design rules for additive manufacturing will be analyzed in detail, trying to exploit all the positive aspects it offers.

Design for Six Sigma (DFSS) for additive manufacturing applied to an innovative multifunctional fan

In an increasing number of aggressive enterprise world, “time to market” concerning products has come to be a solution element because of enterprise success. There are exceptional techniques so expect layout mistakes or open products concerning the need between much less time. Among the most used methodologies in the design and setting about stability the requirements, Quality Function Deployment (QFD) and Design for Six Sigma (DFSS) execute remain used. In the prototyping phase, such is feasible in imitation of tackle the rising science regarding additive manufacturing. Today, three-dimensional stamping is in the meanwhile used as a rapid prototyping technique. However, the actual challenge that enterprise is going through is the use of these machineries for large-scale production about parts, at last viable along current HP Multi fusion. The aim of this article is to study the interactive design and engineering applied to the entire product development process taking advantage of the most modern models and technologies for the final realization of a case study that involves the design and prototyping of an innovative multifunctional fan (Lamp, Aroma Diffuser and fan) through the Multi Jet Fusion of HP. To begin with, issues related to the DFSS, the QFD and their application to identify the fan requirements are explored. Once the requirements have been defined, the modern CAD design systems and the CAE systems for the validation of the case study will be analyzed and applied. Finally, HP’s Multi Jet Fusion methodology and design rules for additive manufacturing will be analyzed in detail, trying to exploit all the positive aspects it offers.