Product Development Methodology Research Articles

Aligning new product development with reverse engineering methodologies for headlamp jig

Abstract This study explores the combination of reverse engineering (RE) and new product development (NPD) methodologies to enhance the manufacturing process of headlamp jigs. RE, utilised as a benchmarking technique, aids in regenerating parametric designs or innovating new product concepts. The distinctive appearance relies on headlamps with protective coatings cured at high temperatures in UV ovens, necessitating jigs capable of withstanding such conditions. Hence, employing RE becomes crucial to fortifying jig performance. While RE often signifies innovation or refinement, the current headlamp jig encounters deformation issues during manufacturing due to high curing oven temperatures and intense water jet cleaning pressures. The absence of an effective NPD approach exacerbates persistent jig deformation challenges. NPD, encompassing stages like idea generation, concept development, design, testing, and marketing, is crucial. The absence of NPD, along with the complexity of RE, could prolong timelines and escalate expenses in bringing marketable products to fruition. This study aims to propose an NPD model for headlamp jigs, leveraging RE methodologies to enhance composite jig fabrication processes. The integration of PDCA methodologies within NPD intends to rectify deformation issues while optimizing manufacturing processes for superior headlamp jigs.

Product Development Methodology Targeting Efficiency and Acoustics of E-Mobility Gearboxes

This paper presents an approach for physical/virtual coupled product development and validation. A method for studying the influence of tooth geometry on the efficiency and acoustics of an electric vehicle’s powertrain will be presented. To achieve improved acoustic characteristics the micro geometry of the teeth will be optimized. The modified gears were analysed on a gear test rig under load and at high speeds and evaluated with regard to their acoustic properties. Established analytical models are used to describe the influence of profile modifications on the gear stiffness of helical gears. The authors’ approach is to calculate the dynamic system behaviour of the gearbox using a 1D simulation. Based on this, studies of the entire gear box will be performed. For this, the results of the 1D simulation are coupled with 3D FEA analyses. This enables acoustic calculations (structure-borne and airborne sound) to be carried out.

Structural Evaluation of a Three-Wheeler VehicleUsing Simulation Tools: A Case Study in Mexico

The mototaxi, a three-wheeled vehicle equipped with a roof, is a widely utilized mode of transportation in Mexico. Typically, it is employed for short-distance journeys in exchange for payment, similar to the operation of a conventional taxi. This study conducts astructural analysis of a mototaxi-type vehicle utilized in Mexico to assess its performance and safety. It underscores the significance of this mode of transportation, widely relied upon by numerous individuals. A product design and development methodology was employed, utilizing torsional deformation simulations to validate the new geometry. The objective was to minimize torsions as much as possible, thereby enhancing the motorcycle taxi’s safety and ensuring the vehicle’s correct positioning. Through computeraided design, the prevailing torsions within the casing were assessed, establishing the operating conditions to which the system is commonlysubjected. The findings from the chosen vehicular structure reveal a flexural rigidity of 6,508.15 N/mm, torsional rigidity of 27.35 KNm/°, and a range of natural frequencies between 8-21 Hz. These values indicate favorable resistance against bending forces and operational frequency. However, the torsional results exhibit deficiencies, suggesting an unsafe structure for all motorcycle taxi occupants. Consequently, technology developers and national legislators should prioritize enhancing the structural integrity of such vehicles.

Concurrent Engineering and Quality Management Integration Methodology for Product Development

Concurrent Engineering and Quality Management Integration Methodology for Product Development

A Review of Analytical Methods for Adeno-Associated Virus Vectors’ Biodistribution and Shedding Studies

Adeno-associated virus (AAV)-based gene therapy (GT) products can effectively deliver transgenes to replace lost or defective genes, providing hope for patients. However, there is limited research on analytical methods for pre-clinical and clinical studies which could impede their development success. During the development of AAV-based GT products, it is crucial to define the biodistribution and shedding profiles following treatment. In this review, we summarize PK studies for the AAV-based GT products approved so far by U.S. Food and Drug Administration and European Medicines Agency. We then comparatively review the analytical methods employed to evaluate AAV vectors’ biodistribution and shedding of approved GT products. We further make recommendations on choice of methodologies for future GT product development based on the study data and the currently available regulatory guidance.

NAVMAT: an AI-powered pathway to knowledge sharing on material failures

The paper describes the product development methodology, the architecture, the modules and features of the operating prototype, as well as future challenges of NAVMAT, a naval materials failure management system. The fundamental compound of the knowledge management platform is the recording and classification of a failure incident. NAVMAT supports different types of users, from the first Reporter to the Analyst and Forensic Engineer through appropriate workflows. In these workflows the incident-related information can be provided as text, files, images and videos, which can be easily associated to the incident and provide structured information. NAVMAT provides a number of Artificial Intelligence (AI)-enabled helpers. During the incident recording, NAVMAT brings into play reactive real-time search which suggests related incidents and literature to facilitate the editor. It also speeds up the classification of incidents by providing AI-suggested labels, chosen from the (multi-lingual) concepts contained in the system Ontology. On the other hand, the intelligent indexing and search infrastructure of the system supports easy identification and retrieval of past incidents, reports and publications, by applying Natural Language Processing. The prototype of the described system has been embedded as a web application validated by potential Users and is being prepared for Operation in a fleet environment.

Adaptation of corporate model of ukrainian aircraft product life cycle to the international methodology of systems engineering

Problems. Under the present-day conditions, the preservation of competences of Ukrainian aircraft construction enterprises will be determined by the possibility of enterprises attracting to participation in international cooperation programs and projects. But this is possible only on the condition of prior harmonization of the product development methodology adopted in Ukrainian aircraft construction to that used in the international aircraft construction projects. Purose. The main goal of this article is to determine the ability and ways of adapting the corporate model of life cycle of aircraft engineering projects by Ukrainian aircraft construction enterprises to modern global aircraft construction practices. Implementation methodology. The research methodology predicted the identification of the main modern trends in the field of system engineering for the creation of a science-intensive product, as well as the analysis of concepts of presenting the life cycle of complex technical systems in international regulatory documents, industry regulations, guidelines and other information sources. Criteria for perspective of using the identified informational and normative sources as close analogues for the development of one's own corporate model of life cycle of an aircraft construction product were identified. On the basis of the criterion analysis of researched concepts of the life cycle of complex technical systems representing, the requirements were formed, which formed the basis of the concept of one's own corporate model of life cycle of the aircraft construction product. The results. The result of conducted research was the proposed concept of a corporate model of the life cycle of an aircraft construction product manufactured in Ukraine, which takes into account the international experience and best practices of leading aircraft construction companies, including focusing on the experience accumulated by domestic aircraft manufacturers. Conclusions. According to the results of analysis of advanced world practices in the field of creating a science-intensive product, an own corporate model of the life cycle of an aircraft product manufactured in Ukraine was proposed. In the future, on the basis of this model, a system for creating an aircraft product can be built and developed, which will be harmonized with existing world practices and will allow the domestic aircraft construction enterprises to fight for participation in international programs and projects.

Enhancing Strategic Planning of Projects: Selecting the Right Product Development Methodology

The selection of an appropriate development methodology is a critical strategic decision when managing a New Product Development (NPD) project. However, accurately estimating project duration based on the chosen methodology remains a challenge. This paper addresses the limitations of existing models and proposes a novel NPD project model that allows for testing and evaluation of different product development strategies. The model considers Waterfall, Spiral, Agile, and Hybrid methodologies and provides system engineers and project managers with decision-making tools to determine the optimal strategy and understand associated tradeoffs. The model is validated using real projects from various organizations and methodologies. It incorporates stochastic variables, risk management, and dynamic resource allocation, while addressing both Waterfall and Agile methodologies. The study contributes to the body of knowledge by offering practical tools for system engineers and project managers for choosing development methodology, improving project duration estimation, and identifying critical processes and risks in NPD projects. The research results also provide a basis for further studies and can benefit researchers interested in systems engineering methodologies. The proposed model fills a gap in the literature by providing a validated NPD model to evaluate the impact of different product development methodologies on project duration.

Endotracheal Cuff System Performance Enhancement through Product Design and Development Methodologies

Rapid prototyping (RP) is a popular method for product development and design in medical industries. Endotracheal tube (ETT) incubation is a common problem when using medical equipment. Among the difficulties that surgeons face during surgical procedures are the misinsertion of an endotracheal tube into the oesophagus and extubation due to the patient's limited mobility. The aim of this work is to design an innovative endotracheal tube holding model. The survey was carried out in order to identify the most common ETT problems. As a result, quality functional deployment and product design and development methodologies were utilised to select the design for all of the ideas, which were designed based on the demands indicated by the consumers. The concept score matrix was used to evaluate the designs. As a result, concept A is selected as the final design. The overall score for each concept was calculated to discover which concept has the highest rating. Based on the results of the concept scoring and concept screening, concept A is the most likely to be produced. The concept meets the most demanding needs of the users. The selected design was then created on the Fused Deposition Modelling (FDM) machine.

Development of a localized production model for the automotive industry, built into the concept of industry 4.0 in the kingdom of Saudi Arabia

Saudi Arabia vision-2030 is mainly focused on industrialization to reduce reliance on oil revenue. Localized Manufacturing (LM) concept, which has gained its importance worldwide in this fast-changing technological world to meet customers’ unique needs of 21st century. Now-a-days, manufacturing industry is shifting from standard product development to customized product development keeping in view the growing unique customer-’s needs. The research objective of this research was to maximize LM Application in the Kingdom of Saudi Arabia to meet unique customers’ needs. Automobile industry was selected to apply Industry 4.0 technologies i.e., 3D Printing/Additive manufacturing. The specifications, fulfilling the customer’s unique needs have been incorporated to manufacture the desired part by 3D printing/additive manufacturing. Data was collected from Saudi automobiles customers regarding their unique needs on a particular automobile part. Using the Product Design and Development methodology by Ulrich et al data was collected, analysed and as a result of data analysis, a model for maximization of localized manufacturing was developed for implementation of LM technique. Results shows that using Industry 4.0 concept, customers’ unique needs can be satisfied and fulfilled in less time and it will be more economical as compared to standard/conventional manufacturing/production methods. Based on the results of this research a model for maximization of localized manufacturing is developed utilizing Industry 4.0 technique

Overview of new product development strategies and models

Motivation: The motivation for the overview presented in this article is to provide a starting point for considering whether existing new product development methodology and its level of detail allows product teams to develop high-quality and business-effective product concepts. Aim: The aim of this article is recognise the current state of research into new product development methodology and to present the strategies and models for New Product Development (NPD). Materials and methods: The systematic review of the literature was applied in the article. Results: The first section outlines the main strategies for new product development and how they are divided by methodological stance, degree of planning, search pattern, focus and response. The second part discusses the known models of new product development including: the craft model and the 5 generations based on the innovation models described by Rothwell and the stages of the manufacturing process defined in the literature. Part four looks at new trends in new product development, including: Open Innovation, Rapid Product Development (RPD), Agile New Product Development (ANPD), Sustainable New Product development (SNPD), the Design Thinking method and the new technologies of Industry 4.0.

Thinking the automobile.

The relationship between Design and Engineering has not its genesis in the 20th century. But it was in this century that the advantage of this association was perceived and came into existence. From the beginning of mass production in the early twentieth century came the need for bringing the two disciplines together: Design and Engineering. Although Design and Engineering are two separate and independent disciplines, much of their applied field overlaps. The automotive product design and industry is a common ground where Design and Engineering strive to achieve, together, a common final product: the automobile. This article aims to discuss how the development of the automobile throughout the 20th and 21st centuries was driven by Design and Engineering, opening the way for a deeper debate on the definition of this interaction. A definition for the Product Development methodology from the Engineering and Design point of view is described, as well as the role of the Design and Engineering disciplines within the automotive product development. Methodologically, a historically relevant case study in the development of the automobile product is presented.

Embedded Sensor Systems in Medical Devices: Requisites and Challenges Ahead.

The evolution of technology enables the design of smarter medical devices. Embedded Sensor Systems play an important role, both in monitoring and diagnostic devices for healthcare. The design and development of Embedded Sensor Systems for medical devices are subjected to standards and regulations that will depend on the intended use of the device as well as the used technology. This article summarizes the challenges to be faced when designing Embedded Sensor Systems for the medical sector. With this aim, it presents the innovation context of the sector, the stages of new medical device development, the technological components that make up an Embedded Sensor System and the regulatory framework that applies to it. Finally, this article highlights the need to define new medical product design and development methodologies that help companies to successfully introduce new technologies in medical devices.

Strategies for achieving circular economy goals in the lighting industry through design for disassembly-based methodologies

The significance of circular economy and its integration into core strategies for smart, sustainable, and inclusive growth, is increasingly being recognized by individuals, organisations, and nations in recent times. The term ‘Design for Disassembly’ may conjure up images about the end-of-life of a product or its disposal. However, design for disassembly connects to numerous circularity and sustainability goals over the lifetime of a product or project and can have a large impact on the carbon footprint of the product. ‘Design for Disassembly’ is a product development methodology which is in line with the vision of a circular economy, and supports increase in material efficiency, extends product lifetimes and improves recycling efficiency. Reduction of the imposed environmental risks and impact on the climate, by utilising circularity approaches such as remanufacturing, are tied to lowering of carbon footprint. This paper describes specific and actionable approaches that can be applied by luminaire manufacturers, specifiers, and other players in the lighting industry. The readers will learn about current tools and methodologies that can be used to improve iterative design, as well as measure, assess, and compare products or materials.

A case study on dynamic capabilities developed by a product start-up to grow at the time of pandemic

ABSTRACT Business operations became challenging when the COVID-19 pandemic struck, and governments applied significant lockdown measures to stop the spread. Start-ups and small-medium businesses started facing hardships due to the changes in the business environment and the resulting constricted cash flow. This case describes challenges faced by a high-tech product start-up company and the way they tackled these hardships. The company had adopted an agile programming methodology for product development which faced a major challenge because of the sudden introduction of “work from remote” (WFR). WFR had disrupted collaboration between clients, sales teams, and development teams. The success of agile methodology was dissipating as teams could not do on-premise huddles. The company witnessed an overrun in the sprint schedule, increase of budgeted cost, and sliding customer satisfaction. Senior management could not manage process parameters properly, and therefore predictability of the processes waned. The start-up owners, through the application of the “dynamic capabilities framework,” focused on reconfiguring the agile working processes and improving the remote working capability of employees. This case shows the start-up’s agile development process transformation journey following the dynamic capabilities framework to overcome the challenges posed by the pandemic. The teaching case focuses on imparting knowledge on agile development and dynamic capabilities to Information Systems students.

DESIGN SPECIFICATIONS OF AN AUTONOMOUS ELECTRIC VEHICLE FOR USE IN FAMILY FARM UNITS

Family farming in Brazil is responsible for the country’s food security, ensuring most of the food consumed by Brazilians. However, the agricultural machinery and equipment industry has not been dedicated to providing innovations to this sector, focusing mainly on supplying large agribusiness properties with the most advanced technology equipment. Thus, the introduction of new technological solutions regarding agricultural machines for family farming is necessary. Considering the need to supply this branch of the Brazilian agricultural sector with new technologies, this study aimed to establish the design specifications of an autonomous electric vehicle that serves as a multifunction platform, which was primarily designed to remove weeds, mainly meeting the needs of family farmers. The product development methodology in its informational phase was applied to obtain and study these needs. As a result, 19 design specifications were established with their associated target values, allowing defining the physical and economic parameters that will be the basis for the development of the autonomous electric vehicle in its conceptual phase.

Design methodology for mass personalisation enabled by digital manufacturing

Abstract Mass Personalisation (MP) is becoming more significant to answer diversifying customer needs, as a result of the advancements in digital manufacturing. In contrary to the modular design in mass customisation, Design for MP (DfMP) proposes more profound changes in product and active user involvement in the design process, while maintaining mass efficiency. Traditional product development methodologies fall short in guiding MP, as it has the distinct differences with product variability and the customer involvement with specific needs. In this study, a dedicated design methodology for MP is presented, focussing on these key dimensions. The proposed methodology guides the designer through the development process of a user modifiable design and demonstrates how to facilitate the user involvement in reaching a personalised design. It proposes a flexible and adaptable seed design architecture, and an interactive customer co-creation process. The development of a seed design, construction of its design space, and management of the solution space with a design solution algorithm are elaborated. The application of the methodology was illustrated on the personalisation of knitted footwear, and 3D printed saxophone mouthpiece. The examples show the potential of the methodology to deal with coupled MP cases. A systematic approach to DfMP will allow expanding MP to more products, and acts as a foundation for the customer co-creation oriented design in the context of this emerging paradigm.

Design for excellence to explore complex product service systems: A case study

Complexity in new product development is claimed to continuously increase, causing challenges that require new and cross-disciplinary solutions. There are at least three major forces causing upheaval in the way we are designing, engineering, producing and using/reusing products: 1) achieving the sustainability goals, 2) availability of digital technology at ever lower costs and 3) personalization and customization of products. This study seeks to investigate future solutions for the street light infrastructure based on Design for X approaches - and enablers and barriers for innovation in the stakeholder network. Light poles are traditionally been an enabler for illuminating the road in a static manner, whilst such structures in the future are predicted to host a multitude of technologies for serving a broader array of functionality. Examples of added value functionality are; crash management, smart control systems for energy saving, ease of maintenance, sensor-service system that provides stakeholders with real time information about the road environment, sensor technology for enabling autonomous driving etc. To explore this functionality, a Design for Excellence product development methodology is used to structure the gathered information from multiple sources. Both a qualitative and quantitative methodologies are used, where the former is conducted by interviewing value chain stakeholders for the complete road light infrastructure domain in one region and the latter is done by a structured questionnaire. The common ground for both approaches is Design for excellence which is regarded as a systematic way of designing products to optimize total benefits over the whole product life span. Findings from this study suggest that safety and reliability are the two most important requirements when designing a light pole for future demands.

Product development methodology: non-quality caused in production by mistakes in product development, its measurement and improvement integration in the product development process

A new quality focused product development (NPD) methodology, applying lean manufacturing principles and Industry 4.0 paradigms is described in this paper. This methodology has been tested in a tailor-made equipment manufacturer for the retail sector, where tight product development times are needed. This requires a high agility in the processes, meaning the overlap of phases, the integration of processes, cooperation, and automation of tasks. We have generated a system concept that collects all the manufacturing incidences related to NPD, integrated in workshops stations, creating a system that enables real time data capture and a valuable feedback loop to NPD processes. Its implementation showed an improvement over 10% in the quality of the NPD process in a period of 3 months, an increase of the productivity in both product development and manufacturing areas, and a boost of the internal customer satisfaction in manufacturing area with the product development area.

Impact Assessment of Lean Product Development and Lean Startup Methodology on Information Technology Startups’ Performance

This research aims to evaluate the impact of lean product development (LPD) and lean startup (LS) practices on startup performance. A survey with 114 responses from Brazilian startups in the Information Technology sector evaluated the direct effects of LPD and LS on organizational performance, as well as the potential cross-effects between them. The assumptions were validated using a structural equation modeling for data analysis, which confirms that the adoption of these methodologies has a positive significant impact on startup performance, especially the practices involving teamwork and the design of minimum viable products.