Nick Matthews The Warwick Manufacturing Group University of Warwick

1. The Importance of Designing in the Real World, Where is our future in Manufacturing? NAAIDT CONFERENCE 2006 Nick Matthews The Warwick Manufacturing Group University of Warwick

2. The value of Design • The most expensive Toyota Yaris is (at least list price) £13,260 with maximum extras it goes up to about £15,500. • A Mini Cooper S Convertible is listed at £17,960 and can easily go to £22,000 with extras. • So the value of design then in this case is about Six and a half grand.

3. Digitalisation • For many of us in manufacturing the holy grail of systems integration is now possible. • We see the emergence of a world platform, a degree of connectivity previous generations of engineers could only dream of. • The digitalisation of content and the ubiquity of the internet seamlessly connect people; so that people can manipulate digitalised content like never before. • Knowledge that would once have taken years to cross the world now travels at the click of a mouse.

4. Leaner • I believe digitalisation can still bring significant cost and time savings to the whole processes of product inception, product design and product development. • The whole new product introduction process can have major time savings from concurrent digital engineering processes. • Now if this is true in automotive who are many ways leading in this area just think of time and cost savings in light rail and aerospace applications.

5. Cleaner • There is no doubt that there will be extra issues that designers will have to take into account when it comes to product design. • As well as design for manufacture I will have to design for disassembly and be able to trace where everything has come from and gone to. • Only by the intensive use of digital technologies will I be able to manage this huge explosion in the data required to manage in this new environment.

6. Smarter The degree of intelligence in all products will mean that the number of things that where only able to be done in certain locations will be vastly reduced. Further blurring the difference between home and office or being on the move. The embedded intelligence in the products we use will “learn” about us and modify themselves to meet our changing needs.

7. Faster • Digital manufacturing will ensure that products get to market more quickly. • No longer will it be necessary to produce physical prototypes in all cases. • Products will be designed, marketed prototyped and tested in ‘silico’. • That is inside computers using increasingly sophisticated 3D visualisation. • Customers will be more intimately involved in ‘concept to delivery’.

8. Globalisation This is the Tata plant at Poona. Not a human being in sight. The new generation of global manufacturing facilities are state of the art. For example employment in the textiles sector in China is falling as new plant replaces older facilities.

9. Personalised For lower volume higher cost products, there will be a demand for an ongoing sophistication of automation to increase the capability of variety. This will require the productionisation of what we currently refer to as rapid prototyping techniques.

10. so und & vib ration tech nology ltd Sound Quality Engineering ( Objective Measures ) ( Subjective Measures ) Sound Quality Target WARWICK Vehicle Customer Vehicle Design ( Engineering Targets )

11. Jury Evaluations • Comfortable, controlled and repeatable environment. • Database of results assembled from WMG and Jaguar Warwick Listening Room

12. Brand A Target Brand B Brand F Refined Factor Brand C Brand G Brand D Brand E Powerful Factor

13. & Visualisation

14. The Future….

15. Single Notes • Monophonic • Very Simple • No Character - just a tune “Close Encounters of the Third Kind”

16. Classical Music • Chords (i.e. polyphonic) • Regular beat • Individual, regularly spaced harmonics can be clearly identified

17. Rock Music • Simpler Harmonic Content • Regular beat i.e. simple temporal structure • Lots of distortion, i.e no longer pure tones

18. Interior Noise of Accelerating Car • Complex, time varying harmonic patterns • Continuously changing • Varies with engine speed, load, gear, road surface, wind conditions, weather … • Lots of broad band (wind/road)

19. Traditional NVH Evaluation • Drive an existing vehicle on the road or track • Not back-to back • Current cars only • No Targets • No New Designs • Listen to fixed sounds in a room / experiencing vibration on a rig • Look at objective data (Test or CAE) • Graphical • Metrics • Increasing difficulty for the non-expert • Limited number of Driving Conditions • Increasing time & difficulty in data interpretation We need a better way to perform NVH assessments

20. The WMG InteractiveNVH Simulator

21. Cascade Model – Complete Vehicle Level L1 Total Vehicle Masking Engine

22. Cascade Model – Vehicle Source Level L2 L1 Total Vehicle Masking Engine Road Road Intake Exhaust Wind Powertrain Air - borne Structure - Borne

23. Cascade Model – Vehicle Path Level

24. Services Or Manufacturing The modern mobile phone comes almost entirely out of Britain. The liquid crystal display comes from the RSRE. The camera is detector technology from astronomy and originally developed at University College London. The design and manufacture of the nipple antennas come from Sarantel in Northampton. The electronic design software behind the huge amount of embedded intelligence comes from ARM in Cambridge. OK they may be manufactured in the Far East, but the largest mobile phone company is British - Vodaphone - a service business which spends £200million a year on R&D.