INTRODUCTION TO PRODUCT AND PROCESS DEVELOPMENT

1. INTRODUCTION TO PRODUCT AND PROCESS DEVELOPMENT J.JAYARAMAN CENTRE FOR AEROSPACE SYSTEMS DESIGN ENGINEERING INDIAN INSTITUTE OF TECHNOLOGY, BOMBAY

2. STUCTURE OF THE PRESENTATION CONCEPTS : PRODUCT , PROCESS, INTEGRATED PRODUCT, INTEGRATED PRODUCT AND PROCESSES WHY AND WHEN: INTEGRATED PRODUCT AND PROCESS DEVELOPMENT BENEFITS OF IPPD WHAT IS IPPD : DoD’s DEFINITION OF IPPD 5 PRINCIPLES OF IPPD THE TEN TENETS OF IPPD GENERAL PNICIPLES OF IPPD INTEGRATED PRODUCT TEAM KEY CONCEPTS OF IPT HOW IPPD : IMPLEMENTING IPPD TOOLS OF IPPD CONCLUSION

3. PRODUCT AND PROCESS • PRODUCT: • -IS WHAT IS DELIVERED TO THE CUSTOMER e.g. • HARDWARE, SOFRTWARE, SERVICES, TRAINING • -IT IS THE PHYSICAL HIERARCHY OF THE SYSTEM OR • PHYSICAL ARCHITECTURE • - IS ALWAYS ACCOMPANIED BY A SPECIFICATION • PROCESS : - MAKES THE PRODUCT POSSIBLE - IT IS AN ACTIVITY OR GROUP OF ACTIVITIES THAT TAKES AN INPUT ADDS VALUE TO IT TO GET AN OUTPUT FOR AN INTERNAL OR EXTERNAL CUSTOMER e.g. DESIGN, MANUFACTURING, TEST& EVALUATION, LOGISTICS

4. 3 TYPES OF PROCESSES • TOP LEVEL : FUNCTIONAL. OVERARCHING PROCESS SUCH AS SYTEMS ENGINEERING, TEST AND EVALUATION • DEVELOPMENT PROCESSES : ARE PROCESSES THAT FACILITATE MAKING OF A PRODUCT. THESE PROCESSES ARE NOT DELIVERED TO THE CUSTOMER- INCLUDE INTEGRATION, PRODUCTION, COMPUTER SUPPORT, MODELLING AND SIMULATION • DELIVERABLE PROCESSES : CAN BE THE PRODUCT OR PROCESS TO SUPPORT THE PRODUCT- INCLUDES SUPPORT, TRAINING, MAINTENANCE

5. INTEGRATED PRODUCT REALISES THAT: -THE WHOLE IS MORE THAN THE SUM OF THE PARTS -WHAT IS BEST FOR THE SUBSYSTEM (OR COMPONENTS) IS NOT NECESSARILY THE BEST FOR OVERALL SYSTEM OR VICE-VERSA

6. INTEGRATED PRODUCT AND PROCESS BECAUSE OF THE LIMITED TIME AVAILABLE TO BRING A PRODUCT TO THE MARKET MUCH OF THE PLANNING AND DEVELOPMENT STAGES DOWNSTREAM FROM DESIGN ( MANUFACTURING, TESTING, DISTRIBUTION etc. ) OCCURS PRIOR TO THE COMPLETION OF FINAL ENGINEERING DRAWINGS AND SPECIFICATION. THIS RESULTS IN THE CONCURRENT DEVELOPMENT OF THE PRODUCT AND THE PROCESS

8. ADE ADE ASSET ASSET

9. COMPETITIVENESS • THE THREE ELEMENTS OF COMPETITIVENESS ARE: • TIMELINESS: CAN THE PRODUCT BE DELIVERED JUST IN TIME DEMANDED BY THE CUSTOMER • QUALITY: WILL THE PRODUCT WORK AS WELL AS INTENDED • AFFORDABILITY: WILL THE CUSTOMERS WISH TO BUY THE PRODUCT TO GAIN COMPETITIVE ADVANTAGE WE MUST DESIGN FOR VALUE

10. BENEFITS OF IPPD • REDUCED TIME TO FIELD SYSTEMS • REDUCED SYSTEM COST • IMPROVED QUALITY • PROGRAMMES THAT ARE EASIER TO MANAGE

11. AS A RESULT OF IPPD IN A FIGHTER AIRCRAFT PROGRAMME 10% REDUCTION IN DEVELOPMENT COSTS 50% REDUCTION IN ENGINEERING CHANGE PROPOSALS 50% REDUCED REWORK/ REPAIR/ SCRAP IN A NAVAL SYSTEM PROGRAM 40% REDUCED MANUFACTURING COSTS 25% REDUCED LIFE CYCLE COSTS IN A MAJOR NAVY PROGRAM FOLLOWING BOEING 777 FOOTSTEPS REDUCED CYCLE TIME AND DEVELOPMENT COSTS

12. BOEING 777- IPPD SUCCESS STORY • BOEING 777 AIRCRFT IS HERALDED IN THE US AS AN UNPARALLED SUCCESS IN ADVANCED CAD/CAM, IPPD & USE OF SIMULATION. • IT IS STILL UNDETERMINED AS TO WHEN BOEING WILL RECOUP IT’S MASSIVE FINANCIAL INVESTMENT

13. DESIGN CHANGES

14. A GENERIC IPPD ITERATIVE PROCESS

15. DEFINITION OF IPPD • DOD’S DEFINITION • A MANAGEMENT PROCESS THAT INTEGRATES ALL ACTIVITIES FROM CONCEPT THROUGH PRODUCTION, FIELD SUPPORT USING A MULTIFUNCTIONAL TEAM TO SIMULTANEOUSLY OPTIMISE THE PRODUCT AND IT’S MANUFACTURING AND SUSTAINMENT PROCESS TO MEET COST AND PERFORMANCE OBJECTIVES

16. IPPD • IPPD IS SOMETIMES CALLED IPD • IPPD IS A MANAGEMENT APPROACH • IPPD IS NOT A SET OF STEPS TO BE FOLLOWED • IPPD HAS NO SINGLE SOLUTION OR IMPLEMENTATION STRATEGY • IPPD HAS IT’S ROOTS IN INTEGRATED DESIGN AND PRODUCTION PRACTICE , CONCURRENT ENGINEERING PRACTICE AND TOTAL QUALITY MANAGEMENT • IT IS PERFORMANCE DRIVEN NOT PROCESS DRIVEN • APPLICATION OF SYSTEMS ENGINEERING PROCESS IS FUNDAMENTAL TO IPPD

17. 5 PRINCIPLES OF IPPD 5 • STAKEHOLDER INVOLVEMENT AND CUSTOMER FOCUS • CONCURRENT DEVELOPMENT OF PRODUCT AND PROCESSES • EARLY AND CONTINUOUS LIFE CYCLE PLANNING • PROACTIVE IDENTIFICATION AND MANAGEMENT OF RISK • MAXIMUM FLEXIBILITY FOR OPTIMISATION AND USE OF CONTRACTOR APPROACHES

18. THE TEN TENETS OF IPPD • CUSTOMER FOCUS • CONCURRENT DEVELOPMENT OF PRODUCTS AND PROCESSES • EARLY AND CONTINUOUS LIFE CYCLE PLANNING • MAXIMISE FLEXIBILITY FOR OPTIMISATION AND USE OF CONTRACTOR APPROACHES • ENCOURAGE ROBUST DESIGN AND IMPROVED PROCESS CAPABILITY • EVENT DRIVEN SCHEDULING • MULTIDISCIPLINARY TEAM WORK

19. THE TEN TENETS OF IPPD • EMPOWERMENT • SEAMLESS MANAGEMENT TOOLS • PROACTIVE IDENTIFICATION AND MANAGEMENT OF RISK

20. CUSTOMER REQUIREMENTS Translate Customer Requirement Level 0 system specification document Mission Need Statement Operational Requirement Document Prepare integrated Master schedule define TPMs IMS doc. TPMs Prepare Integrated Master Plan Event driven IMP doc Prepare SOWs SOW Doc Define Core Program Key Events Prepare WBS WBS doc Allocate Resources Organisation (People) Funds Time Track and execute program Specification tree that follows Product BreakOUT Outline programme Product broken down to 2 levels below System level ESTABLISH AN INTGD. MGMT. FRAMEWORK OUTLINING THE PROGRAMME Planning the Program General Principles of IPPD

21. KEY FEATURES OF IPPD • PRODUCT ORIENTATION: PRODUCTS DICTATE THE ULTIMATE SUCCESS OF THE ORGANISATION IN THE EYES OF THE CUSTOMER • CROSS FUNCTIONAL TEAMING: EFFECTIVE TEAMING BETWEEN FUNCTIONAL REPS. INTELLIGENT DECISIONS BASED ON COMBINED EFFORT OF ENGG. PRODN. LOGISTICS, PGMME. MGMT.,CONTRACTING, FINANCIAL MGMT., SUSTAINMENT,OPS., & OTHER DISCIPLINES • EMPOWERMENT: • GIVE REQUISITE AUTHORITY AND ESPONSIBILITY • CONTD.

22. KEY FEATURES OF IPPD • UPFRONT PLANNING: DELIBERATE UPFRONT PLANNING EARLY IN THE PRODUCT LIFE CYCE. EVENT BASED PLANNING

23. IMPLEMENTING IPPD • CULTURAL CHANGE: INTEGRATED DECISION MAKING , EMPOWERMENT • FRAMEWORK: IN NEW ACQUISITION THE FRAMEWORK IS ESTABLISHED IN THE RFP • IT’S IMPLEMENTATION IS PRODUCT AND PROCESS DEPENDENT

24. INTEGRATED PRODUCT TEAM • THE PROCESS SIDE OF THE EQUATION INCLUDES ALL THE INDIVIDUALS ADDING VALUE TO THE PRODUCT. THESE INDIVIDUALS ARE MULTIFUNCTIONAL IPT’S

25. KEY CONCEPTS OF IPT • HIGH PREMIUM ON INFORMATION AND COMMUNICATION • TEAM LEADERS ARE KEY • CHECKS AND BALANCES PROVIDED BY TECHNICAL CONSCIENCE • STRONG TEAM CULTURE • INDIVIDUALS EMPOWERED WITHIN CLEARLY DEFINED ROLES AND RESPONSIBILITIES

26. TEAM PARTICIPATION AND CROSS FUNCTIONAL INTEGRATION

29. CONCURRENT ENGINEERING TECHNIQUES AND BENIFITS AEROSPACE COMPANY AIRCAFT PROGRAM BENEFITS TECHNIQUES BOEING COMPANY 777 50%REDUCTION IN ENGINEERING IPT, CI, SI, DPD CHANGES DUE TO DESIGN ERRORS DPA, DFX, CIM SIGNIFICANT REDUCTION IN DEFECTS THAT REACHED THE FACTORY MCDONNEL DOUGLAS C-17 SAVED $68m DUE TO COMMON ATE IPT, CI, SI, DFX REDUCED NO. OF PARTS AND FASTENERS TQM, LM, QFD ON CARGO DOOR ASSY. F-15F FUSELAGE FORMERS 38% FEWER IPT, SI, CI, CIM, PARTS, 49% FEWER FASTENERS, 45% FEWER DPD, DFX,TQM FASTENER TYPES, 55%FEWER FAB. & ASSY. TOOLS, QFD 75% LESS ASSY TIME, 29% REDUCTION IN DEFECTS F/A-18E/F 33% FEWER PARTS (4400PARTS,FEWER FASTENERS) IPT, SI, CI, CIM 1500 LB UNDER WEIGHT, FIRST MAJOR A/C DPD, DFX, TQM BELOW COST ESTIMATE QFD MD-11 REDUCED NO. OF PARTS BY 3800, WEIGHT BY 240 LB IPT, SSI, TQM, , COST PER A/C BY $ 1,27,000 DFX, QFD, LM BRITISH AEROSPACE BAE-146 DEVELOPMENT TIME REDUCED FROM 36 TO IPT, SI, QFD, 18 MONTHS LM

30. IPPD TOOLS • Information Technology and decision support • Trade off studies and Prioritization • Cost Performance trade offs • Design for Manufacturing • Prototyping • Modeling Simulation and CAE/CAD/CAM • Metrices (Measures of Success) • Education and Training

32. VIRTUAL FACTORY ENVIRONMENT

33. APPLICATIONS OF VIRTUAL REALITY TO AIRCRAFT DESIGN & MANUFACTURE • VIRTUAL MOCK-UP-BOEING COMPUTER SERVICES IN SEATTLE • VAST AMOUNT OF CAD DATA INTO VR ENVIRONMENT • EXPLORE THE AIRCRAFT BEFORE MANUFACTURING • ENGINEERS COULD CLIMB AROUND TO FIGURE OUT WHERE TO RUN CABLES & HYDRAULICS PIPES • TO ENSURE MECHANICS COULD REACH ALL THE PARTS FOR MAINTENANCE • PROOF OF CONCEPT STARTED IN 1990. COMPLETED NON-REAL TIME DEMO

34. APPLICATIONS OF VIRTUAL REALITY TO AIRCRAFT DESIGN AND MANUFACTURE • AUGMENTED REALITY – BOEING • TO PROVIDE MORE INFORMATION IN FRONT OF THE ENGINEERS DESIGNING THE AIRCRAFT AND THE MANUFACTURING WORKER WHO BUILDS THEM • SIMPLE TEXTS & GRAPHICS, VOICE ACTIVATED THROUGH “SEE-THOUGH HMD” • REGISTRATION OF DATA? VR WALK THROUGH MARKETING – BOEING • ENGINE ASSEMBLY – FOR F18 ENGINE RE-DESIGN AT NORTHROP

35. CONCLUSION IPPD IS SEEN TO BE A NEW WAY OF SIMULTANEOUS DEVELOPMENT OF A SYSTEM’S PRODUCTS WITH THE OBJECTIVE OF ACHIEVING REDUCED TIME COST ALONG WITH OPTIMISED PRODUCTS

36. THE OLD WAYS MISSION TO MAXIMISE FINANCIAL PERFORMANCE HIERARCHIAL AUTHORITARIAN STRUCTURE NARROWLY DEFINED INDIVIDUAL JOBS MANAGE PEOPLE TO MANAGE RESULTS RECRUIT PEOPLE WITH FUNCTIONAL EXPERTISE THE NEW WAYS MISSION OF TOTAL CUSTOMER SATISFACTION,CONTIN-UOUS IMPROVEMENT , LEARNING FLEXIBLE TEAM STRUCTURES WITH AUTHORITY CLOSEST TO WORK CAPABILITY INTEGRATED WORK TEAMS WITH BROAD SCOPE MANAGE PROCESS TO MANAGE RESULTS RECRUIT PEOPLE WITH COMMITMENT TO MISSION, SKILLS AND KNOWLEDGE. PROVIDE TRAINING FOR PERSONAL GROWTH ORGANISATION EVOLUTION

37. SYSTEMANTICS • SYSTEMS IN GENERAL WORK POORLY OR NOT AT ALL (PRIMAL SCENERIO) • NEW SYSTEMS GENERATE NEW PEOBLEMS ( THE FUNDAMENTAL THEOREM) • BIG SYSTEMS EITHER WORK ON THEIR OWN OR THEY DON’T. YOU CAN’T MAKE THEM ( BASIC AXIOM OF SYSTREMS FUNCTION) • A SIMPLE SYSTEM , DESIGNED FROM SCRATCH, SOMETIMES WORKS • A COMPLEX SYSTEM THAT WORKS IS INVARIABLYFOUND TO HAVE EVOLVED FROM A SIMPLE SYSTEM THAT WORKS

38. SYSTEMANTICS(CONTD.) • A COMPLEX SYSTEM DESIGNED FROM SCRATCH NEVER WORKS AND CANNOT BE MADE TO WORK. YOU HAVE TO START OVER , BEGINNING WITH A WORKING SIMPLE SYSTEM • COMPLEX SYSTEMS ARE BEYOND HUMAN CAPACITY TO EVALUATE

40. VIRTUAL PROTOTYPING • BRINGS VISUAL SIMULATION TECHNOLOGY TO PRODUCT DESIGN AND MANUFACTURING TEAMS • PERMITS ASSEMBLY STUDIES – FIND OPTIMUM ASSEMBLY AND DISASSEMBLY SEQUENCES, CLEARANCE BETWEEN PARTS AND REAL TIME INTERFERENCE CHECKS • MAKES DIGITAL MOCK UP A REALITY • CAN CHECK INTERFERENCES EVEN IN LOADED VIBRATING STRUCTURES. COULD BE USED TO PREDICT SHORTS IN ELECTRONIC PACKAGING

41. VIRTUAL PROTOTYPE • PREDICT AND PREVENT TRADITIONAL APPROACH TO DESIGN “ FIND & FIX”

42. VR APPLICATION CAD / CAM • STYLING & CONCEPTUAL DESIGN • ALLOWS DESIGNERS (GEOGRAPHICALLY SEPARATED) TO WORK TOGETHER WITH GREATER SYNERGY BY “VIRTUALLY CO-LOCATING”. RESULTS IN SHORTER DESIGN CYCLE. • ERGONOMIC STUDIES • IS THE USER COMFORTABLE? USER CAN FEEL, LOOK, OPERATE AND UNDERSTAND HOW IT OPERATES. USER CAN FEEL WHETHER THE DESIGN MEETS EXPECTATIONS AND BELIEVES THE DESIGN MEETS HIS NEEDS

43. VR APPLICATION CAD / CAM • ASSEMBLY & MODELLING • ENGINEERS CAN FLY THROUGH A DESIGN FROM ANY PERSPECTIVE AND STUDY THE ASSEMBLY PROBLEMS • STRUCTUTAL, MECHANICAL, THERMA, FLUID, ELECTRONIC AND ACOUSTIC SIMULATIONS TO UNDERSTAND THE s DYNAMIC BEHAVIOUR OF THE SYSTEM

44. VIRTUAL PROTOTYPE • VIRTUAL WIRE – HARNESS PROTOTYPE GENERATED ELIMINATES THE PHYSICAL PROTOTYPES NEEDED FOR VERIFICATION • USING ELECTRONICS THERMAL MANAGEMENT SOFTWARE ONE CAN BUILD AND TEST VIRTUAL PROTOTYPES – AIRFLOW AND TEMPERATURE GRADIENTS CAN BE PREDICTED WHICH HELPS TO CORRECT THE PROBLEMS AND OPTIMIZE A DESIGN BEFORE CUTTING METAL

45. VIRTUAL TESTING • CIRCUIT SIMULATION – LOW TEMP, HIGH TEMP ETC. AVAILABILITY OF COMPONENT PERFORMANCE LIBRARIES • DESIGN FLIGHT SIMULATORS – CONTROL LAW VALIDATION HANDLING QUALITIES ASSESSMENT • COMBAT SIMULATORS – ASSESS PERFORMANCE OF THE AIRCRAFT BEING DESIGNED IN A DOG FIGHT WITH KNOWN AIRCRAFT – PILOT IN THE LOOP OR COMPUTER PILOT

46. PROCESS SIMULATION USED FOR • RAPID PROCESS DEVELOPMENT • REDUCE PRODUCT DEVELOPMENT CYCLE TIME • LOWER THE COST OF DEVELOPING PARTS

47. PROCESS SIMULATION (Contd..) APPLIED TO • RESIN TRANSFER MOULDING (RTM) OF COMPOSITE PART TO SIMULATE RESIN FLOW • CURE SIMULATION IN COMPOSITE PARTS • RESIN INJECTION MOULDING (RIM) OF COMPOSITE PARTS

48. PROCESS SIMULATION (Contd..) APPLIED TO • FORGING – METAL FLOW • SHEET METAL FORMING • CASTINGS – METAL FLOW IN CAVITIES

49. PROCESS SIMULATION • INCREASES THE CHANGES OF BEING RIGHT FIRST TIME • RESLUTS IN SAVINGS • PERMITS PREDICTION OF COMPONENTS RESLUTANT PROPERTIES • OFFERS AN OPPORTUNITY TO DEVELOP A GREATER UNDERSTANDING OF THE PROCESS ITSELF • IS AN EFFECTIVE TOOL THAT OFFERS ENGINEERS TO MAKE FASTER MORE EFFECTIVE DECISIONS REGARDING THE MANUFACTURE OF A COMPONENT

50. VIRTUAL MANUFACTURING • VIRTUAL MANUFACTURING HAS BEEN SHOWN TO BE AN ESPECIALLY POWERFUL TOOL FOR IMPROVING EFFICIENCIES OF MANUFACTURING PROCESSES, ESPECIALLY IN EARLY PRODUCTION • MANUFACTURING SIMULATION