manufacturability

Extent to which a good can be manufactured with relative ease at minimum cost and
maximum reliability.

Definition of 'Value Engineering'

A systematic and organized approach to provide the necessary functions in a project at the
lowest cost. Value engineering promotes the substitution of materials and methods with less
expensive alternatives, without sacrificing functionality. It is focused solely on the functions
of various components and materials, rather than their physical attributes. Also called value
analysis.

Investopedia explains 'Value Engineering'

The concept of value engineering evolved in the 1940s at General Electric, in the midst of
World War II. Due to the war, purchase engineer Lawrence Miles and others sought
substitutes for materials and components, since there was a chronic shortage of them.
These substitutes were often found to reduce costs and provided equal or better
performance.

Manufacturability & Value Engineering

May 27, 2012 by mohamedalb502 and tagged Automobile Platform, Cars, Manufacturability, Modular
Design, MQB, Standardization, Strategy 2018,Value Engineering, Volkswagen, VW
We learned in our Operation Management class that designing operations processes aims to reduce
cost; reduce complexity; additional standardization of components; improvement of functional aspects
of the product; and improved maintainability of the product. Furthermore, manufacturing and value
engineering procedures are concerned with improvement of design and specifications at the research,
development, design, and production stages of product development. Also, we learned that
organizations develop a strategy plan to set their expectations of achieving missions and goals.
Volkswagen (VW) Group set a strategic plan known as Strategy 2018 that aims to make the VW
Group a worldwide leader in 2018. Over the long term, VW aims to increase unit sales to more than
10 million vehicles a year and intends to increase its return on sales before tax to at least 8%. To
achieve these goals, Volkswagen announced an introduction of new manufacturing design platform
called Modular Transverse Matrix or (MQB), which will play a vital role.
Volkswagen Group is a German multinational automotive manufacturing group headquartered
in Wolfsburg. It is the worlds second-largest motor vehicle manufacturer by 2011 unit sales and the
largest based in Europe. The Group is made up of various big brands: Volkswagen, Audi, Porsche,
Bugatti, Lamborghini, Bentley, Skoda, SEAT, VW Commercial Vehicles, Scania and MAN.

Generally, each automobile platform is designed specifically for a market segment and shared between
cars of similar size. A typical mass market of VW platform underpins different brands with several
model variants. VW is now creating shared modular platforms to serve needs of its different
subsidiaries. One of the prominent features of the MQB is the uniform position of all engines designed
to accommodate two new four cylinder engine cars. The new engines will reduce the Groups engines
and gearbox variants in the MQB system by 90% and the MQB will also enables an identical mounting
position for all current alternative drive concepts from natural gas and hybrid versions to the pure
electric drivecitation.

Soon, all of the models and brands under VW Group will be produced on the same assembly line, and
even will produce MQB models of different brands together. The advantages of creating amodular
design are: simplifications of manufacturing and assembly; easier repair and replacement; parts
interchangeability; standardization; and easier diagnosis and remedy of failures. By creating a
standardized, interchangeable set of parts from which to build a variety of cars, VW plans to cut the
time taken to build a car by 30%. The MQB platform will allow the VW Group to produce a worldwide
high volume and niche models at extremely competitive costs over the long term. The MQB takes
advantage of synergies in key technologies and allows for greater boost in sales citation.
The modular platform concept is a radical structural advantage for Volkswagen Group in the global
automotive industry, allowing it to reduce costs and be more competitive on prices. Do you think that
Volkswagen Group cars will dominate the world market share by 2018?

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How product design can create production quality issues

by RENAUD ANJORAN on 23 OCTOBER 2010
Today I was in a factory of silicon products (cookware, phone covers). My client was buying
the cover for a TV remote control. Production started earlier this week, and I was called in
urgently to find solutions to production quality issues.
The defect rate was roughly 40% Because a world-class product designer came up with a coollooking 3D blueprint, because a TV network operator approved it, and because the importer
confirmed it could be done.
The beauty of China is that one can get a production running with very cheap moulds, which
allows for a lot of flexibility and lower quantities per design. The drawback is that these moulds
require lots of manual operators, which means more opportunities for defects.

The factory put in place a complex process:

Injecting liquid silicon in different colors in one mould;

Heating the liquid silicon to get it into a solid state;
Cleaning throughly around the silicon by rubbing and by blowing air;
Putting another piece of solid silicon on top, and doing the compression/moulding
operation;
Getting the piece of silicon out of the mould (it was basically all around the mould).

Each operation creates its own defects. And some defects simply cannot be avoided. For
example, the liquid silicon is not hard enough (in my opinion) and gets spread around a little
with the solid silicon is compressed.
How to sold this issue? The temperature can hardly be modified (below 210 degres is not advised
for silicon), and the warming time cannot be increased (or some pieces dont stick to the mold
any more).
All I could do is reduce some opportunities for defects by correcting some behaviors (and I am
not even sure what they will do once I am gone) and by doing some tests.
But the fundamental issue is that such a design cannot be done properly in China. One needs
highly automatic molds that cost many times more money.
This type of problem is no doubt encouraged by the distance between a French product designer
and a Chinese factory that will be sourced after the project is approved. It is just not the way to
proceed The best designers, in my mind, should be familiar with the production constraints, or
at least have a dialogue with factory technicians.
In some industries, so much has been achieved with such cooperation They usually call it
DFMA (Design For Manufacturing and Assembly).
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What is robust product design?

Robust product design is a concept from the teachings of Dr. Genichi Taguchi, a
Japanese quality guru. It is defined as reducing variation in a product without

eliminating the causes of the variation. In other words, making the product or process
insensitive to variation. This variation (sometimes called noise) can come from a
variety of factors and can be classified into three main types: internal variation,
external variation, and unit to unit variation. Internal variation is due to deterioration
such as the wear of a machine, and aging of materials. External variation is from
factor relating to environmental conditions such as temperature, humidity and dust.
Unit to Unit variation is variations between parts due to variations in material,
processes and equipment. (Lochner and Matar, 18). Examples of robust design include
umbrella fabric that will not deteriorate when exposed to varying environments
(external variation), food products that have long shelf lives (internal variation), and
replacement parts that will fit properly (unit to unit variation). The goal of robust
design is to come up with a way to make the final product consistent when the process
is subject to a variety of "noise".

How do you make a design robust?

Taguchi considers making a design robust in the parameter design portion of product
or process design. In parameter design the goal is to find values for controllable
settings that minimize the negative effects of the uncontrollable settings. Experiments
are used to determine the impact of particular settings on both the controllable and
uncontrollable factors. The idea here is that by observing changes in a controllable
factor (such as the thickness of boards), a value can be found for that factor that
reduces the effect (warping) of something that cant be controlled (the humidity
outside). The ultimate goal is to find the optimal settings to minimize cost by
minimizing variation.
When setting up these experiments, the factors that effect the product need to be
determined. Then the factors can be separated into controllable factors and
uncontrollable factors and experiments can be set up to test the effects of changing the
values of each factor. There are many ways to set up these experiments. Taguchis
method involves finding correlation between variables. He uses orthogonal arrays,
with the inner array consisting of control factors and the outer array consisting of
"noise" factors. Each inner array is to be run with each outer array. (If six control
factor experiments and three "noise" factor experiments are needed, there will have to
be (six times three) eighteen experimental trials to get all the combinations). Another

method for conducting these experiments is to make no attempt to control the "noise"
factors, but repeatedly run the trials for combinations of control factors. (Lochner and
Matar, 152) This type of experiment allows the operator to measure process variability.
The trials should be taken in an environment similar to the one in which the actual use
or manufacturing of the product is going to take place. A third experimental design is to
identify all the control and "noise" factors (adding the control and noise factors yields k)
and run an analysis using at least k +1 trials based on eight-run experiments. (You
could use an eight run experiment for up to k=7, and a sixteen run experiment for up to
k=15.) This will allow the interaction between variable to be seen running fewer tests
than using Taguchi's method. Further instruction as to how to use this method is found
in chapter four of "Designing for Quality" by Lochner and Matar.
The data found from the experimental trials is then analyzed. The analysis will depend
on the method of experimentation. Plot the effect that the variables had on your
variation and/or the correlation between factors. Using this data find settings for the
controllable factors that are found to lower the variation caused by uncontrollable
factors.
Then after the initial experiment trails are run and "optimal" settings are found
confirmation experimentation is needed. By performing a series of replica experiments
at the levels that were picked, we can see if the values achieved matched that of the
values the model predicted. If there is disparity, there may be an interaction or noise
that we didnt see and thus our experiment must be redeveloped.

What are the advantages of robust design?

Robust design has many advantages. For one, the effect of robustness on quality is
great. Robustness reduces variation in parts by reducing the effects of uncontrollable
variation. More consistent parts equals better quality.
Another advantage is that lower quality parts or parts with higher tolerances can be
used and a quality product can still be made. This saves the company money, because
the less variable the parts can be the more they cost.
A third advantage is that the product will have more appeal to the customer. Customers
demand a robust product that won't be as vulnerable to deterioration and can be used in
a variety of situations.

This method is also good, because you are designing the robustness into the product
and process instead of trying to fix variation problem after they occur.
What are the disadvantages of robust design?
One of the disadvantages of robust design is that to effectively deal with the noise, the
designer must be aware of the noise. If there is a noise factor that is affecting the
product and the experiments run do not address it (intentionally or not), the only way
that the product will be robust to that variation is by luck.
Another disadvantage to robust design done Taguchis way is that the problem becomes
large quickly. If you had a lot of different things to consider as control variables and/or
noise variables, it would take a great deal of time to run all the experimental trials.
Controlling noise variables is expense, and when lots of trials are required the dollars
add up.
Another disadvantage is that by using orthogonal arrays, it assumes the noise factors
are independent, which may be helpful in setting up the experiment, but is not
necessarily a good assumption (Lochner and Matar, 153).

What are some examples of why robust design is important?

Consider this example adapted from "Creating Quality" by Kolarik; the designers of a
radio had built and tested a breadboard. After the radio was considered a success, the
specifications were passed to production and the radios began being manufactured.
The first production units radios went into test and failed to meet marketings product
performance requirements, as did the second unit. Analysis of why the process failed
produced no results. They had been following procedure and using standard acceptable
parts. Next the breadboard of the original design was inspected. It was found that the
designers had hand-tested and picked all the component parts. They worked much
better than the manufacturers standard acceptable parts. After review of the design it
was found that there was no way to economically fix the problem without massive
redesign, so personnel were assigned the task of manually sorting the components,
costing the company additional time.
In this example the design of the radio needed to be robust so that it could handle the
amount of variation in the set of standard acceptable parts. Because the design didnt
allow for that amount of variability, it cost the company lost time. They had to stop the

production process and investigate and then they had to expend further manpower in
screening the parts.
Making a product robust is also a concern for companies that manufacture products for
an ever-expanding market. If products are sold nation wide or even globally, the
differences in the environments, conditions, and uses have to be considered for them to
be a success. For example, a manufacturer of a certain type of gas grill that is sold
nationally must consider the robustness of the materials used to make the grill. The
people in Minnesota may use the grill in the summer only and it is stored in the garage
in the winter where the temperature falls to freezing. The consumers in Arizona use the
grill year round and it is stored on the deck where it is subject to sunlight, rain and
higher temperatures. The manufacturer must make sure that the grill can withstand both
conditions. If the freezing temperature cracks the valve connection or if the heat cause
the lid to deform, they will lose the potential buyers in the respective area.

What can be said in conclusion?

Robust design is designing a way to make the final product consistent when the process
is subject to a variety of "noise". This can be done through a variety of experimentation
methods. The results are capable of showing how to develop a product/process that will
be robust. The advantages of robust design are that the products are of good quality,
cheaper, and more customer friendly than their non-robust counterparts. Although there
are disadvantages, having a robust product design can give companies a large
competitive edge.
-Modular design

The term modular design basically means a design of components that can be assembled in a
variety of ways to meet individual consumer needs. This can be something like a pre fabed home
where different sections can be combined to make the home they need.

There are so many modular design examples that are all around us. A good example that we can
all relate to of a modular design example is car. When you need some customization and
additional features, you will need to pay a little bit more. Modular designs are meant to offer
customers an extensive range of satisfaction. This has proved to be of so much benefit to
consumers since they are able to choose from various options available to them.

-CAD

CAD (computer-aided design) software is used by architects, engineers,

drafters, artists, and others to create precision drawings or technical
illustrations. CAD software can be used to create two-dimensional (2-D)
drawings or three-dimensional (3-D) models.
CAD/CAM (computer-aided design/computer-aided manufacturing) is software
used to design products such as electronic circuit boards in computers and
other devices.
CAD / Computer-Aided Design
Computer-aided design (CAD) is the use of computer programs to create two- or three-dimensional (2D or 3D) graphical
representations of physical objects. CAD software may be specialized for specific applications. CAD is widely used for
computer animation and special effects in movies, advertising, and other applications where the graphic design itself is the
finished product. CAD is also used to design physical products in a wide range of industries, where the software performs
calculations for determining an optimum shape and size for a variety of product and industrial design applications.
In product and industrial design, CAD is used mainly for the creation of detailed 3D solid or surface models, or 2D vectorbased drawings of physical components. However, CAD is also used throughout the engineering process from conceptual
design and layout of products, through strength and dynamic analysis of assemblies, to the definition of manufacturing
methods. This allows an engineer to both interactively and automatically analyze design variants, to find the optimal design
for manufacturing while minimizing the use of physical prototypes.

Benefits of CAD
The benefits of CAD include lower product development costs, increased productivity, improved product quality and faster
time-to-market.

Better visualization of the final product, sub-assemblies and constituent parts in a CAD system speeds the design
process.

CAD software offers greater accuracy, so errors are reduced.

A CAD system provides easier, more robust documentation of the design, including geometries and dimensions,
bills of materials, etc.
CAD software offers easy re-use of design data and best practices.

-CAM

CAM / Computer-Aided Manufacturing

Computer-aided manufacturing (CAM) commonly refers to the use of numerical control (NC) computer software
applications to create detailed instructions (G-code) that drive computer numerical control (CNC) machine tools for
manufacturing parts. Manufacturers in a variety of industries depend on the capabilities of CAM to produce high-quality
parts.

A broader definition of CAM can include the use of computer applications to define a manufacturing plan for tooling design,
computer-aided design (CAD) model preparation, NC programming, coordinate measuring machine (CMM) inspection
programming, machine tool simulation, or post-processing. The plan is then executed in a production environment, such as
direct numerical control (DNC), tool management, CNC machining, or CMM execution.

Benefits of CAM
The benefits of CAM include a properly defined manufacturing plan that delivers expected results in production.

CAM systems can maximize utilization of a full range of production equipment, including high speed, 5-axis, multifunction and turning machines, electrical discharge machining (EDM) and CMM inspection equipment.
CAM systems can aid in creating, verifying, and optimizing NC programs for optimum machining productivity, as
well as automate the creation of shop documentation.
Advanced CAM systems with product lifecycle management (PLM) integration can provide manufacturing planning
and production personnel with data and process management to ensure use of correct data and standard resources.
CAM and PLM systems can be integrated with DNC systems for delivery and management of files to CNC
machines on the shop floor.

--

What is Virtual Reality?

Virtual reality can be defined as an upcoming technology that makes users feel in a Virtual
Environment (VE) by using computer hardware and software. It was originally conceived as a digitally
created space which humans could access by donning special computer equipments. It enables people to
deal with information more easily. VR provides a different way to see and experience information, one that
is dynamic and immediate. For example, in a computer game, users joystick motions are tracked and the
objects in the game are moved according to the joystick movements. In the same way a simulated, threedimensional world is created around the user in which he/she could interact with objects, people, and
environments. Typically three-dimensional life-sized images with support of audio devices are presented
around the user and the perspective is modified in accordance with the user input (generally head or eye
movements). Many devices along with the computers are used to create a virtual environment.
To enter in a VE, a user dons special gloves, earphones, and goggles, all of which send their output to
the computer systems. The virtual environments are intended to replace the real world environment with
the digital one and the human senses are immersed in the VE. Immersion is an experience of losing
oneself in the VE and shutting out all cues from the physical world. A Virtual Environment can be created
on different extents depending on the computer based platform ranging from a cell phone screen to a
desktop monitor or a fully Immersive Virtual Environment (IVE).
The tracking and rendering turns the whole process more immersive and interactive than the traditional
media like televisions and video games. The user actions result in immediate and observable impact on
the content of virtual environment. Following are the main components of a virtual environment:

1.

The visual displays that immerse the user in the virtual world and block out contradictory sensory

impressions from the real world.

2.

The graphics rendering system that generates the ever changing images at 20 to 30 frames per

second.
3.

A tracking system that continuously informs the position and orientation of the users movements.

4.

The database construction and maintenance system to build and maintain a detailed and realistic

model of the virtual world.

5.

A sound system that can produce high quality directional sounds and simulated sound fields.

6.

Devices like tracked gloves with pushbuttons to enable users to specify their interactions with the

virtual objects.
How VR works
A simple example of Counter Strike game can give a thought as to how virtual reality works. The
software program for the game is the major element which runs with the help of the computer system and
the interfaced input output devices. Every Character and environment within the game behaves closely to
reality as per the code written for them. The code facilitates characters and environment to interact with
the other characters controlled by the input devices. The code is interpreted by the processor which
handles the input output devices accordingly. This is the simplest example of how VR works. The
working of more immersive virtual reality environment is quite similar to working of the game besides the
fact that a number of advanced input and output devices along with a high performance processor are
added to increase the immersion. The processor executes the processes quickly according to the input
given by the user and output is presented to the user in a way that user feels itself a part of the
environment and its objects. The video below shows an example of more immersive virtual reality.
The 3D visualization component enables the user to see 3D scenarios by using a display methodology
like a head mounted device. Typically the 3D images superimpose the real environment by using one of
the display, screen based or projection based. The screen based virtual environment generally uses a
high quality display screen in terms of resolution and color, or a head mounted device along with the
sound system as output devices. A keyboard, microphone, head tracking sensors, finger trackers, gesture
recognition system, a joystick or similar gears are used as input devices. When user moves the gear or
joystick, make move of the head, or press any key on the keyboard, the objects of the screen are
changes accordingly in a way that user feels if he/she is directly controlling the objects and environments
on the screen. A high speed powerful processor processes the inputs. An Application Programming
Interface (API) provides the interface to the input devices connected to the system as well as to standard
devices like mouse and keyboard. The timings and relationship between input and output devices are so
perfect that user feels an immersion with the virtual environment.

The other technique used to create a virtual environment is projection based, which is more immersive
than the screen based method. The display images are projected on the multi screen spaces ranging
from two to six screens. A six screens would make a better virtual environment. Both floor and ceiling
uses a rear projection while the other four screens yield large surrounding views for both panning actions
and looking down. Consequently objects inside the space could be walked around and virtual entreat to
be touched.