A TECHNICAL SEMINAR PRESENTED BY BEN GEORGE 1RV12MPD06

NEED OF HOUR
Optimization of resources

Change to more secular and user friendly system Work together to reduce cost and market time and increase quality and productivity Avoid negative impact on environment Increase safety and acknowledge global competition

WHAT IPPD MEANS

TRANSFORMS BUSINESS PROCESS

INTEGRATES DEVELOPMENT OF PRODUCTS AND ASSOCIATE PROCESSES

IPPD DEFINATION
IPPD provides a systematic approach to product development that achieves a timely collaboration of relevant stakeholders throughout the product life cycle to better satisfy customer needs.

IPPD TEAM INTERESTS

Customers Suppliers Manufacturers Engineering (design, software, hardware, components, and process) Tools Services Management Miscellaneous (safety, environment, testing)

Nineteen Parts of Concurrent Engineering: Synchronized

Wheel Set
First wheel of integrated product and process

organization: 4 Ms Define types of information, complexity of tasks, degree of incompleteness, timing of decision making, order of decision making, communication mechanism Second wheel of integrated product development: 7Cs -collaboration, commitment, communication, compromise, consensus, continuous improvement and coordination. 3Ps - policies, practice and procedure 4Ms - money, machine, manpower, management

Synchronized Set of CE Wheels

Product Realization Taxonomy
The Whole System Manufacturing Competitiveness

Cooperative Work-groups Life-cycle Management Virtual Personnel Team Models Team

Methods, Metrics, and Measures

Information Logical Modelling Team

Technology Process Reengineering Team Decision Support Systems

Intelligent Information System

Concurrent Function Deployment CE Metrics and Measures

System Engineering

CE Techniques

Life-cycle Mechanization Models, Methods, Metrics and Measures IPD Deployment Methodology

Integrated Product and Process Organization (PPO) Wheel

Capturing Life-cycle Intent

Total Value Management

Frameworks and Architectures

Product Development Methodology

Integrated Product Development (IPD) Wheel

WHAT EXACTLY DO IPPD TEAMS DO?

Seek participation from all disciplines Produce and implement an integrated management plan (IMP) Apply IPPD techniques to new production contracts Take responsibility for the cost and cycle of product development

Make a concerted effort to do the job right the first time

IPD development methodology employs fundamental CE characteristic like: * Re-engineering * System engineering * Product realization * Integrated product development * Total value management

WHAT IS A PDT ?
Cradle-to-grave approach of working together on

every aspect

Cost, performance, support system, and customer relationship

Optimal scheduling to streamline design, manufacturing, and distribution of the product

Early influences on product design goes to early maturity of design, manufacturing, and procurement processes

INTEGRATED TEAM
A group of people with complementary skills and expertise who are committed to delivering specified work products in timely collaboration. Integrated team members provide skills and advocacy appropriate to all phases of the work products life cycle and are collectively responsible for delivering the work products as specified. An Integrated Team should include empowered representatives from organizations, disciplines ,and functions that have a stake in the success of the work products.

WORK PRODUCT
Any product produced by a process. This may include files, documents, parts of the product, services, processes, specifications, and invoices. Examples of processes as work product include a manufacturing process, a training process, and a disposal process. A key distinction between a work product and a product component is that a work product need not be engineered.

Typical Composition of Each Team

decomposition systematization interface development unification common systems standards R&D strategic team software hardware Logical Team

network Agents-based concept functional inference network receiving agents requesting agents affecting agents services on the network Virtual Team brokerage agents client/server mode

Product Development Team (PDT) Manager Technology Team Personnel Team

computer-based tools marketing

engineering
materials process quality communication fabrication

concept quality assurance engineering design Manufacturing/assembly production engineering and planning prototyping management control delivery support sales and service

Logical Virtual Team Team Technology Team Personnel Team

THE TEN COMMANDMENTS OF IPPD

I. Define problems II. Organize teams III. Establish requirements IV. Create product system alternatives V. Refine the best design alternative VI. Define products and processes VII. Perform value analysis/engineering (VA/VE) VIII. Develop products and processes IX. Production X. Continuous process improvements (CPI)

A-plan 1 A-plan 10

Continuous Process Improvements (CPI)

A-plan 9 Production

Define Problems

A-plan 2 Organize Teams

A-plan 3

Develop Products & Processes A-plan 8

CE 7Ts,4Ms, 3Ps, etc.

Establish Requirements Create Product System Alternatives A-plan 4

Perform Value Analysis/ Engineering (VA/VE) Define Products and Processes A-plan 7

Refine the Best Design Alternative A-plan 5 LEGEND Starting of an activity plan Ending of an activity plan

A-plan 6

Ten Commandments of IPD Implementation

1. Define Problems
Understand market need and opportunities Define objectives, milestone, measurement criteria,

and success factor Receive specific customer needs and expectations Obtain marketing and technology plans Develop project plans.

2. Organize Work Groups in PDT

Start the 1-track, 2-track, and 3-track
rack concurrent loops Needed expertise of work groups in PDT

Reasonable work schedule

Set of common check points Other tasks

Organize Work Groups in PDT (cont.)

OTHER TASKS
Review resource requirements

Identify leveraging opportunities

Select and prioritize key projects Designate a system manager Form a core group Identify a champion Involve suppliers: original equipment

manufacturers (OEM) and key suppliers Confirm or redirect business strategies Compute return on investments (ROI)

3. Establish Requirements
Review warranty, field cost, and capacity data

Identify feasible product and process technologies

Steps involved:

Background research or investigation

Competitive tasks
Competitive analysis

Establish Requirements (cont.)

Benchmark for:
Function, feature, cost, weight, investment

Requirements for technical performance Requirements for customer satisfaction Create consolidated requirements Establish a product verification plan Determine performance gaps Validate concept requirements Establish the concept selection matrix Obtain management approval of functional requirements and plans

4. Create Product System Alternatives

Eliminate negative points of the strongest design concept or Generate a new design idea that is inherently superior to previous design Steps involved:
Identify small system and component sourcing

requirements Identify candidate sub-systems Select the best alternative construction Generate preliminary part list

4. Create Product System Alternatives (cont.)

Model a preliminary system concept Establish process capability

Perform system analysis Perform FMEA and complete related documentation Identify process requirements Develop material to feature specifications Perform sensitivity and trade-off analysis Perform an alternative manufacturing process analysis

5. Refine the Best Design Alternative

The team verifies the feasibility of the best design alternative from a technical and economic

standpoint Draw a process flow chart Finalize sub-system specifications Conduct a sub-system FMEA and DFMA analysis Build alternative concept replica (software prototype) Conduct a program team review Concurrent function deployment filtering Concept alternative selection

6. Define Elements of Product and Processes

Finalize systems specification Conduct a system FMEA and DFMA Conduct CFD production planning III analysis Process concept selection matrix Finalize engineering and manufacturing criteria Refine the manufacturing process design proposal Confirm manufacturing capability Finalize supplier selection Develop a process validation plan

7. Perform Value Analysis or Engineering

VALUES DEFINITIONS VALUES ANALYSIS

A problem or opportunity involving managerial and administrative systems analysis as the principle in its resolution (people-oriented)
A problem or opportunity involving the physical sciences as the principle discipline in its resolution (product-oriented)

VALUES ENGINEERING

7. Perform Value Analysis or Engineering (cont.)

Establish a value for that function or service List sources of variations Identify values-added activities Develop fish-bone diagrams Seek creative ideas and evaluate or investigate Evaluate an improved process Redesign ideas process Define an ideal situation Choose an optimal process

8. Develop Production-Intent Products and Processes

Finalize the best design or process objectives

Select manufacturing sources

Establish process capability for critical items Complete validation plan:
Manufacturing process design Financial Manufacturing facilities

Product intent design

9. Production
Order production equipment and tooling Qualify production equipment and tooling at the

suppliers facility Order production material and purchase charts Install production equipment and tooling at the manufacturing facilities Run a production schedule Perform production part verification

10. CONTINUOUS PROCESS IMPROVEMENT

Targets for a future row of tasks R&D row of tasks Quality network row of tasks Other rows of tasks

The steadfast company wins the race along with continuous improvement An innovative jump to newer technology is needed for faster growth

THANK YOU