Proceeding, International Seminar on Industrial Engineering and Management
Inna Kuta Beach Hotel, Bali, Indonesia, Dec.10th-11th, 2009 ISSN : 1978-774X
Integrated Product development method
I Made Londen Batan
Product Design & Development Laboratory
Mechanical Engineering Departement
Industrial Technology Faculty
Sepuluh Nopember Institute of Technology
E-mail:
ABSTRACT
There are many methods developed by scientest and industrial manufacturer to develop a certain product. The most popular method that used in heavy industrial and also in manufacture industrial area is Reverse Engineering (RE). RE method was presented by K.N Otto and K.L. Wood as an approach to product design based on state of the art engineering methods, tools, and processes that when utilized within the discipline of an overall product development process, depict a very powerful practice design.
A new method was built based on the Reverse Engineering (RE) method by inputing the design for manuafcture (DFM) and asemmbly (DFA) guidelines to design process. Evaluation and analysis of product failure is the first step of method, and the last step is prototype testing.
The developed method was applied for developing a bicycle frame. The first frame design was built of 75 components, and the design efficiency is 18.2%. After using DFM and DFA the number of the frame reduced to 58 components, and design efficiency increase to be 31.5%. By using these method, there are many interesting products were developed, and the developed method could be used as the one method for developing a product.
Key words: Reverse Engineering, integrated methods, product development, DFM, DFA
Integrated Product Development Method
Batan, I Made Londen1
Proceeding, International Seminar on Industrial Engineering and Management
Inna Kuta Beach Hotel, Bali, Indonesia, Dec.10th-11th, 2009 ISSN : 1978-774X
- INTRODUCTION
Since economical crise in year 1998, there were many industrial manufacture in Indonesia bang rut, they cannot fulfilled the minimum requirement such as labor cost, fixed cost and operational cost. They cannot grow up from the crises and do not have capability to compete in globalization era. These caused by it does not policy for developing product, the industrial do not have competency to design a product by themselves, and the designer do not intonative and creatives.
Depend on the data in Juli 2006, the Indonesian otomotive industrialis threatenby component reqruiting. These caused by number of steel industrial, especially the number of steel casting industries is limited. However, they produce steel ingod, bar, and the other steel products, the quality and quantity of these product is still not enough to support the industrial manufacture. The limited researches on material sciense and metallurgical product aspect for developing a new product are also stimulated the industrial manufacture crises in Indonesia. Beside that, the product development is not as an importance part in industrial manufacture organization. The industrial do not have many initiative to design and develop a product by itself. The most type of work in industrial Indonesia is maintenance and repair. Furthermore the trading activity is more dominan than technology development or engineeing science.
- THEORETICAL BACKGROUND
Reverse Engineering (RE) is a four-stage process in the development of technical data to support the efficient use of capital resources and to increase productivity. These metode is very populair, because during the application almost do not need a research budget. RE method shows the weaknessof a product and a system.Based on these evaluation, the weakness of a product is corrected and whenever it’s necessary, the product is re-design. The new product design will be tested and investigated by its performance. So that the product capability can be determined, and the cost of product can be calculated. Furthermore, the RE brings also maintainability and improved manufacturability trend to drive the potential documentation.The four steps of RE areEvaluation and verification, Technical data generation, Design verification and Project implementation[Wood, 2001].
Ulrich 95 and Corbett 99, have developed a design for manufacture (DFM) method with aim that whether the product design can be realized in manufacture economically, or the product design must be changed. The DFM method is build with 4 steps, as shown in Figure 1.
Step / Description1 / Estimation of manufacturing cost
2 / Reduce the component cost
3 / Reduce the assembly cost
4 / Reduce the supporting cost
Figure1. DFM method [Urlich95]
The DFM method is very useful inindustrial manufacture [Boothroyd2002,Bralla2003]. There are many advantages in manufacture aspect for developing a product by using DFM such as manufacturing cost and time reduction.
In order to increase the design efficiency, beside the DFM method, the method of assembly must be included into the design process. One of famous method in manufacture industrial for assembly is DFA method, amethod which describes how the number of part could be reduced. How to combine the component to be a new component due to reduce the assembly cost. Furthermore the DFA give also a change to designer to change process of manufacture that used to produce a product.
- DEVELOPED METHOD
The integrated method for developing product is developed base on the RE method with by integrating design for manufacture and assembly (DFM & DFA) method after the product failure was determined. The developed method is consisting of 5 steps, as shown in Figure 2.
Step / Description1 / Evaluation and analysis of product failure
2 / Recommendation for product re-design
3 / Component design
4 / Product prototyping
5 / Prototype testing
Figure 2. Integrated Method of Product Development
During the product evaluation,the failure of a product will be analyzed and then must be determined. Using DFM method the recommendation for re-design a product will be arranged. By using the economical production aspect the component will be designed.It means that the DFM method is used for designing the component. During these step the DFA is also to be included to reduce the number of component. Before testing, the product prototype is the one step this method. The developed method is described systematically by flowchart as shown in appendix B.
4. PRODUCT DEVELOPMENT
As an application of developed method, a bicycle flexible frame is developed. As mentioned in item 3above, a bicycle frame (Fig. 3) is evaluated. The frame is build of 75components (9 sub-parts).
Fig. 3. Bicycle frame (will be developed)
By using the DFA method with a worksheet (Table A - Appendix), the design efficiency of frame is 18,2%. The assembly evaluation is shown in table 1.
Tabel 1. Parameter Assembly for bicycle frame component
Sub- Assembly / Number of part / Op. time (sec) / Design effc.Brackets Part / 12 / 170 / 0.106
Down Tubes / 4 / 41.19 / 0.218
Head Tubes / 4 / 48.60 / 0.185
Top Tubes 1 / 5 / 43.50 / 0.138
Top Tubes 2 / 3 / 38,06 / 0.236
Top Tubes 3 / 7 / 67.80 / 0.177
Stay Tubes / 11 / 157.73 / 0.152
Seat Tubes / 6 / 79.80 / 0.075
Other components / 23 / 209.65 / 0.301
Total / 75 / 856.33 / 0.182
By using the first step of the developed method, the evaluation shows that the number of the frames component is to large (75 components), and also the design efficiency is to low (18.2%). These problem effects to operation time and assembly cost respectively. Due to reduce the assembly cost, the number of frame component must be reduced as minimal as possible. In this step the alternative concept (new concept) will be generated. Using concept selection method the accepted concept will be recommended, and then the selected concept will be developed continuously. Here the alternative concept of product will be re-designed and developed. The new design of bicycle frame is shown in Fig. 3, andthe frame is build of 58 components.
As a step of traditional design, the new design must be evaluated, whether the new product construction (design) is strong enough to receive such load that work on the frame. In this case the external load (rider weight) included to bicycle weight is up until 100 kgf, and it effect must be showed with the strength material calculation. In this research the geometry and dimension of the frame is decided based on JIS standard, as shown in appendix A [Japan Bicycle Standard]. Frame material is Aluminum T6061.
Fig. 3. The new design of frame
By using the Von Misses Evaluation method, the strength of material of bicycle frame is determined, and the critical strength is occurred in pivot tube connection, as shown in Figure 4.
Figure 4. Strength of material analysis of 100 kgf load
Figure 4 shows the maximum of material strength with external load of 100 kgfis 5,58x107 N/m2. That value is still less than yield strength of material Al-6061 such as 2,75 x 108 N/m2.. It means, the frame component design is safe and the requirement of designwas fulfilled.
By using the DFA method the design efficiency is calculated, and the result is 31.50%. It means the design efficiency is increased to 13.3%.The assembly analyzed is shown in table 2.
Table 2. Parameter DFA of sub-assembly frame for a new design
5. CONCLUSION
Based on the discussed and application of integrated method as mentioned, it shows that the developed method is useful and easily to design and develop a product. However, before the new design is decided, the design efficiency of product must be calculated.
6. REFERENCES
- Ali Safrani,Batan, I Made Londen. Rancang Bangun Flexy Bike Sebagai Alat Transportasi Altenatif Keluarga. Jurusan Teknik Mesin ITS, Surabaya, 2006.
- Batan, I Made Londen (1998): Developing a New Method on Design Engineering. International Seminar of Institute of Scientific and Technology, Paderborn, Germany.
- Boothroyd, Geoffry & Dewhurst, Peter, (2002), Product Design for Manufacture and Assembly. Second Edition Revised and Expanded, Marcel Dekker, Inc.
- Bralla, James G., (2003),Design for Manufacturability Handbook, Second Edition, McGraw-Hill book.
Sub –Assembly / Number of part / Op. time (sec) / Design effc.
Brackets Part / 8 / 75.01 / 0.320
Down Tubes / 3 / 19.21 / 0.469
Head Tubes / 3 / 30.40 / 0.296
Top Tubes 1 / 2 / 15.80 / 0.381
Top Tubes 2 / 3 / 7.89 / 0.760
Top Tubes 3 / 7 / 15.80 / 0.381
Stay Tubes / 9 / 113.93 / 0.237
Seat Tubes / 3 / 22.39 / 0.401
Other components / 20 / 147 / 0.281
Total / 58 / 447.43 / 0.315
- Chao,P Lawrence and Ishi, Kosuke, (2003),Design Process Error Proofing: Failure Mode and Effect Analysis of Design Process, Proceding of DETC’03,Chicago Illinois
- Corbett, J., Dooner, M., Meleka. J. and Pym, Christopher (1997): Design for Manufacture – Strategies, Principles and Techniques. Addison – Wesley Publishing, Co.
- Djawahir, I. S. (1997): Design for Manufacturing and Assembly, Center of Manufacturing, Department of Mechanical Engineering, University of Kentucky, USA. ITB, Bandung.
- Ehrlenspiel, Klaus, Kiewert, Alfons, Lindemann, Udo, 1998, Kostenguenstig Entwickeln und Konstruieren – Kostenmanagement bei der integrierten Produktentwicklung. 2. Auflage. Springer, Berlin.
- Gevirtz, Carles (1994): Developing New Product with TQM. Mc Graw-Hill, International Edition.
- Henry W. Stoll (1996): Design for Manufacture – an overview: in Handbook Design for Manufacture, John Cobatt, Addison Wesley.
- Kevin Otto & Kristin Wood (2001), Product Design Techniques in Reverse Engineering and New Product Development.
- Komang Gede Nara Utama, Rancang Bangun Lipatan dan Sambungan Rangka Pada Flexy Bike. Jurusan Teknik Mesin ITS, Surabaya, 2006.
- ……, JIS Cycle 1993, Japan Bicycle Promotion Institute, Japan.
- Pahl and Beitz (1996): Enginering Design - A Systematic Approach, Spinger- Verlag.
- Urlich, Karl T., Eppinger, Steven D. (2002): Product Design and Development. Mc Graw-Hill, Inc.
Integrated Product Development Method
Batan, I Made Londen1
Proceeding, International Seminar on Industrial Engineering and Management
Inna Kuta Beach Hotel, Bali, Indonesia, Dec.10th-11th, 2009 ISSN : 1978-774X
Appendix A
Table A. Worksheet to calculate a design efficiency [Boothroyd, 2000].
1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 / 9 / 10 / 11Part ID Number / Number of times / Manual Handling Time code / Manual Handling time per part / Two digit Incretion code / Manual insertion time per part / operation time / operation cost / Figure for estimation of theoretical minimum part / Name of Assembly / Remark
1 / 00 / 1,13 / 0 / 1,5 / 2,63 / 1 / Bottom bracket shell / In Fixture list
TOTAL / Design Efficiency
Appendix B
Flowchart of Integrated Product Development Method
Integrated Product Development Method
Batan, I Made Londen1