P.G. Leaney

A systems engineering framework for integrated automotive development

Automotive development faces tightening regulatory requirements, shortening development cycle times, and growing complexity. To cope with such an environment, it is moving from a traditional evolutionary to a systems engineering approach. Great effort is being made for a shift from the traditional component focus, which has been enhanced by concurrent engineering, to a more broadened view supported by systems thinking. This broader view, however, is in practice strongly focused on the product elements of the system. This paper proposes a systems engineering framework for integrated automotive development—the total view approach. It is a modeling framework that integrates the product, its life cycle processes and their associated organizations throughout the requirements, functional and physical analysis processes, at all levels of the product breakdown structure, deriving attributes as emergent properties of a whole integrated system. The paper justifies the framework through a review of traditional and current automotive development and two case studies. A major benefit of the application of the framework is the ability to investigate early in the product development process the interactions between requirements and attributes not only of the product, but also of its life cycle processes and their associated organisations. This can lead to better product quality, lower life cycle cost, shorter development time, and manageable complexity.

A systems engineering approach to product modularity

Abstract Product modularity has been successfully adopted in a number of specific industries, such as computer technology and software development, where it provides a number of advantages over monolithic product architectures. This paper presents initial findings from research at a range of companies within the United Kingdom where modularity is being applied or considered to address increasing product complexity and the growing need for the symbiosis of mechanical, electrical, electronic, optical and software technologies in a wider range of manufactured products to meet discerning market requirements. The research identifies a need to address the current application of modularity within industry at three levels: A systems engineering based framework, a methodology for product modularization and the underlying process of modular product development. Concluding remarks highlight the issues drawn from the research and opportunities for addressing these issues.

Implications of the End-of-Life Vehicles Directive on the vehicle recovery sector

Abstract To cope with the environmental effects of 9 million tonnes of vehicles that reach the end of their useful lives each year in Europe, the EC have created the End-of-Life Vehicles (ELVs) Directive. Two of the most radical measures included in the Directive are to provide free takeback to last owners and to achieve targeted levels for the recycling and recovery of material by set dates. This paper aims to provide a basis for future research by evaluating the potential direction of the recovery industry. This is achieved firstly by assessing the origins of the directive and previous research surrounding the subject. The paper then describes the current recovery infrastructure and practices in the UK, highlighting all the stakeholders involved in the recovery industry. This paper also highlights the issues related to the provision of takeback and the attainment of targets through two stages, namely the implementation and management of takeback, and the use of new technology to achieve the recovery targets. The paper concludes by identifying key aims for future research to support the objectives of the implemented legislation and the financial stability of all stakeholders.

A systems and concurrent engineering framework for the integrated development of space products

Abstract This paper proposes a framework for the integrated development of space products. The framework is called ‘total view framework’ because it provides the total set of product, process and organisation elements and their interactions from the outset in the development process. It uses systems engineering (SE) and concurrent engineering (CE) in an integrated manner, as part of the same framework. The framework extends the application of the SE process to life cycle processes and their performing organisations and applies CE at all levels of the hierarchical product breakdown structure. The ‘total view framework’ is supported by a method, called ‘concurrent structured analysis method’, that consists of the three analysis processes: requirements, functional and physical. These processes mirror the bulk of the SE process and are applied concurrently to product, process and organisations. The outputs of the method are requirements, functional attributes, physical attributes and the interactions among them. These outputs are then analysed using a clustering algorithm and a complexity metric based on cohesion and coupling shows the clustering effects.

Dimensional control as an integral part of next-generation aircraft development

Abstract The next generation of both military and civil aircraft are now being designed and developed. Research undertaken by the authors has highlighted particular product and process characteristics that are becoming more critical in the design and manufacturing processes of modern and future aircraft structures. A particular requirement is for reduced assembly variation. This requirement emerges, for example, from design strategies seeking to maximize the structural use of carbon fibre composite materials, from the increasing requirements for low observability in military aircraft and from the need for flight cruise efficiency in civil aircraft. Large companies such as Boeing, McDonnell Douglas and BAE Systems and Industrie have all performed studies in dimensional control. One theme, that emerges is that dimensional control must be exercised with design and manufacturing departments working in close partnership. This is particularly true when considering the introduction of advanced material technologies such as carbon fibre composites and in the application of automation to major aircraft subassemblies. Such challenges are found to occur across both military and civil sectors. This communication highlights some such challenges and identifies a seven-point response for the basic technological infrastructure to support the deployment of an effective dimensional control methodology as an integrated part of the next-generation aircraft product development process. Further work is in progress on detailing and demonstrating such a methodology.

Holonic Product Design: A process for modular product realization

This paper introduces a fresh perspective on product modularization and proposes a process for modular product realization called Holonic Product Design (HPD). The holon has recently been adopted from Arthur Koestlers work to represent subsystem entities within manufacturing systems and the enterprise chain. In addition, it has been embraced as a philosophy for change that attempts to fashion modern manufacturing businesses and manufacturing activity. This paper demonstrates the holon as being equally valid as an approach to product development. Through research at a number of UK companies, HPD is developed and presented as a structured approach to product realisation. Addressing a total view through systems engineering, HPD provides an accessible and customizable modular product development workbook. The efficacy of the new approach is demonstrated through the initial results from an HPD case study. Further work remains in refining the integration of HPD elements and thoroughly testing the approach through a full new product development process.

Improved tennis ball design: incorporating mechanical and psychological influences

Engineering design decisions for sporting goods are traditionally made with regards to objective performance measures with little regard for perceived product feel and performance. This paper develops a design methodology to relate measurable performance properties to player-perceived performance, feel, and aesthetics. By accounting for player perception in the design process, manufacturers have the opportunity to develop high-performing products that are well received by consumers. Product performance and perception are assessed using tennis balls, a frequently purchased tennis item subject to wear during play. Ball flight and impact performance are evaluated and related to player perceptions of ball performance and sensations trigged during the ball–racket impact. Results suggest tennis ball damping, peak force, and drag coefficient measurements can be used to infer perceptions of ball liveliness, hardness, and flight speed. Aesthetic differences, such as ball fuzziness and logo condition, are proposed to play a more important role in perceptions of ball quality than previously thought.

A QUALITY MODELING SYSTEM FOR PREDICTING THE YIELD OF ASSEMBLY AND TEST PROCESSES IN THE PRINTED CIRCUIT ASSEMBLY INDUSTRY

In the electronics industry, and particularly in the contract manufacturing arena, product quality is one of the keys to success or failure. Major companies looking for contractors as strategic partners frequently select them on their ability to produce a quality product at the right price and on time. To be selected, the manufacturer needs to be able to convince the major companies that they can supply a high quality product. In order to achieve this a contract manufacturer has, amongst other things, developed a tool to predict the quality of printed circuit boards. The tool covers the assembly and test of printed circuit boards. This paper presents details of the system and how it was developed to fulfil changing business needs. The development of the model is discussed and how it could be improved. The model has been validated against production boards and the results are presented in this paper. The tool was built on a detailed analysis of historic fault data and runs on two Microsoft applications. It has been in use, as a quoting aid and design feedback tool, since early 1994 and has attracted considerable interest from the customer base of the contract manufacturer.

Tennis ball fuzziness: assessing textile surface roughness using digital imaging

Wear plays an important role in the game of tennis as it affects both ball performance and player perceived ball quality. Visual appearance can be used in ball differentiation, but has so far been limited to subjective assessments used to estimate ball wear and performance characteristics. A metric for ball surface condition will allow performance and perception data from varied testing set-ups to be objectively compared and analysed. A versatile new method of assessing surface roughness using digital imaging has been developed to allow the quantitative assessment of tennis ball condition. This metric allows manufacturers and researchers to predict ball performance and player perception from worn ball samples, developing acceptable wear limits. In the successful implementation of this metric, several key factors, including lighting, image thresholding, algorithm implementation and camera specifications, were identified to aid future alternative implementations.

Human sensory evaluation of tennis balls for quality improvement

Abstract Tennis balls are one of the most widely used commodities in the sporting goods industry as pressurized balls can be deemed unfit for play as soon as nine games after opening. This paper utilizes sensory evaluation techniques to collect aesthetic quality attribute information for tennis balls at varying stages of wear. These quality attributes play an important role in quality function deployment and are of particular importance when considering differentiation between commodity products. Professional tennis players performed ranking evaluations with two trials of worn tennis balls, eliciting characteristics associated with aesthetic quality and performance. Five customer quality attributes were identified from the trials: ball colour, logo condition, stiffness, size and shape, and fuzziness. Quality rankings suggest an optimum range of fuzziness, surrounding the condition of a new ball, that is preferred by players. As visual evaluations also influenced the perception of non-aesthetic ball properties, it is suggested that these quality attributes offer manufacturers design solutions to suit a range of customer product preferences and improve product differentiation in the commodity market.