Wai Ming Cheung

Predicting the whole-life cost of a product at the conceptual design stage

Abstract This paper describes cost modelling research, industrial approaches and commercial systems and how these relate to whole-life cost estimating. The particular focus of the research described is the applicability of current approaches for the modelling of low-volume, infrequent products, such as complex electronic systems at the conceptual design stage. Traditional approaches, in particular those used to predict costs for mechanical systems, are described in detail, and the approach by which cost estimating relationships are ascertained is summarized. The approaches used within sectors such as aerospace, construction and injection moulding are discussed and evaluated. All of these are placed in the context of the design process, and in particular their relationship to the conceptual design of a product is described. Finally, a review of commercial systems and the methods they adopt and domains to which they are applicable are described. The use of these approaches in terms of whole-life cost of a product is then mapped.

Cost Engineering for manufacturing: Current and future research

The article aims to identify the scientific challenges and point out future research directions on Cost Engineering. The research areas covered in this article include Design Cost; Manufacturing Cost; Operating Cost; Life Cycle Cost; Risk and Uncertainty management and Affordability Engineering. Collected information at the Academic Forum on Cost Engineering held at Cranfield University in 2008 and further literature review findings are presented. The forum set the scope of the Cost Engineering research, a brainstorming was held on the forum and literatures were further reviewed to understand the current and future practices in cost engineering. The main benefits of the article include coverage of the current research on cost engineering from different perspectives and the future research areas on Cost Engineering.

Standards and inference of design information in through-life costing of innovative defence electronic products

Abstract Through-life costing (TLC) is a term used in cost estimation for costing a product from its conception to the end-of-life. However, there seems to be no common representation of the terminologies in the various stages of TLC. This paper reports the findings of research into TLC practices for defence electronic products and includes the terms and elements used in the TLC methods. The terminologies used for this research are adopted from the International Organisation for Standardisation (ISO), including ISO 15288 and ISO 10303 Application Protocols 233 and 239. A TLC spectrum diagram representing how design information is inferred to support the application of top-down and bottom-up approaches is also discussed. A case study focused on the concept and the development stages of design is presented and is followed by suggestions on how the proposed method can be applied to the succeeding stages of manufacturing, in-service, and disposal.

Advanced product development integration architecture: an out-of-box solution to support distributed production networks

This paper presents novel collaboration methods implemented using a centralized client/server product development integration architecture, and a decentralized peer-to-peer network for smaller and larger companies using open source solutions. The product development integration architecture has been developed for the integration of disparate technologies and software systems for the benefit of collaborative work teams in design and manufacturing. This will facilitate the communication of early design and product development within a distributed and collaborative environment. The novelty of this work is the introduction of an ‘out-of-box’ concept which provides a standard framework and deploys this utilizing a proprietary state-of-the-art product lifecycle management system (PLM). The term ‘out-of-box’ means to modify the product development and business processes to suit the technologies rather than vice versa. The key business benefits of adopting such an approach are a rapidly reconfigurable network and minimal requirements for software customization to avoid systems instability.

A Study of Life Cycle Costing in the Perspectives of Research and Commercial Applications in the 21st Century

This paper presents a review of research in the area of life cycle costing and offers a critique of current commercial cost estimation systems. The focus of the review is on relevant academic research on life cycle cost from 2000 onwards. In addition to this a comparison of the current cost estimation systems is presented. Using the review findings and industrial investigations as a base, a set of mathematical representations for design and manufacturing costs and the introduction of the critical factors is proposed. These are considered in terms of the operational, maintenance and disposal costs to create a method for ascertaining the life cycle cost estimate for complex products. This is presented using as an exemplar, research currently being undertaken in the area of low volume and long life electronic products in the UK defence sector. The benefit of the method proposed is that it aims to avoid the inflexibility of traditional approaches which usually require historical and legacy data to support the cost estimation processes.Copyright

A Novel Knowledge Management Methodology To Support Collaborative Product Development

This paper discusses the theoretical aspects and applications of a novel methodology for exploiting a knowledge management editor tool to structure organizational knowledge. An organizational knowledge framework for capturing and representing design and manufacturing know-how has been defined using an ontological approach. The key business benefit of adopting such an approach arises from the closer integration between the key technical and business activities taking place during early design. In particular the effectiveness of decision making is increased.

Cost data modelling and searching to support low-volume, high-complexity, long-life defence system development

This article presents a data modelling and a semi-automatic data searching method to support cost estimation in the product development process, particularly for low-volume, high-complexity and long-life products typified by defence products and systems. This article covers a literature review in the area of cost estimation in product development, the data sets needed to perform cost estimation, the method of modelling the data and the techniques of supporting cost data searching. The proposed method will be used to support cost estimation of product development decisions for defence electronic products. To compare with the traditional approach, the method has demonstrated that by creating a centralized environment such as the ‘databases and using a data-driven’ approach. The system is made more efficient by reducing the number of processes in carrying out cost estimation, and thus, this provides more information to make an informed concept design decision during the product development process based on the system’s competence of instant cost estimation feedback.

Linking design and manufacturing domains via web-based and enterprise integration technologies

The manufacturing industry faces many challenges such as reducing time-to-market and cutting costs. In order to meet these increasing demands, effective methods are need to support the early product development stages by bridging the gap of communicating early design ideas and the evaluation of manufacturing performance. This paper introduces methods of linking design and manufacturing domains using disparate technologies. The combined technologies include knowledge management supporting for product lifecycle management systems, Enterprise Resource Planning (ERP) systems, aggregate process planning systems, workflow management and data exchange formats. A case study has been used to demonstrate the use of these technologies, illustrated by adding manufacturing knowledge to generate alternative early process plan which are in turn used by an ERP system to obtain and optimise a rough-cut capacity plan.

Data-driven through-life costing to support product lifecycle management solutions in innovative product development

Innovative product usually refers to product that comprises of creativity and new ideas. In the development of such a new product, there is often a lack of historical knowledge and data available to be used to perform cost estimation accurately. This is due to the fact that traditional cost estimation methods are used to predict costs only after a product model has been built, and not at an early design stage when there is little data and information available. In light of this, original equipment manufacturers are also facing critical challenges of becoming globally competitive and increasing demands from customer for continuous innovation. To alleviate these situations this research has identified a new approach to cost modelling with the inclusion of product lifecycle management solutions to address innovative product development. The aim of this paper, therefore, is to discuss methods of developing an extended-enterprise data-driven through-life cost estimating method for innovative product development.

Computer numerical control machine tool information reusability within virtual machining systems

Virtual machining allows simulation of the machining process by realistically representing kinematic, static and dynamic behaviour of the intended machine tools. Using this method, manufacturing-related issues can be brought to light and corrected before the product is physically manufactured. Machining systems utilised in the manufacturing processes are represented in the virtual machining environment, and there is a plethora of commercial virtual machining software used in the industry. Each software system has a different focus and approach towards virtual machining; more than one system may be needed to complete machining verification. Thus, the significant increase in the use of virtual machining systems in the industry has increased the need for information reusability. Substantial time and money has been put into the research of virtual machining systems. However, very little of this research has been deployed within industrial best practice, and its acceptance by the end user remains unclear. This article reviews current research trends in the domain of virtual machining and also discusses how much of this research has been taken on board by software vendors in order to facilitate machine tool information reusability. The authors present use cases which utilise the novel concept of machining capability profile and the emerging STEP-NC compliant process planning framework for resource allocation. The use cases clearly demonstrate the benefits of using a neutral file format for representing machining capability profiles, as opposed to remodelling and/or reconfiguring of this information multiple times for different scenarios. This article has shown through the use cases that machining capability profiles are critical for representing recourse information from a kinematic, static and dynamic perspective that commercial software vendors can subsequently use. The impact of this on mainstream manufacturing industry is potentially significant as it will enable a true realisation of interoperability.