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Concurrent Engineering: An Effective Tool for Modern Industries

Conference Paper · October 2011

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 Concurrent Engineering: An Effective Tool for Modern Industries
Raminder Singh1 and Ashwani Tayal2
1
Dept. Of Mechanical Engg, RIMT, Mandi Gobindhgarh,Punjab,INDIA
Singh2raminder@yahoo.com
2
Dept. Of Mechanical Engg, IGCE, Abhipur, Mohali,Punjab, INDIA
2
ashwaqnigupta01@yahoo.com

Abstract: The organizations are facing tougher order to better understand the chip formation mechanism
challenges in the field of machining where market and accurately predict machining performances, such as
requirements are increasing. To obtain high cutting forces, cutting temperatures, tool wear, surface
production rates with minimum costs effective methods finish and the machined surface integrity. The methods
are required to optimize tool geometry. Concurrent commonly employed include experimental, analytical,
engineering is a systematic approach which can be and numerical methods. It has been observed that the
achieved when all design activities are combined and cutting tool edge geometry significantly influences many
executed in parallel. This paper focuses on various fundamental aspects such as cutting forces, chip
designs process steps for management while formation, cutting temperature, tool wear, tool-life and
implementing CE in complex product development characteristics like surface roughness and surface
process (PDP) projects. damage .The variation in cutting speed, feed and depth
of cut can help in achieving the desired chip form in
Key Words: complex product development, concurrent order to improve the productivity. But changing cutting
engineering (CE), product development process (PDP) conditions to break the chip is usually not feasible due to
the requirements of the machining processes and their
I.INTRODUCTION impact on tool life, surface finish and surface integrity.
Concurrent engineering refers to an approach used in So the variation in the tool geometry is one of the
product development in which functions of design important parameter to be considered for desirable chip
engineering, manufacturing engineering and other form without hindering the turning performance. The
functions are integrated to reduce the elapsed time objective of the paper is re design the tools for
required to bring new product to market. The basic machining using the principles of concurrent
premise for concurrent engineering revolves around two engineering.
concepts. The first is the idea that all elements of a
product’s life-cycle, from functionality, producibility, II. DEFINITION
assembly, testability, maintenance issues, environmental Concurrent engineering is a systematic approach to the
impact and finally disposal and recycling, should be taken integrated, concurrent design of products and their related
into careful consideration in the early design phases processes, including manufacture and support. This
approach is intended to cause the developers from the
The second concept is that the preceding design outset, to consider all elements of the product life cycle
activities should all be occurring at the same time, or from conception to disposal, including quality, cost,
concurrently. The overall goal being that the concurrent schedule, and user requirements.
nature of these processes significantly increases
productivity and product quality, aspects that are III. PRINCIPLES OF CE
obviously important in today's fast-paced market. The
most important reasons for the huge success of The various principles of CE as given accordingly and
concurrent engineering is that by definition it redefines implemented properly can contribute to reduction in costs
the basic design process structure that was common and improve product quality and achieve high production
place for decades. During the process of machining the rates.
magnitude of cutting forces, temperature, tool life and 1) Iteration principle
surface finish properties of work material are influenced 2) Parallelism principle
by cutting tool material, geometry of tool, Tool rake 3) Decomposition principle
angles the design of cutting edge geometry and its 4) Stability principle
influence on machining performance has been developed
through the principles of concurrent engineering. 1) Iteration principle:
Concurrent engineering is concerned with the timely First, designers are only human and have a bounded
availability of critical design information to all rationality. They cannot simultaneously consider every
development participants. For most complex engineering relevant aspect of any given design. As the design process
tasks all relevant information required by a specific progresses, new information, ideas, and technologies
development team cannot be completely available at the become available that requires modifying the design.
start of that task. Therefore, CE requires the Second, design systems are limited; there is no known
maximization of such information and the ability to system that can directly input a set of requirements and
share and communicate useful information on a timely yield the optimum design. Rather, the designer must
basis. It is important to consider the tool-edge effect in iteratively break down the set of requirements into
dimensions, constraints, and features and then test the (2) PROCESS:
resulting design to see if the remaining requirements were The process focus on ultimate goal and the efforts and
satisfied. strategy evolved to achieve it. This is based upon factors
like
2) Parallelism principle: (a) Strategy involving work
Scalable and complex systems must be highly (b) Problem identification
parallelizable if short development times are required;
otherwise valuable development times and resources are (3) TOOLS REQUIRED:
wasted. According to Amdahl’s law, the system’s The various tools required are
performance (i.e., achievable speed-up) of a parallel (i) Organizational tools – TQM, computer network QFD
system can be significantly limited by the existence of a (ii) Statistical tools – DOE, Taguchi method, statistical
small fraction of inherently sequential tasks, which cannot process control (SPC)
be parallelized. Consequently, multiple development (iii)Production tools – CAM, CNC, CPI. & JIT
stages have to be performed in parallel or with some
overlap by sharing early preliminary upstream information V. SERIAL OR SEQUENTIAL ENGINEERING Vs
with downstream stages. CONCURRENT ENGINEERING

3) Decomposition principle: Serial or sequential engineering: The following process

Complex systems are often decomposed into a number of chart shows the serial or sequential engineering used in
simpler subsystems that can be controlled independently, manufacturing industries.
and whose individual behaviours yield the performance of
the original complex system. Decomposition is also
intended to exploit opportunities for parallel execution.
The decomposition of a complex system into nearly
independent subsystems is an inevitable consequence of
‘bounded rationality’; i.e., the limitations on the cognitive
and information-processing capabilities of processors (e.g.
the designer’s decision-making). In complex product
development, processes are generally divided up into tasks
and subtasks. Proper decomposition of design
development tasks is concerned with assigning into the
same team tasks that are anticipated to require high
problem-solving interaction, while assigning to different
(‘‘independent’’) teams tasks that require low problem-
solving interaction.

4) Stability principle:
At a macroscopic level, complex systems show a Fig.1 Process Chart
coexistence of multiple ground states or, equivalently, Concurrent Engineering: the following chart showing the
multiple equilibrium which are robust against changes in chart for concurrent engineering used in the same
the internal structure of the system. The system is said to manufacturing industries.
be stable if the state of the system converges to one of the
equilibrium states for any initial conditions. A product
development process is said to be stable if the total
number of design problems being solved remains bounded
as the project evolves over time, and eventually falls
below an acceptable threshold within a specified time
frame.

IV. REQUIREMENTS OF CE

(1) PEOPLE:
The human resource is the best available resource and is
critical and detrimental to development process. This
involves aspects like
(a) Team work
(b) Communication
(c) Multidisciplinary team

Fig. 2 Concurrent Engineering Chart

TRADITIONAL PRODUCT DEVELOPMENT 2. Increasing global competitive pressure that
PROCESS FLOW CHART: results from the emerging concept of
reengineering.
3. The need for rapid response to fast-changing
consumer demand.
4. The need for shorter product life cycle.
5. Large organizations with several departments
working on developing numerous products at the
same time.
6. New and innovative technologies emerging at a
very high rate, thus causing the new product to be
technological obsolete within a short period.
The following improvements to specific product lines by
the applications of concurrent engineering can be seen in
an industry.
1. Development and production lead times
 Product development time reduced up to
60%
 Production spans reduced 10%.
2. Measurable quality improvements
 Yield improvements of up to four times.
 Field failure rates reduced up to 83%.
3. Engineering process improvements
 Engineering changes per drawing
reduced up to 15 times
 Early production engineering changes
reduced by 15%.
 Inventory items stocked reduced up to
60%.
 Engineering prototype builds reduced up
to three times.
Fig. 3 Traditional Flow Chart
 Scrap and rework reduced up to 87%
NEW IMPROVED FLOW CHART: 4. Cost reduction
 Boeing reduced a bid on a mobile
missile launcher and realized costs 30 to
40% below the bid.
 IBM reduced direct costs in system
assembly by 50%.

VII.SCHEMES FOR CE
CE is the application of a mixture of all following
techniques to evaluate the total life-cycle cost and quality.
1. Axiomatic design
2. Design for manufacturing guidelines
3. Design science
4. Design for assembly
5. The Taguchi method for robust design
6. Manufacturing process design rules
7. Computer-aided DFM
8. Group technology
9. Failure-mode and effects analysis
10. Value engineering
Fig. 4 CE based Flow Chart 11. Quality function deployment

VI.WHY CONCURRENT ENGINEERING: BENEFITS OF CE

1. Increasing product variety and technical 1. Significant Decrease In Time To Market
complexity that prolong the product development 2. Faster Product Development
process and make it more difficult to predict the 3. Better Quality
impact of design decisions on the functionality 4. Less Work In Progress
and performance of the final product. 5. Fewer Engineering Change Orders
6. Increased Productivity
 7. Cost reduction Mechanical Engineers. Part B. Journal of Engineering
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12. Grzesik, W., Wanat, T. 2006. Surface finish generated
CONCLUSIONS in hard turning of quenched alloy steel parts using
This research paper supports the facts that the process of conventional and wiper ceramic inserts. International
concurrent engineering is important in product Journal of Machine Tools and Manufacture.46(15): 1988-
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process where regular feedback is essential to optimize 13. Hirao, M., Tlusty, J., Sowerby, R., Chandra, G., 1982.
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