DSM-Based Product Representation for Retirement Process-Based Modularity

2009 ◽  
Author(s):  
Xiaoxia Lai ◽  
John K. Gershenson
Keyword(s):  
Product Design ◽  
Modular Design ◽  
Design Method ◽  
Value Added ◽  
Design Methods ◽  
Process Efficiency ◽  
Modular Architecture ◽  
Product Representation ◽  
Modular Product ◽  
Product Modularity

Researchers have expanded the definition of product modularity from function-based modularity to life-cycle process-based modularity. In parallel, measures of product modularity have been developed as well as corresponding modular product design methods. However, a correct modularity measure and modular design method are not enough to realize modular product design. To apply the measure and design method correctly, product representation becomes an important aspect of modular design and imperative for realizing the promised cost savings of modularity. In this paper, a representation for retirement process-based modular design has been developed. Built upon previous representations for assembly and manufacturing-based product design, the representation includes a process similarity matrix and a process dependency matrix. The retirement process-based similarity is based on the similarity in components’ post-life intents (recycling, reuse, disposal), and either the degree of their material compatibility if the components will be recycled, or their disassembly direction or disassembly tools if they need to be disassembled from each other for retirement. Process similarity within a module leads to increased process efficiency (the elimination of non-value added tasks) from the sharing of tooling/equipment. Retirement process-based dependency is developed based on disassembly difficulty, one aspect of the physical interactions between components. Retiring components together as a module to eliminate disassembly and differential processing and reducing the disassembly difficulty between the modules can increase the efficiency of the retirement process. We have first presented which process elements we should consider for defining retirement process similarity and dependency, and then constructed the respective similarity and dependency factors tables. These tables include similarity and dependency factors, which, along with their quantifications, are used to determine a product’s modular architecture to facilitate the retirement process. Finally, a fishing reel is used to illustrate how to apply these factors tables to generate the similarity and dependency matrices that represent a product for retirement-process based modular design. Using these representations as input to the DSM-based modular design methods, we can achieve a design with a modular architecture that improves the retirement process efficiency and reduces retirement costs.

DSM-Based Product Representation for Design Process Modularity

2008 ◽  
Author(s):  
Xiaoxia Lai ◽  
John K. Gershenson
Keyword(s):  
Product Design ◽  
Design Process ◽  
Modular Design ◽  
Early Stage ◽  
Modular Architecture ◽  
Product Representation ◽  
Stage Design ◽  
Design Efficiency ◽  
Product Modularity ◽  
Definition Of

An appropriate modularity representation is of critical importance in modular design. Without an appropriate representation, modular design cannot realize its benefits. In this paper, a representation for DSM-based modular product design is developed that facilitates product modularization with respect to the design process. The representation is based upon previous work presented in this venue that details representations for the assembly and manufacturing processes (Lai and Gershenson, 2007a; Lai and Gershenson, 2007b). The representation for the design process includes a design process similarity matrix and a design process dependency matrix. The definition of design process similarity uses information available in early stage design and is based on the similarity of the design tools and resources required for later stage design. Design process similarity within a module leads to increased design efficiency from the sharing of functional and geometric analyses and possibly the savings of not needing to “un-immerse” from a particular design task to “re-immerse” in the design of the next component. The definition of design process dependency is based on the connectivity caused by components’ design process attributes with the goal of fewer design interactions between different modules. With zero dependencies between modules, we hope to contain the cascade of design changes within each module, and prevent the need to redesign other modules. In this paper, we first present which design process elements we should consider for defining design process similarity and dependency, and then construct respective similarity and dependency factors tables. These tables include similarity and dependency factors, which, along with their values, are important in determining a product’s modular architecture at the early stages of design. Finally, a computer mouse is used to illustrate how to apply these factors tables to generate the similarity and dependency matrices that represent product modularity for the product design process. Using these representations as input to the DSM-based modular design methods, we can achieve a design with a modular architecture that improves design efficiency in the later stages of design. In the future, we hope to extend and generalize the process for developing product modularity representations so that it is applicable across all life-cycle processes.

Representation of Similarity and Dependency for Manufacturing Process-Based Product Modularity

2007 ◽  
Author(s):  
Xiaoxia Lai ◽  
John K. Gershenson
Keyword(s):  
Product Design ◽  
Manufacturing Process ◽  
Design Method ◽  
Cost Savings ◽  
Manufacturing Processes ◽  
Dependency Matrix ◽  
Modular Product ◽  
Product Modularity ◽  
Design And Manufacturing ◽  
Physical Interactions

Previously in this forum, we validated a product modularity measure and modular product design method and developed a way to extend these product modularity fundamentals to encompass the impacts of assembly process similarity and dependency. This paper expands the life-cycle process-based modularity representation to the manufacturing process and beyond. Modularity representation, including similarity and dependency, is an important aspect of modular product design and it is imperative for realizing the promised cost savings of modularity. The component-component similarity matrix is used to cluster components with similar manufacturing processes into one module. Similarities are based on component processing codes that represent their manufacturing attributes. Clustering these manufacturing process similarities leads to cost savings through module-wide sharing of process plans, manufacturing tools, and equipment, and the reduction of manufacturing tool and equipment changes during manufacturing. The component-component dependency matrix is based on physical interactions among the components that affect the material, shape, size, surface finish etc. of the components, and therefore affect the component manufacturing processes. If components are independent of other components not in the same module with respect to these physical interactions, the redesign of components in one module will not cause a cascade of design and manufacturing process plan changes for components not in the same module. A fishing reel example is used to illustrate the application of manufacturing process similarity and dependency representations, in association with a product modularity measure and a modular product design method, to form manufacturing process-based component modules. The work in this paper establishes how to represent manufacturing process similarity and dependency for use in product modularity decision making. The use of such modules improves the efficiency of manufacturing process planning, and reduces design and manufacturing process costs.

HOME: House Of Modular Enhancement—a Tool for Modular Product Redesign

2002 ◽  
Vol 10 (2) ◽  
pp. 153-164 ◽  
Author(s):  
J. C. Sand ◽  
P. Gu ◽  
G. Watson
Keyword(s):  
Lead Time ◽  
Modular Design ◽  
Design Method ◽  
Product Architecture ◽  
Functional Requirements ◽  
Overall Design ◽  
System A ◽  
Modular Product ◽  
Design And Manufacturing

Product modularization aims to improve the overall design, manufacturing, operational, and post-retirement characteristics of products by designing or redesigning the product architectures. A successful modular product can assist the reconfiguration of products, while reducing the lead-time of design and manufacturing and improving the ability for upgrading, maintenance, customization and recycling. This paper presents a new modular design method called the House Of Modular Enhancement (HOME) for product redesign. Information from various aspects of the product design, including functional requirements, product architecture and life cycle requirements, is incorporated in the method to help ensure that a modularized product would achieve the objectives. The HOME method has been implemented in a software system. A case study will be presented to illustrate the HOME method and the software.

A Modular Product Design Method to Improve Product Social Sustainability Performance

2015 ◽  
Author(s):  
Junfeng Ma ◽  
Gül E. Okudan Kremer
Keyword(s):  
Product Design ◽  
Clustering Algorithm ◽  
Focal Point ◽  
Design Method ◽  
Social Sustainability ◽  
Social Responsibilities ◽  
Labor Time ◽  
Modular Product ◽  
Potential Synergy

Sustainability has been the emphasis of intense discussion over recent decades, but mostly focused on addressing critical aspects of environmental issues. An increasing awareness of social responsibilities and ever-shifting customer requirements have led manufacturers to consider social sustainability during the design phase in tandem with addressing environmental concerns; thus, design for social sustainability has evolved as a new product design direction. Modular product design (MPD), has been widely used in both academia and industry because of its significant benefits in design engineering. Because of the potential synergy, investigating design for social sustainability in association with MPD holds promise as a field of investigation. In this paper, we introduce a novel MPD approach that uses the elements of key component specification and product impact on social sustainability. The key components carry core technologies or have the highest sustainability effects in a product (i.e., the most costly or environmentally polluting parts). Product competitiveness strongly relies on a few key components that should be a focal point during product development. However, to the best of our knowledge, key components have not been well addressed in modular product design. In this paper, we employ labor time as an indicator to measure social sustainability. A heuristic-based clustering algorithm with labor time optimization is developed to categorize components into modules. A coffee-maker case study is conducted to demonstrate the applicability of the proposed methodology.

2108 A Modular Product Design Method Considering Defense from Leakage of Synthetic Functions : A Case Study on a Paper Handling Equipment

2009 ◽  
Vol 2009.19 (0) ◽  
pp. 259-261
Author(s):  
Akihiro Hirao ◽  
Tsuyoshi Koga ◽  
Takashi Niwa ◽  
Kazuya Oizumi ◽  
Kazuhiro Aoyama
Keyword(s):  
Product Design ◽  
Design Method ◽  
Modular Product

Determining Relationships Between Modularity and Cost in Product Retirement

2001 ◽  
Author(s):  
Y. Zhang ◽  
J. K. Gershenson ◽  
S. Allamneni
Keyword(s):  
Life Cycle ◽  
Economies Of Scale ◽  
Modular Design ◽  
Design Method ◽  
Initial Study ◽  
Design Change ◽  
Modular Products ◽  
Product Modularity ◽  
Definition Of ◽  
The Relationship

Abstract Modular product design allows the designer to control the degree to which changes in requirements affect the product. By promoting interchangeability, modularity also gives designers more flexibility, with decreased cycle time, to meet changing requirements. Specific advantages associated with modular products include economies of scale, standardization of assemblies, minimization of assembly time, improved serviceability, and many more. Modular architecture is traditionally made up of functionally independent clusters of components. Past definitions of modularity have centered on a one-to-one correspondence between form and function. An expanded definition of product modularity has been used, which not only includes function, but also form and life-cycle process (manufacture, assembly, retirement, etc.) relationships. Modules contain a large number of components having very few similarities and dependencies on components not in the same module. This definition of product modularity differs from most, due to the inclusion of the similarity aspect. Modular products that are modular with respect to retirement are well designed for reuse, remanufacturing, recycling, and disposal. Apart from addressing the incorporation of product retirement into product modularity, a comparison of retirement costs and product modularity has been shown in this paper. Comparing costs with modularity is essential since cost is a major factor in the success of a product. Any design change made to improve retirement modularity will be practical only if the benefits accrued from an environment-friendly design are coupled with decreased costs due to the design change. One question that remains to be addressed is — do improvements in product modularity always decrease retirement costs? In this paper, an existing modular design method was focused on product retirement. Our initial study of the modularity-cost relationship is based upon the retirement of a consumer flashlight. We took a single flashlight and redesigned it, making it more modular, using a modular design method. The method has a set of guidelines helping in direct product development towards modular products. These are: 1. Eliminate the modules if they are not necessary. 2. Eliminate individual components of the modules. 3. Shift die components to other modules to increase the relative modularity of the product. 4. Redesign the attributes of the components to decrease or eliminate similarities or dependencies with outside components or increase similarities with components of the same module. After completing the modular design method, we measured the product modularity and retirement cost of the product at each intermediate stage of redesign. Costs associated with retirement including, recycling, reuse, remanufacturing, and disposal were measured at each stage using the cost equations listed below. The result of the research in this paper is studying the relationship between measured retirement modularity and product retirement costs. Statistical analysis of the flashlight data was carried out to look at the relationships between relative modularity, number of design changes made, and retirement cost. Our initial study of the relationship between product modularity and product retirement costs showed several trends. As was the hypothesis of this work, as product modularity and retirement modularity increase, product retirement costs tend to decrease. However, this trend is not as strong as previous literature has assumed. Our study of this hypothesis was complete but limited in scope. We have begun follow on research that expands this work to additional products and additional life-cycle stages.

Modular Product Design, Considering Functions and Properties

2012 ◽  
Author(s):  
Israel Aguilera Navarrete ◽  
Alejandro A. Lozano Guzmán
Keyword(s):  
Product Design ◽  
Data Clustering ◽  
Design Problem ◽  
Modular Design ◽  
Recursive Method ◽  
Clustering Method ◽  
Data Presentation ◽  
Modular Product ◽  
Technical Solutions ◽  
Minimum Vector

In traditional machine, equipment and devices design, technical solutions are practically independent, thus increasing designs cost and complexity. Overcoming this situation has been tackled just using designers experience. In this work, a data clustering method which allows this data presentation in a more systematic way using a matrix arrangement, is shown. From this matrix, data can be reorganized in clusters with a hierarchical structure, in such a way that modular design is now more tractable. Proposed method is based on a Euclidean algorithm which allows finding the shortest vectorial distance among technical solutions. Taking product properties as vector dimensions, a recursive method for moving matrix rows and columns is applied. As a result of this procedure, the minimum vector distances are found thus being possible to identify the best technical solutions for the design problem raised. The proposed modular procedure is shown with a 30 inches oven door design.

Mastering High Product Variety of an Underwater Vehicle Class in the Concept Design Stage

2018 ◽  
Author(s):  
Willem Hendrik Wehner ◽  
Nicolas Richter ◽  
Marc Schiemann ◽  
Pia-Maria Haselberger ◽  
Sebastian Ritz ◽  
...  
Keyword(s):  
Modular Design ◽  
Design Method ◽  
Product Variety ◽  
Underwater Vehicle ◽  
Design Stage ◽  
Concept Design ◽  
Vehicle Class ◽  
Diving Depth ◽  
Modular Product ◽  
Payload Capacity

The paper provides considerations for a novel unmanned underwater vehicle class that offers new options to the offshore industries and marine science in matters of endurance, payload capacity, development time and economic viability. Today, different mission scenarios require different underwater vehicles. By applying modularization approach to the development of modular product classes, another way to design such vehicles is shown. Radical modularization of the vehicle enables collaborative as well as independent development of payload modules by industry or science. The design idea allows the combination of proven basic modules with novel mission modules. This allows assigning development activities of mission modules to diverse 3rd-party developers or customers. Topics covered in this paper are related to potential missions and the requirements they make on the vehicle. An evaluation of application scenarios considering the technical challenges vs. their economical relevance is made. The requirements for the MUM system are identified by analyzing the mission procedures regarding specific scenarios. The modular design method and challenges to validate feasibility of an extreme number of possible vehicle variants follow. Examples of variant drivers like diving depth or vehicle range as well as possible solutions will be discussed. The topics covered are the basis for further work within the three year research project MUM – Large Modifiable Underwater Mothership.

scholarly journals Modeling an Innovative Green Design Method for Sustainable Products

2020 ◽  
Vol 12 (8) ◽  
pp. 3351 ◽  
Author(s):  
Yao-Tsung Ko
Keyword(s):  
Product Design ◽  
Design Method ◽  
Value Added ◽  
Green Manufacturing ◽  
Green Technology ◽  
Green Design ◽  
Green Product ◽  
Environment Impact ◽  
Sustainable Products ◽  
Green Product Design

Global warming and climate change are currently the world’s most pressing issues. The causes are the results of people pursuing a better quality of life and a material civilization. Thus, if the concept of green design can be applied when designing and manufacturing products, it will greatly reduce the environment impact of such production. This paper addresses a novel green design method based on the extension theory and concept of Green DNAs, which embraces the concepts of green technology, green material, and green manufacturing. The proposed method can provide designers with a decomposing–recomposing approach with rigorous logic and deduction processes for transforming general products into green products. It can also facilitate the use of green modular approaches in product design and improve product disassembly to raise the value added by product recycling. It offers companies concrete guidance and detailed steps to apply in green product design. Finally, a practical green product design of a medical air purifier is demonstrated to validate the feasibility and effectiveness of the proposed method.

Energy Factor Analysis in Modular Product

2011 ◽  
Vol 130-134 ◽  
pp. 1314-1317
Author(s):  
Qing Di Ke ◽  
Hong Chao Zhang ◽  
Guang Fu Liu ◽  
Bing Bing Li
Keyword(s):  
Energy Consumption ◽  
Energy Saving ◽  
Modular Design ◽  
Design Method ◽  
Energy Performance ◽  
Physical Parameters ◽  
Physical Analysis ◽  
Energy Factor ◽  
Modular Product ◽  
Energy Equations

Nowadays, due to the huge energy consumption, the energy-saving problems of the product have been emphasized with many designers. In this paper, informed by the modular design method, the total energy performance in modular product can be analyzed and separated into the energy performances of basic modules. And with the physical analysis of basic modules, the energy equations are established with the band graphs theory. Then, the physical parameters, which could influence the energy consumption, are identified as “energy factor”. Thus, the energy consumption of the modules could be optimized with adjusting design factors, and the energy-saving design scheme for the whole product is obtained in the optimized model. Finally, the model and the method in this paper are demonstrated by an instance of the crank block pump.

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