White Paper
Tool Shop Optimization:
Concurrent Engineering for Today’s Tool Shop
David Lindemann
Sr. Application Engineer
Cimatron Technologies, Inc.
Concurrent Engineering for Today’s Tool Shop
Why Concurrent Engineering?
One of the most pressing challenges faced by tool shops today is the
need to shorten delivery times. As customers are vying to cut their own
lead times from design to production, the pressure on toolmakers to
deliver tools faster than ever continues to grow, even as die and molds
are getting increasingly complex.
Applying Concurrent Engineering principles and work processes can help
tool shops get more tasks accomplished at any given time period,
shrinking the overall lead time required to complete a project. Moreover,
the by-products of Concurrent Engineering—such as standardization and
improved communication—can reduce the time and effort required to
complete each task on its own, and can produce significant efficiencies
when it comes to applying engineering changes.
What Is Concurrent Engineering?
“Concurrent Engineering is a management/operational approach which
aims to improve product design, production, operation, and maintenance
by developing environments in which personnel from all disciplines work
together and share data throughout all phases of the product lifecycle.”
(http://cedar.web.cern.ch/CEDAR/glossary.html)
Applied specifically to the tool shop environment, Concurrent Engineering
embodies the following principles:
ƒ A well-designed workflow: Concurrent Engineering does not
mean that everybody is doing everything at the same time.
Rather, it requires a well thought-out workflow which enables
different phases of the process to be performed at the earliest
possible times without sacrificing the efficiency of each individual
task.
ƒ Synchronization: With multiple tasks being performed in
parallel, the synchronization of information at all phases is crucial
to maintaining the integrity of the final product.
ƒ Adaptability: Change is built into the process, enabling all
phases of design and manufacturing to adapt on the fly with
engineering changes.
© Cimatron Technology, Inc. 2006
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Concurrent Engineering for Today’s Tool Shop
How Does It Work?
Concurrent Engineering begins with the initial interaction with the
customer—the job quotation. Quoting is the lifeline of the business. It is
also the first time the part data is being handled at the shop. For a
company practicing Concurrent Engineering, common design standards
and manufacturing strategies are used throughout, starting with the
quoting phase. For example, material shrinkage parameters, part
rotation and tip positions, and what standard components are going to be
used. Incorporating these standards and strategies into the quoting
process will ensure the quote reflects how design and engineering will
approach the job.
Once the job is released, Concurrent Engineering can drastically shorten
tool design time, as multiple design tasks can be performed
simultaneously. For example, one designer may work on the cavity side
while another works on the core side; or one designer can finalize
ejection while another designs the manifold and hot drops; or one
designer is finishing waterlines while another begins pulling electrodes.
Manufacturing and assembly work can start while the design details are
still being worked out, further compressing product delivery times.
Concurrent Engineering: Keys to Success
For a tool shop to implement a true Concurrent Engineering process that
delivers tangible business benefits, a number of prerequisites have to be
met:
ƒ Mindset: You cannot keep doing the same thing and expect
different results; adopting concurrent engineering practices
requires letting go of existing conventions and work habits.
ƒ Leadership: Getting everybody on board with a new way of
doing things is best achieved with a top-down approach;
management needs to lead the way not only with words, but by
making the necessary investments to support the change.
ƒ Education: You cannot expect people to just figure it out as they
go; getting up-to-speed on new processes requires training and
education.
ƒ Platform: No process can be successfully implemented without
the appropriate system to support it.
© Cimatron Technology, Inc. 2006
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Concurrent Engineering for Today’s Tool Shop
Concurrent Engineering Software Requirements
The software systems used at the shop play a critical role in its ability to
transform concurrent engineering from theory to practice. While some
systems can greatly facilitate the Concurrent Engineering process, others
may pose an obstacle.
Probably the most important requirement for enabling Concurrent
Engineering is a single system and database that can be used for every
job from start to finish—from quoting to delivery and engineering
changes.
With a single software system used throughout the shop, the quote
produced can be ensured to accurately reflect the actual design standards
and manufacturing strategies that will be applied to the job.
Using a single system for design and manufacturing not only saves time
and eliminates potential translation errors, it also ensures that NC and
assembly work can start as early as possible, providing these
departments with direct access to the design data, including up-to-date
drawings and bill of material.
Last but not least, Concurrent Engineering and the integrated design and
manufacturing system pay huge dividends when engineering changes
take place. Any changes done in design are immediately reflected in the
data available on the shop floor, and a good portion of the changes can
be automated by recalculating NC operations and eliminating the need for
time-consuming reprogramming.
© Cimatron Technology, Inc. 2006
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Concurrent Engineering for Today’s Tool Shop
Getting Started: Implementation Roadmap
Getting your tool shop to practice Concurrent Engineering is not
something you can do overnight. It is also not something you can do
without the proper preparation and commitment.
The following is an eight-step roadmap that can be used to guide you
through this effort:
1.
2.
3.
4.
5.
6.
7.
8.
Define your goals
Get management buy-in
Understand your current processes
Design the new process
Put the systems in place
Get people trained
Measure your progress
Redefine goals and restart the process
As you go through the process, you will learn new things, come up with
new ideas, and aspire to become even “more concurrent.” While the
process is iterative in nature, you don’t have to wait long to start
benefiting from incremental changes implemented. The benefits are
there for you to reap—it is up to you to make the most out of it!
For more information, visit www.cimatrontech.com.
© Cimatron Technology, Inc. 2006
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