International Journal of Engineering Trends and Technology (IJETT) – Volume 8 Number 1- Feb 2014
Forward Engineering Elements Unified with Flexible
Manufacturing System Results in Excellent Cost
Effective and Highly Qualitative Product with
Reduced Lead Time, and Increase in Productivity.
Akant R. Patel#1
UG student, Department of Mechanical Engineering, AIT, Gujarat Technological University, Gujarat State, India
A/201 Gokul Apartment, K.K Nagar Road, Ghatlodiya, Ahmedabad-380061, Gujarat State, India
Abstract- In present era of globalization customer is a centre of
focus. Consequently, it becomes custom of every organization to
accommodate customer’s requirements in product attributes and
at same time product should be cost competitive. In order to
provide product as per customer needs the essential thing is
marrying together design requirements, process capabilities and
customer wants while ensuring maximum parallel working
throughout delivery process. In earlier days business functions
were restricted to management and kept isolated from the
factory operations .The integration between them is done by
Computer Integrated Manufacturing (CIM) but still there is
need to relate customer’s demands at each level of both factory
operations and business functions. Absence of parallelism among
these parameters may result into undesirable output and huge
time loss. Superior integration among Quality Function
Deployment (QFD), Simultaneous Engineering (SE), and
Integrated Engineering (IE) which plays vital role in maintaining
parallelism is achieved by Forward Engineering (FE). Further,
subsequent integration of elements of Forward Engineering with
Flexible Manufacturing System (FMS) enables entering into
market first with high quality standards and innovating through
the conversion of customer wants into designed product and
services that will fulfil those wants into unique fashion.
Keywords- Forward engineering, Flexible manufacturing system,
Simultaneous engineering, Integrated engineering and Quality
function deployment.
I. INTRODUCTION
Flexible Manufacturing System (FMS) is a highly
automated group technology comprises of group of work
stations interconnected by an automated material handling and
storage system [1]. FMS is capable of processing number of
parts. Though it provides less manufacturing lead time, high
quality and low cost it suffers from lack of decision making
and doesn’t give fair justice to pre-planning. Customer
requirements should be linked with Simultaneous Engineering
(SE) and FMS. By connecting QFD, simultaneous engineering
and FMS voice of customer is taken into account at each step
of concept development, design, planning and manufacturing
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throughout delivery process. Moreover, maximum parallel
working between design requirements and process capabilities
is also ensured throughout delivery process. In this way by
following the improved integrated structure there is no need to
return back at completed levels as chances of error are
reduced at great extent which makes structure one direction
flow type and reliable. It makes business delivery process
transparent and the hidden customer requirements become
much more visible. It is therefore powerful concept in
developing teamwork and a cross-functional approach to
working. In addition to stated or spoken customer needs,
unstated or unspoken needs or opportunities should be
identified.
II.
CONVENTIONAL DESIGN INTEGRATED FMS
APPROACH
In conventional design and FMS integrated approach there
are chances of error due to lack of parallelism among design
and process capabilities which may result in back and forth
process between design and FMS elements. This is time
consuming and lengthy process even it doesn’t ensure that
whether the final output will be as per predictable output or
not. Once design process has been completed, if during
planning or manufacturing level some requirements found
absent in current model then whole design process must be
revised. These types of problem increase product development
process time and manufacturing lead time. In order to
accommodate implementation during design it becomes
critical where to accommodate once process has been started.
As shown in fig.1 conventional design integrated FMS
approach, design process elements are unified with FMS
system which reduces gap between design and manufacturing.
By following this structure, first concept is built from
definition of problem by taking requirements into
consideration.
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International Journal of Engineering Trends and Technology (IJETT) – Volume 8 Number 1- Feb 2014
Fig. 1: Conventional design integrated FMS approach
In synthesis by using “geometric modelling”, model of
product is prepared. Further analysis and optimization
examines product critically in order to judge its suitability for
the task. Then in evaluation design is measured against
specification sets by using simulation software. At this stage
complete description and information of product and its
components is available in CAD/CAM database [1].Then tool
design, tool layout, material procurement etc. are carried out
in process planning which is followed by production planning.
Then computer control system deals with storage system,
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loading and unloading of machining centres, manufacturing of
product, material handling, tool changing etc. of FMS as
shown in fig. 1. In this integrated structure requirements are
taken into account only at beginning then in conventional way
work flow is carried out.
The main problem of FMS is lack of effective pre-planning
of design aspects. Consequently, conventional approach
becomes unreliable and does not fair to adopt for
manufacturing highly qualitative product where for employing
opinions of customer throughout whole process is prime need.
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International Journal of Engineering Trends and Technology (IJETT) – Volume 8 Number 1- Feb 2014
III. ELEMENTS OF FORWARD ENGINEERING
Forward Engineering (FE) is integration of Integrated
Engineering (IE), Simultaneous Engineering (SE) and Quality
Function Deployment (QFD) as shown in fig. 2. It is about
determining organizations ability to meet customer’s wants on
a continuous basis, through the use of QFD using a
multifunctional team approach and deploying people's efforts
through forward engineering [2].The description about
elements are as follows:
A. Quality Function Deployment (QFD)
QFD is converting the customer’s requirements into quality
characteristics and developing a design quality for the finished
product by systemically deploying the relationship between
demand and the characteristics, starting with quality of each
functional component and extending the deployment to the
quality of each part and process [3]. QFD is a new pioneering
technique used in many progressive organizations to bring the
voice of customers into everything they do. The main
problems of QFD are lack of integration with other tools and
techniques and difficulty in team building. By integrating
QFD with simultaneous engineering these problems are
completely abolished and QFD works more efficiently.
B. Simultaneous Engineering (SE)
Simultaneous Engineering (SE) is a systematic approach to
integrated product development that emphasizes on response
to customer expectations. It embodies team values of
cooperation, trust and sharing in such manner that decision
making is by consensus, involving all perspective in parallel
from beginning of product life cycle, from conception to
disposal, including cost, schedule, quality and user
requirements [4]. Simultaneous engineering intends to
optimize the design of product or service and business
delivery process in order to achieve reduced lead times and
improved quality and cost. It encompasses entire product life
cycle and includes several broader measures of success, such
as cost, quality, and time and user satisfaction.
C. Integrated Engineering (IE)
Integrated engineering focuses on design through team
efforts to ensure that there is cost effectiveness in use of parts
and process that produce high quality products and services
capable of meeting customer and business needs [2]. As such
integrated engineering relies on the use of simultaneous
engineering, the use of team work, and the use of tools and
techniques. Integrated engineering sometimes referred as
Design for Manufacture (DFM). It spans from part design,
process design, and process plan to system design.
Above mentioned elements of forward engineering relies
on each other for making excellent design decisions as well as
ensuring working of it in parallel manner with process
capabilities and customer’s wants with aid of team work.
Additionally, manufacturing of product in optimal cost
effective manner while maintaining its quality and reducing
lead times. In such a manner all requirements of customer and
business functions satisfied economically.
Fig. 2: Relationship among elements of Forward Engineering (FE)
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International Journal of Engineering Trends and Technology (IJETT) – Volume 8 Number 1- Feb 2014
Fig. 3: Structure of forward engineering elements unified FMS approach
IV.
FORWARD ENGINEERING ELEMENTS UNIFIED
FMS APPROACH
Forward engineering joins the elements in such a way that
all the elements give their optimal performance by
maintaining parallelism with each other. It is essential to
ensure that customer wants are taken into account from
product concept to disposal. QFD works on this matter it
converts customer’s wants into quality characteristics and
developing design quality for finished product. But QFD
needs help of simultaneous engineering for overcoming
problem of team building and lack of planning and
prioritizing. For simultaneous engineering, QFD works as key
element because it brings about the discipline of continuously
matching the design requirements of customer against the
process capability and ensures organizations have the required
ability to deliver what the customer wants [2]. Simultaneous
engineering is far better approach when finance and time to
market are limited. The most innovative design in the world is
basically useless if it cannot be cost-effectively manufactured.
Integrated engineering is integration of product service design
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and process design into one group to simplify the
manufacturing. Integrated engineering ensures cost
effectiveness in use of part and processes that produce high
quality product. Each element of forward engineering needs a
good team work. The different team related to new product
development come in a common domain comprises members
from different disciplines including professional knowledge
workers. The more effective team assures better working
results. Each team must have broad range of professional
skills including engineering, science, manufacturing, finance
and marketing. Each team must deals with inherent
uncertainties of innovation [5].
As shown in fig. 3, QFD is joined with levels of
simultaneous engineering. This is illustrated in figure by red
arrows. Unlike to conventional simultaneous engineering, in
this improved approach simultaneous engineering covers
process plans and production planning as well which makes it
better. The simultaneous engineering improved structure
wheel and its elements are shown in fig. 3 elements are
numbered in sequence in wheel.
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International Journal of Engineering Trends and Technology (IJETT) – Volume 8 Number 1- Feb 2014
After product identification, product concept is built by general, it reduces the level of intensity of all activities related
taking customer’s needs and essential attributes which can add to the product during its entire life.
true values into consideration then concept further needed to
After production planning next is manufacturing system
develop and improve in “concept development stage”. All which is controlled by a computer control system .The
stages of QFD are in form of matrix which known as “house computer control system is the brain of FMS which monitors,
of quality”. Product planning phase of QFD is linked with integrates and controls the functioning of automated storage
concept development stage which comprises prioritizing system, automated material handling system, manufacturing
customer needs, analysing competitive opportunities, forming operations, loading system and unloading system. Besides this
plans to respond to needs and opportunities and establishing automated tool changing unit changes tool and employ
critical target values [6]. This may result into effective suitable tools as per requirement of operations without taking
concept development helps for creating strong foundation of much time for changing. The FMS is shown in fig. 3 in green
design subsequently. Cultivated concept is followed by colour. This whole manufacturing system is automated and
surface and solid modelling which prepares model of concept. uses group technology for taking advantages of similarities of
Subsequently, design analysis and optimization is carried out design and manufacturing characteristics of parts.
which critically examines the model and by means of
Manufacturing system is followed by maintenance linked
simulation design is measured against sets of specification. At with disposal. Thereafter quality control comes which is
this stage the complete information of product is available in connected with process/quality control phase of QFD. This
database which is called 3-D geometric database. Rapid phase has activities such as establish process control methods
prototyping takes place across the models and oncoming and its parameters and establish inspection, test methods and
documentation is done. Such steps in designing will ensure its parameters. The manufactured parts are passed through
about optimal design efficiency which satisfies all design inspection and quality tests in order to ensure quality and
decisions effectively.
performance of product and its components. This is followed
At this stage design and engineering drawings are by marketing of product.
completed which also first stage of integrated engineering.
By means of this improved integrated structure approach
Next stage is process planning which is linked with process the main drawback of conventional approach which is
planning phase of QFD deals with determining how to deviation of decisions from design to manufacturing at several
transform expected design of product for benefits of end stages eliminated completely whenever implementations are
customers. This phase includes determining critical process being included. This becomes possible because of various
and process flows, developing production equipment effective teams coming together while product development
requirements and establishing critical process parameters such and planning process.
integration improves process planning and assist parallelism
[6]. In this stage decisions are taken by the team with
reference to the latter information available in common V. PREDOMINANCE OF FORWARD ENGINEERING
ELEMENTS UNIFIED FMS APPROACH OVER
database hence there are no chances of mismatch between
CONVENTIONAL DESIGN INTEGRATED FMS
design and process plan. At the end of this stage “system
APPROACH
design” is completed which is output of integrated
engineering. Thus integrated engineering relies on the use of
Forward engineering elements acts as tools and techniques
simultaneous engineering and team work. The team efforts in order to overcome drawbacks of conventional approach.
ensure that there is cost effectiveness in use of part and Unlike to conventional design integrated FMS approach, the
process which will produce high quality products and service forward engineering elements integrated FMS approach
capable of meeting customer and business needs. Thus assures working of design needs and process capabilities into
integrated engineering provides integration of product service parallel manner by joining them together while keeping
design and process design instead of their working separately. customer’s wants and business needs into account. Such
The span of integrated engineering is depicted in fig. 3.
integration of needs and capabilities is best way to adopt for
The production planning stage of simultaneous engineering those organizations have limited time to market and less
is connected with part deployment phase of QFD. This phase finance. Forward engineering enables organization to pursue
comprises activities such as identifying critical parts and most essential parameters quality and time to market. Time to
assemblies, flow down critical product characteristics and market means introducing product in market with high quality
translating into target values [6]. These activities contribute standards and innovating through conversion of customer
lots for reduction of the number of parts, design for ease of needs into designed product and service which will give
fabrication, minimize assembly directions and maximize justice to those needs in unique fashion. If any product is most
compliance. The reduction of number of parts in a product is innovative but not cost effective then it becomes futile. In
probably the best opportunity for reducing manufacturing order to make product cost effective conventional approach
costs. Less parts implies less purchases, inventory, handling, performs very poor, on the contrary by means of integrated
processing time, development time, equipment, engineering engineering which uses effective team work and cross
time, assembly difficulty, service inspection, testing, etc. In functional process based working ensures cost effectiveness.
In conventional design integrated FMS approach design
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International Journal of Engineering Trends and Technology (IJETT) – Volume 8 Number 1- Feb 2014
changes have to do frequently in order to get better deign
aspects but in case of forward engineering integrated FMS
approach QFD element eliminates or minimizes design
changes and through design optimization reduces lead time at
great extent and improves quality. Consequently, it is proved
that forward engineering elements unified FMS approach is
far better than conventional design integrated FMS approach.
VI. CONCLUSIONS
In current days, market competition becomes exorbitant
hence every organization makes hurry in launching a new
product which can perform well in market and satisfies the
customer. Forward engineering elements unified FMS
approach provides optimal reduction in lead times and it’s
time to market attribute allow organization achieving right
first time for introducing a new product into market.
Moreover, resulting product is excellent cost effective and
highly qualitative which encloses customer needs in form of
product attributes making sure that product will satisfy
customer in an effective manner. This approach is appropriate
and most suitable for all types of organizations irrespective
their volume of production and varieties in product because it
works like bridge among design, planning and manufacturing
which fill up gaps among them and provide best predictable
output. These characteristics assure increase in productivity of
firm as well. Forward engineering elements unified FMS
approach acts as gift for both company and customers. Thus,
forward engineering elements unified FMS approach is a
superior tool getting immense popularity for achieving
excellent cost effective and highly qualitative product with
reduced lead time and increase in productivity.
REFERENCES
[1]
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[6]
R.B. Patil, Computer Integrated Manufacturing, Tech-Max
Publication, Pune.
Mohamed Zairi, Measuring Performance for Business Results,
Chapman & Hall, 1994.
Akao Y., Quality Function Deployment: Integrating customer
requirements into product design, 1990, Cambridge, Mass.:
Productivity press.
Karl T. Ulrich, Steven D. Eppinger, Anita Goyal, Product Design
and Development, Tata McGraw Hill Edition 2009.
Smith, Preston G., Your product development process demands on
going improvement, research-technology management 39(2):3744, 1996.
URL:http://www.ieee.li/tmc/quality_function_deployment.pdf
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