ME 59700 Spring 2015 Systems Engineering, Part II Session 21 31 March 2015 Mr. Larry Hopp, CPL

Measures of Producibility Manufacturability More quickly and inexpensively produced Manufacturing lead time Set up time, operational and nonoperational time Production time per unit Significant in terms of cost and profit Continuous improvement

Measures of Producibility Market Measures Flow of finished goods to the consumer PHS&T Delivery and installation Environmentally sustainable Cost of processing to the consumer Packaging, easily handled, transportable

Measuring Manufacturing Progress Repetition Production process Reduction in the time to produce a unit Increase in the rate at which selected activities are preformed Corresponding increase in the number of units produced Reduction in the overall time in process Reduction in the cost per unit

Measuring Manufacturing Progress Repetition Learning Curve Graphical representation of an increase of learning with experience Labor hours will decrease

Figure 16.3 Sample learning curves for production batches of 10.

Design for Producibility Producibility is more comprehensive than manufacturability Includes packaging and transportation Characteristic of design

Producibility Measure of the relative ease of manufacturing What does this mean to you? Design engineering, NOT manufacturing, is the technical group responsible for producibility. Program offices and design engineers often dislike producibility because it usually requires performance functionality sacrifices, especially if cost is a set value. (Cost as an independent Variable , (CAIV)).

Producibility Many design engineers do not have proper training or experience in designing for producibility. Manufacturing facilities must be explicitly recognized as a major design constraint. This includes process capabilities and rate capabilities at each facility.

Producibility Principles Simplicity of design Economical materials Economical manufacturing techniques Standardize materials and components Process repeatability Product inspectability Acceptable materials and processes

Producibility Objectives Minimize procurement lead time Minimize scrap, chips, and waste Minimize energy consumption Reduce part count Design to a low skill level for manufacturing Minimize test systems Use appropriate tolerances

Producibility Design Producibility Engineering Plan Transition from Concept exploration to low rate initial production Purpose to ensure that material designs reflect good producibility considerations prior to release to manufacturing.

Classification of Manufacturing Processes Forming Deforming Removing Joining Material properties modifications

Manufacturability Principles Design Gravity Fewer parts Ease of fabrication Reduce nonstandard parts More functionality per part.

Manufacturability Principles Assembly Automatic inserters Preoriented parts Sudden and frequent changes in assembly direction Process compliance Accessibility Handling

Manufacturability Principles Guidelines Foundation As few positions as possible Independently replaceable Order assembly Commonality in design

Manufacturing & Demanufacturing Issues Reuse High manufacturing cost Remanufacturing Refurbish or partial rebuilding Recovery Raw materials or reusable components

Figure 16.4 A production system with demanufacturing and disposal.

Engineering Change Proposal (ECP) During Production Impacts? Production line Reliability/Maintainability Logistics Support Disposal

Figure 5.11 Change control process.

Transition to Production EDM to a production model Production Plan Standard components New manufacturing technology Special tooling New assembly and test training Automated production equipment Tolerances good enough for full production Can you test before final assembly Configuration management

Transition to Production EDM to a production model Logistics support planning Change in size, weight, wiring, parts, materials, internal interfaces, assembly and test procedures. Customer inputs

Production Considerations Inventory Raw Materials Just in time Warehouse space Work in progress or in-process inventory Completed Product Storage Scrap Cost Shipping

Production Considerations Skilled workers Set up Time Constraints Scheduling Continuous/Intermittent/Special Projects Equipment layout Identifying all work steps Quality Control Testing

Thursday 9 April Tuesday 14 April Tuesday 21 April Homework Ch 16 Problems 4 (List and describe 3), 6, 7 (some = 2), 15 (some = 1), 21 Tuesday 14 April Quiz Ch 16 Tuesday 21 April CP 4