Implementing Concurrent Engineering in Small Companies Book

	Preface	iii
1	An Introduction to Concurrent Engineering	1
1.1	Is this your company?	2
1.2	What is concurrent engineering?	4
1.3	The benefits of concurrent engineering	6
1.4	How concurrent is your company now?	10
1.5	Requirements for success?	12
1.6	Philosophy of this book	12
2	Succeeding with Concurrent Engineering	15
2.1	Organizational change and CE	15
2.1.1	Product development organizational structures	16
2.1.2	Teams and teamwork	18
2.1.3	Do you have a vision?	22
2.2	Barriers to change	24
2.3	Steps to successful change	26
3	A Concurrent Engineering Methodology	29
3.1	An Overview of CE methodology	29
3.1.1	The product development model	30
3.1.2	The production process development model	31
3.2	Product and process development teams	31
3.2.1	The development management team	35
3.2.2	The new technology team	35
3.2.3	Cross-functional product development team	40
3.2.4	The cross-functional process development team	40
3.2.5	The product team	41
3.3	Development phases	42
4	Product Design: Steps and Tools	47
4.1	The Project planning phase	49
4.1.1	Identify needs	49
4.1.2	Product specifications	51
4.1.3	Plan development tasks	52
4.2	The conceptual design phase	56
4.2.1	Define architecture/functions and assign sub-teams	56
4.2.2	Generate concepts	64
4.2.3	Virtual/physical modeling	66
4.2.4	Evaluate concepts	66
4.2.5	Integrate concepts	69
4.3	The design phase	70
4.3.1	Define engineering specifications	70
4.3.2	Embodiment design	73
4.3.3	Virtual modeling	73
4.3.4	Design review	75
4.3.5	Prototyping	76
4.3.6	Detail design	77
4.3.7	Design verification	78
4.4	The production preparation phase	78
4.4.1	Procurement	79
4.4.2	Field trials	79
4.4.3	Pilot production	80
4.4.4	Production validation	81
5	Process Design: Steps and Tools	85
5.1	The project planning phase	89
5.1.1	Identify needs	89
5.1.2	Define process specifications	91
5.1.3	Plan development tasks	91
5.2	The conceptual design phase	93
5.2.1	The manufacturing process model	94
5.2.2	The testing model	100
5.2.3	The packaging model	102
5.3	The design phase	103
5.3.1	Define engineering specifications	105
5.3.2	Embodiment design	105
5.3.3	Vendor selection and approval	109
5.3.4	Modeling and prototyping	111
5.3.5	Facility requirements	111
5.3.6	Design review	112
5.3.7	Line simulation	112
5.3.8	Detail design	114
5.3.9	Design verification	115
5.4	The production preparation phase	115
5.4.1	Procurement	115
5.4.2	Line installation	117
5.4.3	Equipment integration	117
5.4.4	Equipment acceptance	118
5.4.5	Debug	118
5.4.6	Documentation	118
5.4.7	Training	119
5.4.8	Pilot production	119
5.4.9	Production validation	123
5.4.10	Release to production	124
5.5	Production and service phase	125
5.5.1	Production	125
5.5.2	Distribution	126
5.5.3	Customer support	127
5.5.4	Product retirement	127
6	Tailoring the Methodologies	131
6.1	Tailoring the product design methodology	131
6.1.1	New project assessment	132
6.1.1	Product development target	139
6.1.2	Creating the customized product development model	140
6.1.3	Customizing the product development model	144
6.1.4	Tailoring process example	144
6.2	Tailoring the manufacturing process design methodology	147
6.2.1	New manufacturing project assessment	147
6.2.2	Manufacturing process development targets	166
6.2.3	Creating the customized manufacturing process development models	167
6.2.4	Customizing the manufacturing process development models	176
6.2.5	Tailoring process example	176
7	Assessing Risk in Design: an Example of Customization	183
7.1	The risk assessment model for sheetmetal and plastic parts	184
7.1.1	General questions	187
7.1.2	Level one questions	188
7.1.3	Level two questions	190
7.1.4	Risk assessment graphs	191
7.2	Examples of the use of the risk assessment model	194
7.2.1	Design of a sheetmetal component	195
7.2.2	Design of a plastic component	200
8	Integrating industrial ecology into the concurrent engineering framework	205
8.1	Methodology overview	206
8.1.1	Production and service phase	207
8.1.2	Project planning phase	214
8.1.3	Conceptual design phase	219
8.1.4	Design phase	224
8.1.5	Production preparation phase	227
8.1.6	Production and service phase	228
8.2	DFE example	228
8.2.1	Company background	228
8.2.2	Project overview	229
8.2.3	Production and service phase	230
8.2.4	Project planning phase	232
8.2.5	Conceptual design phase	234
9	Implementing Concurrent Engineering	239
9.1	Identify need for change	240
9.2	Preparation	240
9.2.1	Senior management	241
9.2.2	Project development management team	241
9.2.3	Cross-functional development teams	243
9.3	Pilot project	244
9.4	Pilot project review	244
9.5	Implementation expansion	244
9.6	Managing the new approach	245
9.7	The benefits	245
Appendix A	House of quality	247
Appendix B	Risk assessment tool for sheetmetal and plastic parts	251
Appendix C	Streamlined life cycle assessment matrix scoring guidelines	281
Appendix D	Concept comparison using cost and environmental considerations	297
	Index	299