This is your latest, therefore the most current schedule. Last update: January 31, 2002 (Update history: December 14, 2001)
Please Read This! It Contains Vital Information about the Course as well as All the Assignments, Homework and Grades!
PLEASE save the TREES! Please DO NOT Print this syllabus. Use this web site to read it in this electronic format; it will be updated during the semester. Thank you!
The DL class: Concurrent Engineering
This is a combined Welcome Letter and Course Outline. Please read it carefully. You will find all essential course information here.
Please note, that this document will be updated during the semester. If anything is unclear please contact me.
by
Paul G. Ranky, PhD
Professor
Chartered Professional Engineer
Department of Industrial and Manufacturing Engineering
NJIT, University Heights, NJ 07102 -1982
Email at NJIT: ranky@njit.edu
Tel at NJIT: (973) 642 4984, Fax at NJIT: (973) 596 3652
Tel at home (in case of an emergency only, 24 hrs, but preferably during normal hours, 8.00 am to 10.00 pm) (201) 493 9561
Note, that my office is in ITC 2519 at NJIT
My office hours for the Spring 2002 semester are: Wednesdays 1.30 pm to 3.00 pm and Fridays 10.30 to 12.00 pm, unless I am away on official NJIT business. If these are inconvenient hours for you please ask for an appointment by email, or by phone.
Find out more about the Professor’s past and current research work and background at:
http://www.cimwareukandusa.com/aboutpgr.htm
Important News:
IMPORTANT NOTES TO ALL STUDENTS :
As always, Happy Learning, Professor Paul G Ranky, PhD
NJIT IE655
Welcome to IE655…one of the most useful engineering courses you’ll ever take! Please read these notes. If anything is unclear please call me or email me. I am here to help you!
Narrative Description of the Course
An object oriented (i.e. modular design) approach to the introduction of various integrated product and process design methods, tools, technologies and their management issues within a variety of small, medium and large enterprises.
Upon completing this program of study the candidates will be able to understand Concurrent/ Simultaneous Engineering methods and tools such as object oriented product/ process/ system analysis, system modeling and system integration using CIMpgr, market oriented, integrated design for manufacturing, assembly, quality and maintenance, product design analysis, integrated product design and manufacturing innovation methods, QFD (Quality Function Deployment) - applied to Concurrent Engineering, Object/ Component Oriented (OO) Requirements Analysis, FMEA (Failure Mode and Effect Analysis), Disassembly Failure Risk Analysis (with MS-Excel spreadsheets), POKA-YOKE, KANZEI, waste reduction, quality circles, rapid prototyping of designed objects and various other advanced processing methods, and TOPS (Team Oriented Problem Solving), i.e. virtual teaming over the Internet.
Note, that besides the above, this semester we'll specifically focus on disassembly and multi-lifecycle engineering aspects of Concurrent Engineering.
Furthermore, several US and international case studies will be discussed and advanced multimedia learning tools such as 3D VR web-objects, as part of a library of digital educational knowledge assets, will be used during interactive exercises, as well as for the purpose of completing of assignments.
Why is the course needed?
There are many methods and solutions to innovate and develop new products and processes, to cut down waste and to improve an organization, a design office, a manufacturing enterprise, or a product. One major discipline is Concurrent Engineering (CE). CE is also widely known as Simultaneous, or Parallel Engineering.
Concurrent Engineering represents a structured, logical framework which supports a systematic approach to the integrated, concurrent design of products and their related processes, including manufacture and support.
This method is intended to ensure that developers consider all elements of the product life cycle from conception through to final disposal, including quality, cost schedule and user requirements. In contrast to the old, conventional, or sequential product design method, Concurrent Engineering focuses on customer satisfaction, on teamwork as well as on Design for Manufacturing, Design for Assembly, Quality and Total Lifecycle issues.
It is essential to understand that none of the Concurrent Engineering or CIM (Computer Integrated Manufacturing) methods work in practice unless they are applied to all levels of the enterprise, that they are introduced gradually and that they are managed by people who understand and support them. (In order to promote this thought CIM, or Computer Integrated Manufacturing is now often referred to as the lean, or agile, or adaptive, manufacturing and design system.)
The aims of CIM & CE are very clear: getting rid of waste, organizing our knowledge in our minds, focusing on new opportunities driven by the customer and integrating the
In other words, CIM and Concurrent Engineering address the whole enterprise, including humans and machines, the business systems, product design, process planning, manufacturing planning, the shop floor, packaging and maintenance, for several life-cycles.
For Whom is the Course Intended?
Graduate / Master of Science programs in IE (Industrial Engineering), in EM (Engineering Management), in MnE (Manufacturing Systems Engineering) as well as an elective course for Graduate Mechanical Engineering, Graduate Computing Science and Graduate Environmental Engineering students. Note, that we follow an Object Oriented (OO) approach that makes the topic very adaptable to a variety of different hardware and software areas. This approach has been successfully tested and run for several years at NJIT as well as on a consulting basis at large software houses, such as IBM and Raytheon.
Furthermore, the course is aimed at engineers and managers working in industry, wishing to learn about new, integrated design and manufacturing methods, tools and technologies for the purpose of improving products.
A special note to distance learners: This course is interactive multimedia enabled, meaning that the learning pack includes minimal printed material as well as several interactive multimedia CD-ROMs, interactive, digital videos on CD-ROMs and of course the web.
Topics covered in different Modules/Units of the OO Concurrent / Simultaneous Engineering (CE/SE) Videos on CD Program (Tapes 1 to 20, playable with most Win Media Players on PCs, or with Apple’s QuickTime 5 on the Mac) with on-line, web-based multimedia workbooks at the http://www.cimwareukandusa.com/VideoMM.html#VideoCE web-site include all necessary Workbooks you'll need.
VERY IMPORTANT: As you watch these tapes on CD ROMs, keep remembering that you want to be part of these engineering and management discussions and understand all the important information technology and software development related implications! Why? Because there are good jobs waiting for you if you do understand how to work and add value in a multi-disciplinary engineering management software team!
You’ll have fun with all these learning tools and resources but in order for not getting lost in the "jungle of information" make sure that you keep in touch with the instructor and the other students in virtual teams using email and other usual means. If you wish to do so, please set up email lists and collaborate as you wish with each other. This is most welcome, because you'll learn how to work in local and global teams. (Note, that this collaboration can include live students working with DL students in virtual teams, in case the live as well as the DL courses run in parallel).
Clearly, I am the guide for you in this jungle of information. Furthermore I have "armed" ourselves with several multimedia objects, code, CDs, and the web.
As you will see there are hundreds of excellent sources and publications on Concurrent Engineering… obviously we cannot cover them all, but we will gain substantial knowledge as well as have fun learning these methods and applying them to various engineering and management problems. It is then up to you to carry on learning further, either in a formal way or on your own, as a lifetime learner. This is the basic challenge for all of us! (We have no problems, only challenges…).
Distance Learning Students receive their Learning Packs from the publishers, pls. contact Marti at Tel: (201) 493 0521, (or email: cimware@cimwareukandusa.com).. It includes the following:
These CDs will give us a great opportunity to work on projects in collaboration with the Four Selected Companies (also in your Learning Pack). PLEASE NOTE, that each learning pack is different, nevertheless the methods we use are the same. Each student should therefore use one learning pack. Also note, that you will need a multimedia PC (approx. 300 MHz, with CD drive and 800x600 resolution screen min.), a link to the Internet and email, as well as a recent version (not older than yr. 1999) version of MS-Excel in your machine. PLEASE NOTE, that as a student of NJIT, you are entitled to educational software and hardware discounts, therefore make sure that you take advantage of the huge discounts offered. (See NJIT's bookstore, as well as contact NJIT's computing helpdesks at http://njit.edu).
Every student can keep all above, with the exception of the Video CD pack, meaning the 10 Video CDs plus the Custom CD, that you must return by week 11 to CIMware (see address below).
PLEASE DON’T FORGET!
During Week 10-11 please do not forget to return the CE1-20 video CDs and the Custom CD in the same CD holder, in good condition to CIMware (not to the instructor!) - thank you!
Please Contact Marti at:
CIMware USA, Inc.
226 Brookside Ave
Ridgewood, NJ 07450
Tel: (201) 493 0521
Fax: (201) 493 0522
Email: cimware@cimwareukandusa.com
Web: http://www.cimwareukandusa.com
A brief note on the "HANDOUT" or "COURSE WORKBOOK" or alike…
Please note that I rely on the mostly modern, 3D, browser readable multimedia-based (electronic) learning material. This means that I will point out to you
Furthermore note, that I try to trigger your interest to learn and explore by giving you problems to solve. I also give you of course good methods and practical examples… Later you’ll find that you have learned most because of this approach… and don’t forget I am always here to help you!
Schedule: This semester is 15 weeks long. Deadline for all assignments on zip disk, and/or CD-ROM and/or as a web URL, is May 3, 2002.
Last day of submitting any assignments: May 3, 10.00 am 2002! NO Exceptions, Sorry!
Class 1 (Note that class numbers correspond to the semester week numbers at NJIT).
Introduction and overview of the course as well as the subject: Concurrent / Simultaneous Engineering (meaning exactly the same) in a traditional and in a modern design and manufacturing enterprise. Object oriented (OO) process and enterprise models are introduced. Systems and integrated processes are explained using traditional as well as new, OO methods.
Based on the book:
Please read pages 1 to 72, think through exercises 2 and 3 in Chapter 1 and 1 to 6 in Chapter 2.
Based on the web:
Search for the terms: "Concurrent Engineering", also for "Simultaneous Engineering"; what answers do you get? What can you learn from this?
[DL students only: Based on the videos on CDs]:
View tapes 1 to 4 on the Video CDs.
Note, that many students found it useful to view all tapes all in one go…(try not to fall asleep though…) This is because this approach gave them a good foundation. Also note that these presentations are not typical taped classroom sessions… so don’t be upset; readiness to change and flexibility makes us all survive even in the rapidly changing, collaborative Internet knowledge age!
Furthermore note that the videos have "Interactive exercises". (All video manuals are on the web. Just click on "Professional Educational Videos on Tapes and CDs…" at the http://www.cimwareukandusa.com web site, and then click on the appropriate video tape you are watching on your computer off the CD, http://www.cimwareukandusa.com/VideoMM.html#VideoCE. The videos are interactive and digital. At first viewing let me suggest to stop the CD for 5 minutes, or so, to try to think about the answers for the raised questions. If you have to study alone, you should still try to network with myself as well as others and create a "virtual team experience". It should be fun and educational! Note, that we are using the WebBoard collaborative software package at NJIT; a great opportunity to virtually team! A skill that we all have to learn to survive in the 21st century!
IMPORTANT! Answer the ENGINEERING related interactive exercise questions (as posted on the web at http://www.cimwareukandusa.com/VideoMM.html#VideoCE) of the above indicated Video CDs and email your notes, comments and answers to the interactive questions as PART of ASSIGNMENT #3.
Concurrent Engineering Methods, Tools and Technologies.
Based on the book:
Please review the case studies in the book at pages 185 to 206.
Based on the web:
Give it a rest…
[DL students only: Based on the videos on CDs]:
View videos 5 to 8 on Video CDs.
IMPORTANT! Answer the ENGINEERING related interactive exercise questions (as posted on the web at http://www.cimwareukandusa.com/VideoMM.html#VideoCE) of the above indicated Video CDs and email your notes, comments and answers to the interactive questions as PART of ASSIGNMENT #3.
Object Oriented Concurrent Engineering Information System Models (CIMpgr, Object Oriented Process Modeling is explained and discussed through exercises and examples).
Based on the book:
Pages 45 to 61 are crucial. Try to solve some of the review questions. Choose two by yourself…
Based on the web:
There are some good articles on CIMpgr at ADAM over the web at http://www.cimwareukandusa.com in the ADAM with IT magazine. Read the case study oriented (CIMpgr) articles and see the OO process model examples. (There is a good overview at http://www.cimwareukandusa.com/CIMpgr1.html. read this article, and adopt, NOT copy, but again: adopt the contents and the methods/ thinking to your system/ process modeling assignment). You’ll grasp it quickly. You can draw these diagrams with any simple 2D drawing tool, maybe with VISIO, or CORAL Draw, or Powerpoint, or AppleWorks, or ADOBE Illustrator, or others.
[DL students only: Based on the videos on CDs]:
Try to view tapes 9 and 10 on Video CDs today.
IMPORTANT! Answer the ENGINEERING related interactive exercise questions (as posted on the web at http://www.cimwareukandusa.com/VideoMM.html#VideoCE) of the above indicated Video CDs and email your notes, comments and answers to the interactive questions as PART of ASSIGNMENT #3.
Submit by the End of Week 4! Assignment No. 1: CIMpgr CE System Model (After having submitted this to me I’ll make comments on it that you suppose to consider and then rework your assignment. This reworked version will then be part of your Final Project Report: see Assignment #6).
Please note, that the best assignments show evidence that the student has worked through the learning material provided on CD-ROMs, web and in the book. Therefore feel free to incorporate digital images, text and even video clips or 3D VR objects provided on the CDs into your assignment; nevertheless never forget to credit the source of such objects in the bibliography.
Project/ Assignment No.1: CE Information System Model / Architecture
Typical Mistakes: Why am I loosing grade points in this assignment?
QFD (Quality Function Deployment); Requirements Analysis is discussed with 3D Virtual Reality examples as an OO Concurrent Engineering methodology. (Note, that we are dealing with the "Product Planning Stage QFD diagram/ matrix. i.e. the very first one!)
Based on the book:
Read pages 107 to 120. Focus on QFD Phase 1 (or in other words QFD1) because this is the simplest. Try to answer exercises: 1 to 7
Based on the CORA CD:
The CORA CD shows a requiremnents analysis method for a user interface design. You should understand this and based on the MS-Excel Template, develop your own Requirements Analysis solution for the product you are developing, in a concurrent fashion, with the 4 collaborative companies (in the Learning Pack). You can choose any well engineered product. It is YOUR product! (You can also use any of the 3D objects for new, or improved product ideas in the CDs). Study the method and the 3D objects. Consider the requirements analysis aspects when designing them. Also: focus on multi-lifecycle design issues and understand how products are disassembled; this should be part of the overall CE approach in the 21st Century. Focus on how these disassembly operators must face your design (i.e. product/ process design mistakes/ successes!) How can you improve? (Hint: this is a good business opportunity... your boss will like this...)
Based on the web:
Try to find any case studies or applications of QFD. (Just a hint: try automotive companies; they all use it! They have some great web sites too!)
[DL students only: Based on the videos on CDs]:
View tapes 11 to 18 on Video CDs.
IMPORTANT! Answer the ENGINEERING related interactive exercise questions (as posted on the web at http://www.cimwareukandusa.com/VideoMM.html#VideoCE) of the above indicated Video CDs and email your notes, comments and answers to the interactive questions as PART of ASSIGNMENT #3.
QFD (Quality Function Deployment) is discussed with 3D Virtual Reality examples as a Concurrent Engineering methodology.
Focus on the Assignment this week! We like professional quality assignments!
Submit by the End of This Week! Assignment No.2: QFD1 (Component Oriented Requirements Analysis)
The student’s main task is to pay attention to the multimedia presentations, to take notes on every important issue, item, principle, and example, to interact with the tutor (on Email, Fax, Telephone, etc.) and the class members (on Email, Fax, Telephone, etc.) and fully understand the topics covered.
In terms of assignment development method, please follow the CORA CD-ROM in your Learning Pack.
When developing the QFD1 matrix for a product try to put down all customer requirements for the WHAT’s side, prioritize them, then create the HOW’s, this is the "engineers’ voice", then the HOW MUCH’s, which will give you the parameter ranges for satisfactory data and then develop the rest of the correlation and the comparative quality models on the right hand side of the matrix. The crucial thing is that in the report you should explain what you have done and why?
Please note, that the best assignments show evidence that the student has worked through the learning material provided on CD-ROMs and in the book. Therefore feel free to incorporate digital images, text and even video clips or 3D VR objects provided on the CDs into your assignment; nevertheless never forget to credit the source of such objects in the bibliography.
Project/ Assignment No.2: QFD1 (Component Oriented Requirements Analysis)
Typical Mistakes: Why am I loosing grade points in this assignment?
FMEA: The Failure Mode and Effect Analysis methodology and its use in CE. Interactive FMEA modeling / Disassembly Failure Risk Analysis modeling with the 3D Virtual Reality examples on the DFRA CD-ROM.
Based on the book:
Please read pages 89 to 106. The diagram in Figure 3.2 is very important. You should deal with "System FMEA" because that is the most generic approach to the problem.
Based on the web:
Search for FMEA case studies. They are great to learn from!
Study the DFRA CD Case Study!
Note, that the DFRA CD is focusing on using the FMEA method for disassembly failure risk analysis. Learn this method, as well as read the book chapter on FMEA, and then based on the MS-Excel Template in the DFRA CD develop process/ design (potential) failure modes of YOUR product, that you are designing. Please make up missing data.
Submit by the End of This Week! Assignment No.3: Video CDs and the Custom CD in your Learning Pack Video CD. The student’s main task is to pay attention to the multimedia presentations, to take notes on every important issue, item, principle, and example, to interact with the tutor (on Email, Fax, Telephone, etc.) and the class members (on Email, Fax, Telephone, etc.) and fully understand the topics covered.
Project/ Assignment No.3: Video CDs and the Custom CD in your Learning Pack
Typical Mistakes: Why am I loosing grade points in this assignment?
Design For Manufacturing, Quality, Assembly, KANRI, KAISEN, MUDA, MURA, MURI, POKA-YOKE, the role of Quality Circles, and other methods discussed with 3D Virtual Reality examples.
Based on the book:
Pages 121 to 168. Try to answer exercises: 1 and 2.
Based on the web:
Try to find FMEA / DFRA case studies. There is also a "bad designs site" with some great examples… try to find it over the web!
Submit by the End of This Week! Assignment No.4: FMEA/ DFRA of your product design/ process
The student’s main task is to pay attention to the multimedia presentations, to take notes on every important issue, item, principle, and example, to interact with the tutor (on Email, Fax, Telephone, etc.) and the class members (on Email, Fax, Telephone, etc.) and fully understand the topics covered.
The book has the key FMEA diagram (Figure 3.2) that you should understand and follow. Look at the BOM file of the product (Bill Of Material) and gradually build up elements to subassemblies and parts, products. Then analyze each important failure mode. In case you choose to deal with a larger system, such as an automobile, or tank, etc. deal with larger objects only in the BOM /DBOM file, else you’ll spend your life on it… Nevertheless the "trick" is to find the critical subsystems that might fail, and then find out why they might fail?
We are interested in seeing that you understand the methods... we don't want you to spend your entire life on these assignments...you follow...Please note, that the best assignments show evidence that the student has worked through the learning material provided on CD-ROMs and in the book. Therefore feel free to incorporate digital images, text and even video clips or 3D VR objects provided on the CDs into your assignment; nevertheless never forget to credit the source of such objects in the bibliography.
Project/ Assignment No.4: FMEA (process) / DFRA
Typical Mistakes: Why am I loosing grade points in this assignment?
Design For Manufacturing, Quality, Assembly, KANRI, KAISEN, MUDA, MURA, MURI, POKA-YOKE, the role of Quality Circles, and other methods discussed with 3D Virtual Reality examples and classroom exercises.
Based on the book:
Revise again pages 121 to 168. Try to answer exercises: 3, 4 and 5.
[DL students only: Based on the videos on CDs]:
Revise selected tapes by yourself.
Finish THIS WEEK all the Videos on CDs and the Custom CD included… Congratulations!
Don’t forget to return them to the publishers in EXCELLENT CONDITION IN THE ORIGINAL BOX! ...by secure UPS mail please. THANKS!
Address:
CIMware USA, Inc.
226 Brookside Ave
Ridgewood, NJ 07450
If you need to, contact Marti at Tel: (201) 493 0521
Email: cimware@cimwareukandusa.com
Object Oriented Design For Manufacturing, Quality, Assembly, KANRI, KAISEN, MUDA, MURA, MURI, POKA-YOKE, the role of Quality Circles, Design for Demanufacturing, disassembly, Virtual Product Disassembly over the web, and other methods discussed with 3D Virtual Reality examples and classroom exercises.
Based on the book:
Please read pages 169 to 184 and attempt exercises 1 to 4.
Based on the Rapid Prototyping CD-ROM:
Focus on the engineering related challenges/ questions in this CD. Try to answer all of them! Incorporate these answers into the Assignment below!
Based on the web:
Try to find good Rapid Proto. sites. There are many… FOCUS on the METHODOLOGY they are using!!! This is important!
Submit by the End of This Week! Assignment No.5: Design For Manufacture/ Assembly and the Rapid Prototyping Process of YOUR New Product
The student’s main task is to pay attention to the multimedia presentations, to take notes on every important issue, item, principle, and example, to interact with the tutor (on Email, Fax, Telephone, etc.) and the class members (on Email, Fax, Telephone, etc.) and fully understand the topics covered.
Project/ Assignment No.5: Assignment No.4: Design For Manufacture/ Assembly and Rapid Proto
Typical Mistakes: Why am I loosing grade points in this assignment?
Class 13. (It's almost over...)
Concurrent Engineering Team management methods and issues. The TOPS method (The Ford Motor Company). Virtual teaming methods over the Internet. A 3D Virtual Reality web-based method and code is discussed in detail.
Based on the book:
Read pages 207 to 225. How would you set up and run a CE team?
Based on the CORA, DFRA and the Rapid Proto CDs: study collaborative teamwork opportunities.
Based on the web:
Search for TOPS team management issues on the web!
Class 14. (Note, that Class 15 is kept for late students/ discussions/ live presentations; if applicable)
Submit This Week! Assignment No. 6: Final, Well Polished Assignments submitted electronically on a zip disk, CD, or URL. NO PRINTED DOCUMENTATION IS REQUIRED, if you submit your project electronically.
Final Documentation Structure of All Assignments (1 to 5).
May 3, 10.00 am, 2002: ABSOLUTELY THE LAST DAY TO SUBMIT any assignments!
Schedule and due dates:
As above. The total course duration is 15 weeks. Students will be required to complete each assignment. Each assignment is valued at 20% max., totaling 120% max., meaning a built-in 28% max. bonus opportunity. Grade "A" for this class requires min. 92% total.
It is over! Congratulations! You can now analyze and improve many products!
PLEASE save the TREES! Please DO NOT Print this syllabus. Use this web site to read it in this electronic format; it will be updated during the semester. Thank you!