General Notes

1. In this section we'll post notes that effect all students. This will save us all time. Please collaborate.
2. Please note, that in case your email is not answered it means that my response wasn't delivered due to email address / account issues at your end, or perhaps at the NJIT end... Sorry, You have to fix your side, I'll fix my side. If everything fails, pls. call by phone (as above).
3. Naturally my email at NJIT can fail too, therefore suggest you use the alternative email (as above). You also have my home telephone number above, in case of an emergency.
4. Last year's statistics shows that about 40 percent of the questions asked by students about this course were actually answered in this combined Welcome Note/ Course Syllabus... so PLEASE READ THIS and try to beat last year's poor statistics... it saves time for all of us, most importantly for you!
5. Due to the fact that I teach and supervise several students every semester, I cannot confirm the receipt of your homework assignments. The safest way for both of us not to miss any important submissions is that you always email me your course URL, rather than individual files... this way I can always see your entire work and grade it too.
6. As I issue a grae for an assignment, I always email it to you. PLEASE make sure, that I have your email in your web page as a hot-link to your email address!
7. PLEASE set up your own web page, and/or use NJIT's web server, or your company's, or your own... submit your assignments electronically. I will NOT accept assignments on paper. Please make sure that your URL works before you send me an email with a URL in it so that I can click on it and directly link to your assignment(s). The best approach is to set up your own web page (NJIT offers you free web server space for this, please contact the NJIT Computer Help Desk, I cannot help with NJIT server details, I use only professional servers) and then add every assignment to this URL as you develop them. This will be an extremely valuable knowledge documentation method to share your knowledge, to learn, and a marketing resource when you apply for a job!

8. As an NJIT undergraduate, graduate, live and/ or Distance learning, or in other words eLearning Student, or hybrid course student you are entitled to benefit of significant FREE computing resources, meaning hardware, software, as well as on-line email, web-site storage space, and related Internet and NJIT intranet server services. The steps below intend to help you on how to set up a web page for documenting your assignments for this course. Please read and follow each step. Obviously if you already have a web page, either through work, or business, or otherwise, please feel free to use that, or the one you prefer. (All we want is for you to learn the method, and then put all your assignments on the web, learn how to manage your knowledge over the web, and then email your URL with your assignments to the instructor for grading). Note, that you can use any suitable web authoring software. NJIT has a few on free offer too.

   These are the steps to follow (as provided by NJIT's IT and Computing Services):

   Hopefully all works... I'd like to see your beautiful webpages!

   1. Visit: http://csd.njit.edu/resources/webservices.php and read the instructions for Home page Setup. If you don't understand the details offered, please contact NJIT Academic Computing at Tel: (973)-596-2900, and they'll take you through. (Note, that lines can be busy during peak times, such as at the beginning of the semester, or towards the end of the semester, therefore to sort this out the earlier the better!)
   2. You should have an index.html file as your 'title page', because search engines will find you via the index.html file, and your hyper links to other files should be programmed passing through this index.html file.
   3. Please make sure, that you create your index.html file in your public_html directory and have all your other .html, .jpg, .xlx, .mov, etc. files in the same directory, else you will have a 'path error', meaning that your files will not link when viewed by others over the Internet.
   4. Last, but not least: ALWAYS test your uploaded assignment using your own, as well as somebody else's computer, to make sure, that everything works fine. (If you don't have a second, independent computer on the web, ask one of your classmates, or friends to check it for you, by sending him/her an email with a full URL in it, like this: http://www.mycoursewebpage.edu). Also note, that besides the class discussions (live class), the eLearning pack CDs have several examples on the architecture of simple and complex web-pages. All of these are in open source, please study them! We'll discuss some of this in class too!
9. PLEASE do NOT use MS-Publisher as a web authoring tool, since according to last semester's experience it has linking problems even within an entirely MS 'industry standard' environment... not to mention the internationally accepted Internet community... 'If they cannot see your web pages then why to bother at all...' therefore make sure that your web pages are being used for knowledge collection and knowledge management and therefore are accessible from anywhere in the world!
10. ESCAPE route: every semester about 3% of my students decide not to develop a web page... this is a poor decision, nevertheless in some cases I can see the reasons... therefore if you don't want to develop a web page, pls. send me your work in compressed PDF format (not zillions of Word and Excel files please!) Of course your PDF file will not be as active as a web page with all hyperlinked companies, text in .html, images in .jpg, .xls files with the spreadsheets, videos in .mov. or .AVI, etc. but still better than sending zillions of files by email that I cannot integrate for you... Please remember: there are other great software and knowledge communications tools out there besides Word... maybe it is time for you to master them, because you'll be left behind VERY RAPIDLY... actually you are already behind if you even think about going down this rute... (sorry this is the truth...)
11. In your web page, please include your photo, so that I can remember you easier. THANKS!
12. WARNING! Make sure that your web page works fine! THERE ARE MANY web pages that do NOT LINK! Please make sure, that your URL does link well, and then send it to my email: cimware@mac.com (NOT via webCT!) to notify me of a new submission, with your tested URL in the email, else I won't be able to give you a grade... and everything will be delayed, which is bad for both of us. (Never forget: Your success is my success too, and I am keen for both of us to succeed!)
13. We DO NOT plan to use webCT for this class but I encourage you to discuss your assignments with other members of the class. We don't use webCT only due to the unfriendliness and huge limitations imposed by webCT compared to other modern FREE web-based software tools and resources. For us, this means, that in this class

• I will send out emails to the entire class via the NJIT Highlander Account, and
• You can respond to those emails to the above specified email address. I will furthermore
• Email you the grades as they become available. We'll work on email with URLs in them and then you'll get a grade for each assignment as we move along with the material we study. It works very well, and it is very flexible.
• I kindly ask you again, to set up your webpage for documenting your assignments, and then include your URLs into an email and then send it to me via the above specified email address. (Again, I will NOT accept zillions of unintegrated Word files with Visio and .jpg image files all bundled into an email, excel files emailed separately, etc. because your knowledge integration for each assignment will be your task, not mine...)
• I furthermore suggest that students use various chatgroup options to discuss issues, to team and exchange data and information within the class, to network and to email each other. I will try to help whatever I can but feel free to set up your instant messaging systems with each other, and even video conference if you have a cable modem. NJIT is setting up alternative solutions besides Highlander, webCT and BlackBoard... there are some really good free solutions out there for video conferencing (AOL) and chatting... I would definitely use those...

These are the steps my students suggested in the past to follow when uploading web pages to the NJIT server (Note: I use professional servers; I do not use the NJIT server, therefore if you need help please contact the NJIT computing help desk, and/or network with other students via chat groups). Read these instructions (kindly offered by Ashley John).

Last, but not least: ALWAYS test your uploaded assignment using your own, as well as somebody else's computer, to make sure, that everything works fine. (If you don't have a second, independent computer on the web, ask one of your classmates, or friends to check it for you, by sending him/her an email with a full URL in it. The 'full URL' should have this, or similar format: http://www.mycoursewebpage.edu).

Also note, that besides the class discussions (in our live class), the eLearning pack 3D eBook CDs / DVDs have several examples on the architecture of simple and complex web-pages. All of these are in open source, please study them!

Of course open source does NOT mean that you can put an entire eBook, or DVD video, etc. onto the web, NOT even on your own server! This action would be illegal, since you would break the USA and the International Copyright Laws! Don't get in trouble with publishers... it is nasty and costly, and if you illegally put any published and copyrighted material on teh web, you'll definitely loose in court...

PLEASE OBBEY THE USA and the International COPYRIGHT LAWS! DO NOT ILLEGALLY COPY ANY OF MY, or somebody elses PUBLICATIONS! What you can do of course is use individual objects, images, video xclips in your assignments, also spreadsheet templates customized with your own data, etc. with credit (i.e. include the sourse in the Bibliography). This is legal.

The 21st Century Engineer must be a professional information searcher, information and knowledge creator, as well as somebody who can reason over several different sets of information and then select the best possible solution path under constraints... not an easy task. In order to help this process, in this course we'll visit NJIT's wast and advanced electronic library, see some of the typical information searches and how the results can be evaluated. For our purposes, we'll use NJIT's SCOPUS electronic database. You can reach it via: http://www.scopus.com.libdb.njit.edu:8888/scopus/home.url, all you need is your UCID and password (as offered by NJIT to every NJIT student) to access this site.

As always,

Happy Learning,

Professor Paul G Ranky, PhD

Contents (IE655) Course All Options: Live, Hybrid and Distance Learning (DL, or eLearning, the same).

• Narrative Description of the Course
• Why is the course needed?
• For whom is the Course Intended?
• Class 1
• Class 2 Submit by the End of This Session! Assignment No. 0: Design your Own Concurrent Engineering / PLM Product / Process Design Challenge in collaboration with the 4 Collaborative Companies in your eLearning Pack (1 page Executive Summary)
• Classes 3 and 4 Submit by the End of Week 4! Assignment No. 1: What is Concurrent Engineering (CE) and PLM (Product Lifecycle Management) and why is this subject important for our future? DVD video exercises (20% max.)
• Classes 5 and 6
• Class 7 Submit by the End of This Session! Assignment No. 2: QFD1 (Design: Quality Function Deployment; Component Oriented Requirements / Needs Analysis in the CE context, CORA) extended with the Ranky-Taguchi Design of Experiments method and spreadsheet tools (20% max.)
• Class 8
• Class 9 Submit by the End of this Session! Assignment No. 3: Design: Process Failure Mode / Design Failure Risk Analysis in the CE context, extended with the Ranky-Weibull reliability analysis method and spreadsheet tools (20% max.)
• Class 10
• Classes 11 and 12 Submit by the End of this Session! Assignment No. 4: Rapid Prototyping and Rapid Manufacturing Methods and Technologies Study (20% max.)
• Class 13
• Class 14
• Class 15 Submit by the End of this Session! Assignment No. 5: Concurrent Engineering (Digital Design & Digital Manufacturing = PLM) Product Design Assessment and Improvements: New Product Innovation & Introduction (NPI & I) Challenge: Innovative Toy PLM/ Concurrent Engineering Design, or a Cuncurrent Engineering Product/Process design of your choice, and Marketing Plan (Press Release of your new product/process/service) (40% max.)

NJIT IE 655

Welcome to IE655: one of the most useful engineering / engineering management courses you’ll ever take! Please read these notes and work hard on your assignments. What you'll learn in this class will help you to be amongst those who will continously win and prosper. If anything is unclear please call me or email me. I am here to help you!

In IE655 we discuss and learn a conceptual, as well as a practical approach how to innovate, and minimize the time required to successfully execute complex product / process / resource design focused projects. Techniques utilized and discussed in detail include systems analysis and integration, needs analysis, product modeling, system modeling, process risk analysis, Taguchi design of experiments methods, Weibull reliability analysis methods, collaboration and integration methods, rapid prototyping, digital design & digital manufacturing, design for manufacturing / assembly, and others. Relevant open source software is employed and made available to students in the form of a customized eLearning Pack, and commercial software for educational purposes via the NJIT servers. The course should be of interest to individuals concerned with integrated product/ process innovation and introduction to the market, minimizing lead time, reducing project development cost and time to market new products, and/or services.

Narrative Description of the Course
An object - oriented (i.e. modular product, process, service design) approach to the introduction of various product and process design methods, tools, technologies and their management issues within a variety of small, medium and large enterprises for the purpose of reducing lead time, and cutting waste.

The purpose of concurrent / simultaneous engineering methods is to cut product and/or service process development lead time, to reduce waste, to reduce the number of costly product design changes, to improve quality, and to create a lean workflow. This is applied from concept to integrated product/process design, manufacture, assembly, maintenance and after-sales support, based on analytically established customer requirements, and process models.

The diagram below clearly illustrates the essence of this course. As it can be seen, it is every company's aim to innovate, create new products, processes and services that are required by customers, that are high quality, and can be introduced to the market at a competitive price.

The diagram below clearly illustrates the extremely high cost of product design changes. This is typical without deploying concurrent engineering / PLM methods... in the IE655 class we'll learn methods, tools and technologies, that will lead us to innovate, and minimize the number, and therefore the cost of changes during the entire lifecycle of a product (hence the terminology: PLM).

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Furthermore, as illustrated below, it is important to understand, that Concurrent Engineering, combined with PLM, Total Quality Management, and Project Management offers major product life-cycle cost reductions.

As you study the graph below, consider the following:

In engineering systems the term 'life-cycle cost' means the sum of all the costs, both recurring as well as non-recurring, related to product, structure, system, process, IT, and/or service during its life span. (A typical life-cycle is illustrated below.)

As you can see from this graph, life-cycles typically start by identifying a customer need, a requirement, a want, a desire, and/or a sound business opportunity, and end with product/process retirement, conversion, re-engineering, recycling and eventual disposal activities. (Note, that in the case of a modern, environmentally friendly concurrently engineered product/process design system, 85-90% of products are eventually re-used and recycled.

Since by understanding the underlying drivers and processes of concurrent engineering, the opportunities for saving valuable product/process design and development cost and time are huge, the aim is obviously close to 100% re-use and re-cycling, and as we will discuss this issue in the course, there are already good examples for achieving this goal...

Besides others, the graph below underlines the fact, that concurrent engineering economic studies, process-by-process cost and gain assessments are essential part of the big picture, because they help to analyse and compare alternatives in virtual environments, costing a lot less than real-world experimentation on the shop floor when the product/process is already in full swing production and the commited costs are already high.

We can furthermore see, that the greatest savings occur at the acquisition phase, in other words around the basic idea to detailed design transition phase. This is why a factory with a future (i.e. a digital, networked factory) will have to understand and master concurrent engineering, PLM and NPI&I methods and apply them at all stages of the business to be able to successfully compete.

It is also important to recognize, that as shown below, the commited cummulative life-cycle cost curve increases rapidly during the basic product/process idea to detailed design transition phase. In general typically 80% of life-cycle costs are 'locked in' at the end of this phase and at the beginning of the 'release design to manufacturing' phase by the decisions made during the requirements analysis, preliminary and detailed design phases. As illustrated by the cummulative, actual life-cycle cost curve, only about 20% of actual costs occur during the acquisition phase, in other words around the basic idea to detailed design transition phase, with about 80% being occured at the product construction, operation phase.

The conclusion is, as shown below, that the concurrently engineered NPI&I activity must understand the potential for product / process life-cycle savings in all processes, with their requirements and risks involved. This should include their time and cost demands too. The key then is to simulate these issues in advanced virtual (digital) environments, and take decisions as early as possible (i.e. 'front loading') to avoid dead-end paths and costly changes downstream... easier said than done! (Note, that this statement is true for every product/process, IT, and service product development activity!)

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It is interesting to see, that the above illustrated principles apply to literally every industry, but most importantly to all manufacturing and design industries, as well as to IT and service environments. As an example, in the IT industry the opportunities for savings are enormous, due to the fact that over 85% of IT projects fail (1990-2004 figures). This is costing the USA economy over 56 billion (!) USA dollars.

Using concurrent engineering and NPI&I methods this amazing level of failure can be reduced significantly (as a reference only 10-15% of engineering projects fail, and when they fail mostly they overrun, rather than truly fail, like don't work... or crash like software does...). The major challenge though is to convince IT professionals to actually learn, understand and then apply these methods during their everyday work, versus jump into code-writing, clicking... as many of them do even now as you read this text... and they are charging for every click with the mouse... big $$$$...

Of course, the root cause is to convince many (not all) computing and information sciences professors to change the way they teach IT, information sciences, software design and computer programming... but this is outside the scope of this class... Nevertheless any fool can see that even if we could just save 10% of the $ 56 billion, we could gain $ 5.6 billion every year; not an ignorable sum... the potential savings of course are at least 80% of the 85% failure, therefore we really talk about saving 80% of $ 56 billion = $ 44.8 billion USA Dollars in the USA only... World-wide this figure is estimated to be several times this value... imagine how many hungry kids we could feed out of this money... and how many could get university level education... now you feel the pressure; amazing but all true!

To move on with some positive thoughts, as seen below, the good news is that the above discussed challenges are recognized by many. The Design for Manufacturing (DFM) / Concurrent Engineering (CE) / PLM software market is forecast to grow very agressively not only in the mechanical (like the automotive) but also in the electrical, and electro-mechanical industries.

This is because the electronics industry recognizes the significant cost saving, quality improvement, and time-to-market reduction opportunities with CE.

As an example, at a recent Design for Manufacturability conference in San Diego, CA, USA, the electronic engineering community expressed their views, that 'DFM / CE / PLM solutions have emerged to help designers to cope with process variability reductions and yield increase' (... hope you recognize the link here with what we teach in Total Quality Management, IE673).

As EE Times, the industry newspaper for electronic engineers and technical management (by United Business Media, USA) reports in their June 14, 2004 issue, 'taking one of the boldest steps yet to merge design with manufaturing, Magma Design Automation Inc., USA announced an integrated solution...' Furthermore, IBM and academic research partners are working on methodologies for manufacturing-driven design rule exploration, physical verification, design rule checking (DRC), and other hot CE topics... As Vasilios Gerousis, Chief Scientist at Infineon Technologies AG put it: 'Design and process parameters need to be adjusted at the same time'; a clear success for concurrent / simultaneous engineering principles!

The graph below illustrates the above planned, industry-driven, drastic electronic design DFM/CE software growth rate.

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In order to lead the above outlined plan, our students are prepared for this challenge and are educated to respond to the rapidly growing employment opportunities in the field of concurrent / integrated product / process, PLM and service system design engineering management.

In the IE655 course they learn several well established methods in-depth, such as quality function deployment, requirements analysis, collaborative concurrent engineering (and service) process modeling, process failure mode and risk analysis methods, Poke-Yoke, Kanzei, rapid prototyping methods, PLM (Product Lifecycle Management), NPI & I (New Product Innovation and Introduction), and others, including methods, tools and technologies in the product / process / service system design field, covering the following:

• How to identify opportunities early, measure their impact and pursue the best possible alternatives ?
• How to deliver against focused objectives ?
• How to advance in new product development ?
• How to start a product development process / team ?
• How to achieve competitive edge ?
• How to re-engineer the organization for digital factory and networked enterprise design management ?
• How to manage change ?
• How to develop metrics, that can capture the potential for long term growth ?
• How to maintain innovation and cost control ?
• How to take advantage of digital design & digital manufacturing (PLM) methods and technologies ?
• How to front-load the entire product development process and gain over competitors ?
• How to decide wheter it makes sense to outsource or not, and many others.

The course is supported by a comprehensive eLearning package (this pack is the same for live, hybrid and distance learning students) with some printed material, and several web-browser readable, open source 3D interactive multimedia eBook CD-ROMs and DVDs and DVD videos. It includes real-world research and industrial case studies, as well as open source, professional active code and spreadsheets, that the students can customize when developing their assignments with their own data.

To summarize, the methods taught in this course are relevant not just to innovative design, manufacture, test and quality control of products, but to a large variety of services too, because they reduce development costs, and improve working capital management, by offering powerful methods and software tools.

Upon completing this program of study the candidates will be able to understand Concurrent/ Simultaneous Engineering, and related PLM, Digital Design & Manufacturing, NPI&I, and total quality engineering management methods and tools. Note, that besides the above, in this semester we'll specifically focus on PLM / Digital Design & Manufacturing.

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, and lately referred to as PLM (Product Lifecycle Management) reflecting the fact that in our knowledge age we are dealing with digital factories networked all around the world.... exciting, but also challenging...

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, and re-engineering / recycling, 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.

We further illustrate this concept with Dr. Peter Rayson's GICCA enterprise lifecycle curve (Technology Innovation Centre, University of Central England, Birmingham, UK).

As it can be seen from the figure above, and below, 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, digital manufacturing and design system, preferably implemented in a digital factory (more on this topic in a web-article...).

It is furthermore obvious from the table below, that the extended enterprise (with a future) must focus on all aspects of product / process and service system innovation and introduction to the international marketplace.

This process needs knowledgeable and empowered individuals who understand the importance of enterprise knowledge management, digital design & digital manufacturing, exactly the professionals industry needs, and this course aims to develop!

Note, that various views and angles of this complex topic is addressed by Ranky in this Concurrent / Simultaneous Engineering course, in his Total Quality Management class, and also in his Project Management and Lean, Flexible Automation / Manufacturing Systems Engineering classes.

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In broader terms, the aims of CE, PLM, or integrated lean, or agile, or adaptive, 3D digital design and manufacturing are very clear: getting rid of waste, reducing the number of costly changes, integrating product and process engineering better, focusing on high quality at low cost, offering product data management and PLM within all the companies involved in the product creation and manufacturing processes, organizing our knowledge in our minds, and helping us to focus on new innovative opportunities driven by the customer. The key is to be able to integrate the

• Information flow, meaning objects, and object classes communicating with each other, the
• Material flow, meaning actual material or information about material being moved in design studios, in the factory, as well as between globally networked factories, and the
• Processes, such as design, manufacturing, marketing, quality control, and others, in our digital factories (i.e. the internal and external supply chains) in order to create wealth for several product life-cycles.

In other words, CIM (Computer Integrated Manufacturing), Total Quality Management, Engineering Project Management and Concurrent Engineering, and PLM (Product Lifecycle Management) address the whole enterprise, including products, processes, controls and resources, enabled and created by humans, machines and networked global partners, including the business systems, product design, process planning, manufacturing planning, the shop floor, packaging and maintenance via the internal, as well as the external supply chains.

As we can see when we analyze successful companies, innovative, quality design is very important: As an example look at Toyota, BMW, DENSO, Nissan, Honda, Boeing, Airbus, Dassault Systemes, or another giant industry innovator: Apple Computers.

Engineering excellence is central to Apple’s vision: Apple’s leader, Steve Jobs, in Paris at the Apple Expo 2005 talked about the beating heart at the centre of Apple’s core, the company’s world-class engineering teams.

“At its core Apple has great engineering and confidence that it has the ability to take complex technology and make it easy for the end user.” Remaining relevant in a changing world is critical. The idea of making powerful technologies easy to use matters: “That need is becoming more necessasry as technology becomes more complex”, he said.

“Apple does that better than any other company in the world. What makes us different? Most of our competitors don’t have engineers anymore. Everyone else designs in the Far East.”

Given that claim, a question was asked as to why Apple says “designed in California”, rather than “designed in the US” on its products. Jobs responded: “(It’s) because we like California. It is where we are from. It’s not because we are ashamed by the US”.

The October 24th Time Magazine issue features Steve Jobs on the Cover holding a Video iPod and an iMac with the words "What's Next". (The article is available to subscribers, but is also available in full at TimeCanada).

In it, Jobs talks about how and why Apple continues to be innovative in this industry. He points to their product development cycle as "deep collaboration" or "concurrent engineering". Products don't pass from team to team. Instead products are developed in parallel by all departments "in endless rounds of interdisciplinary design reviews".

Jobs also places emphasis on control. Through controlling the hardware and software, integration can be more seamless. This also reduces your dependance on third party companies. The iPod, iTunes, iTunes Music store is an example of this control and integration.

The product now is the iTunes Music Store and iTunes and the iPod and the software that goes on the iPod. A lot of companies don't really have control, or they can't really work in a collaborative way to truly make a system. We're really about a system.

Jobs also provides more insight into his opinion about the new video capabilities of the iPod:

"There is no market today for portable video," he says. "We're going to sell millions of these to people who want to play their music, and video is going to come along for the ride. Anyone who wants to put out video content will put it out for this. And we'll find out what happens."

... and some more facts about Apple (to underline the fact, that concurrent engineering principles, as the CEO has identified the key, works well), as Apple is heading to become a $20 billion corporation:

- Net Mac sales increased 27% year over year
- Average price of a Mac fell 7%
- 21% year over year growth in sales in higher education
- 11% growth in K-12
- 28 Million iPods sold with 248% revenue increase year over year
- 38 new brick and mortar retail stores were openned in 2005
- Retail sales almost doubled to $2.4 billion
- Research and Development increased (up 9%)

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Ranky: Well, this is what happened: within 2 weeks of the introduction of the first Video iPod, Apple sold 1 million videos for it over the iTunes music store, and within 1 year the music iPod gained 60% market share in Japan... where Sony and others typically rule... Apple's market share of the same product in the USA is over 85% for downloads, and 75% for hardware devices... real success, and real concurrent engineering methods... and you can learn many of these in this class.

I firmly believe, that the key to all this is the following:

1. A good, successful design is based on culture, created by progressive thinkers (i.e. HUMANS!), and the

2. Methods and toolset MUST have a strong emphasis on integration, like Concurrent Engineering, TQM and PLM. Isolated thinkers, with isolated tools will NOT succeed in our complex, networked, global infrastructure of creators, producers, manufacturers, and consumers.

Sounds really simple, nothing really new, nevertheless not easy to actually deliver... but we'll learn this in this class.

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In a different industry, we can identify similar eager to develop new products, processes, resources and service. As BMW's Dr. Burkhard Goeschel (CTO) states:

The BMW Group is the only major manufacturer of automobiles and motorcycles worldwide that concentrates entirely on premium products and outstanding quality for all its brands and across all relevant segments.

Like all other members of the automotive industry, the BMW Group operates in an area characterized by two contradictory developments. On the one hand, customer demands as well as requirements within the society, are constantly on the rise. On the other hand, competition within the industry is continuously shortening development times for new models even as cars become ever more complex products.

Therefore, developing and implementing innovations is the key element in the BMW Group's strategy to meet this twofold challenge and to maintain its position at the forefront of the automobile industry. Innovative products are clearly distinguishable from the competition, create desire and thus command a higher prize - with all three points being of vital importance in the premium segment. The company acknowledges only products and components that are clearly recognized as useful by our customers. In the same way, research activities are focused on so-called strategic innovation areas such as powertrain or driving dynamics in which the company seeks to maintain or achieve technological leadership.

Two areas that enjoy top R&D priority are Sustainable Mobility and Intelligent Mobility:

Sustainable Mobility
"To ensure the long term availability of adequate energy supplies, the BMW Group is committed to the principle of sustainable mobility, a concept that places emphasis on the efficient use of today's energy sources and the development of innovative solutions to meet future transportation needs. In order to reach this goal BMW Group further develops and enhances a variety of approaches, such as lightweight vehicle construction or the Valvetronic system which all help to decrease the consumption of carbon-based fuels.

The fuel of the future however, will be hydrogen. If generated with the use of regenerative energy sources, hydrogen is the only truly emission-free energy-carrier available. With the initiative BMW CleanEnergy the BMW Group strives to establish the hydrogen-powered internal combustion engine as the propulsion system of the future. Far from being a new player in this field BMW Group has started researching hydrogen technology 25 years ago. In 2004 the H2R prototype-vehicle set nine world records for hydrogen-powered cars, including a top speed of more than 300 km/h, thereby clearly showing the future potential of the hydrogen-powered internal combustion engine.

Intelligent Mobility
Communication and information technologies give the automotive industry new opportunities for intelligent mobility in the future. BMW Group's ConnectedDrive networks telematics, online communication and driver assistance systems in order to enhance both safety and efficiency in transport. ConnectedDrive acts like a virtual co-driver presenting the right information at the right time, while still leaving the driver in total control. The active gas pedal, for example, "tells" the driver to slow down under specific conditions by exerting a greater counter-pressure against his foot. Intelligent route guidance taking even more detailed traffic information into account, helps to reduce road congestion and makes individual mobility more efficient in times of rapidly increasing vehicle numbers.

(Note, that whilst GM, Ford and Chrysler shrunk between 45 to 17%, BMW actually grew 17% in 2005-2006... guess why...)

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A few words about Lean Product Development... by Nancy Rouse-Talley. (She is a freelance writer who focuses on technology subjects, Desktop Engineering, December 2006)

'...Successful execution of a lean manufacturing program requires assessing processes, recognizing bottlenecks, and making improvements that not only eliminate holdups but improve efficiency. Simply automating existing processes is not the best way to implement product lifecycle management (PLM) programs. In fact, it might be a recipe for disaster because computerization could simply speed up unproductive processes without improving them, leading to an endless cycle of ineffective changes.

Software that manages design data, moves it to the factory, and promotes factory automation should be used once processes are streamlined and improved. Programs such as UGS Corporation’s Teamcenter, PTC’s Windchill, Agile Software Corporation’s PLM products, Centric Software’s Product Intelligence Software, and Dassault Systèmes’ Enovia Virtual Product Lifecycle Management (VPLM), Smarteam, and MatrixOne make it easier to share complex engineering data across the enterprise. Digital manufacturing programs such as UGS’ Tecnomatix and Dassault’s Delmia, on the other hand, help manufacturing engineers validate production processes.
(Ranky: we use Dassault's Delmia, and other tools in this course...)

Companies that in the past were primarily concerned with lean manufacturing now also focus on lean product development. Lean methods have formed the foundation of Japanese automobile manufacturer Toyota’s factory processes for more than 50 years, for example, but today the company also uses PLM to perpetuate lean product development processes.'...

==========================

For Whom is the Course Designed?

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, and Biomedical Engineering students. Note, that students with science background can take this course too. We follow a modular approach that makes the topic very adaptable to a variety of different environments. This approach has been successfully tested and run for several years at NJIT as well as on a consulting basis at large companies and software houses, such as Rolls-Royce, IBM, GM, Ford, Raytheon, and others.

Furthermore, the course is aimed at graduate research students, professional engineers and managers working in industry, wishing to learn about new, integrated design and manufacturing methods, tools and technologies, and management methods, for the purpose of improving products and services, and to learn how to innovate in a cost effective and productive way.

Note, that if you have taken the IE673, Total Quality Management course with me, you will find this course to be an integrated part of our advanced project management, total quality and new product/process/service creation approach.

Live as well as Distance and Hybrid (blended) Learning (eLearning) Students purchase their educationally priced, customized eLearning Packs from the NJIT Bookstore (PLEASE ask for the Spring 2006 IE655 eLearning Pack. The pack changes every semester, therefore you need the current version. Both Live, as well as eLearning (DL) students get the same type of eLearning Pack from the bookstore). Every eLearning Pack is different, because it is customized, and this semester includes the following incredible resources:

• The Main Textbook of the course. Ranky: Concurrent / Simultaneous Engineering (Methods, Tools and Case Studies), ISBN 1-872631-04-5. You keep. The textbook includes 3 interactive multimedia eBooks in one DVD inside the textbook as a book / DVD combo:
• • 3D eBook: Concurrent Engineering, which is the same and more, than the printed text, (run this browser readable multimedia program by opening the a_StartCase.html file. It will support every topic we learn and every assignment in this class, and more...)
  • 3D eBook: Rapid Prototyping with plenty of integrated text, images, videos, active code, and 3D objects explaining a variety of rapid proto. methods, by Upcraft, S. and Ranky, P.G. You keep. , (run this browser readable multimedia program by opening the a_StartCase.html file) and another one on
  • 3D eBook: Component Oriented Requirements Analysis (Quality Function Deployment) with plenty of integrated text, images, videos, active code, and 3D objects (run this browser readable multimedia program by opening the a_StartCase.html file) (You keep.)
• Four Collaborative Company Information Packs. (You keep.) You'll need these, because you will have to collaborate with them in designing your new integrated PLM / CE product/ process in a collaborative/ concurrent engineering, digital design & digital manufacturing fashion, simulating virtual collaboration over the web. (Note, that company info is provided either in form of a printed document, and/or on CD-ROM, or as a URL, or as a mix of these media formats)
• DVD Label 1: CE Lecture Videos on DVD (in small size, computer playable MPEG2 PC/Mac/Unix/Linux format using a MediaPlayer, or even better Quicktime), showing you the past 20 plus years of CE; a valuable introduction to the topic by multiple authors; definitely start with these videos. You keep;
• DVD Labels 2a, 2b, 2c, 2d: Industrial Case-1 Full-size Video on 4 DVDs (the latest and best on PLM1, 2, 3, 4); You keep;
• DVD Label 3: Industrial Case-2 Full-size Video on DVD; you can see the future today! (IGES CAD Doctor); You keep;
• CD-ROM Label 4: Ranky-Taguchi Design of Experiments files (in Beta) on CD-ROM. You'll use this together with the CORA method, as explained in the textbook as well as on the Component Oriented Requirements Analysis eBook. You keep: if you find a bug in this spreadsheet program I will reward you with an extra 10% on the top of the achievable max. for the entire course! This CD-ROM also includes Ranky-Weibull Reliability Analysis files (in Beta). You'll use this together with the PFRA method, as explained in the textbook as well as on the Disassembly Failure Risk Analysis eBook. You keep: if you find a bug in this spreadsheet program I will reward you with an extra 10% on the top of the achievable max. for the entire course!
• DVD Label 5: Innovative Toys: DVD Video. You keep.

Important notes:

• Please note, that each customized eLearning Pack is different, nevertheless the methods we use are the same for every student. Each student should therefore use one eLearning Pack and work in collaboration with the companies offered. This is extremely important for you to learn about innovation, collaboration, globalization, networking, project management, and of course our core subject in this course, CE / PLM.
• Also note, that you will need a multimedia PC (approx. 500 MHz, with a CD/ DVD drive and 800x600 resolution screen min.; as always in IT the faster the better...), a link to the Internet and email, as well as a recent version (not older than yr. 1998) of MS-Excel in your machine. (Note, that NJIT has thousands of these, and faster computers if you need access to a computer.)
• To view the DVD videos you should have access to a computer with a DVD player, or a TV/DVD player. There are many of these systems at NJIT, as well as in public libraries in the USA, obviously you can use them too.
• PLEASE NOTE, that as a student of NJIT, you are entitled to educational software and hardware discounts, some free software, and site licenses, therefore make sure that you take advantage of the huge discounts and opportunities offered. (See the NJIT's bookstore, as well as contact NJIT's computing help desks and the NJIT website for further details).

Reading for a degree... A few words about 'reading for a degree'... for hundreds of years, academics all over the world emphasized the importance of reading for a degree. Since we fully support this philosophy, in the eLearning Packs you'll find significantly more material than required for an 'A', to help even the most progressive students to learn more. Also, you are encouraged to use the Internet, and the NJIT Library. Here is a short list of excellent resources that will help you to deepen your understanding of the subject area of this course:

• Priest, J.W. and Sanches, J. M.: Product Development and Design for Manufacturing. A Collaborative Approach to Producibility and Reliability. Quality and Reliability Series, 2nd Ed., Marcel Dekker, Inc., ISBN 0-8247-9935-6, 434 p.,
• Boothroyd, G., Dewhurst, P., and Knight W.: Product design for Manufacture and Assembly, 2nd. Ed., Marcel Decker, Inc., ISBN 0-8247-0584-X, 698 p., and others.
• Morgan, J. M. and Liker, J. K.: The Toyota Product Development System. Integrating People, Process, and Technology, Productivity Press, New York, 2006, 377 p.

Academic Calendar

Please look up the accurate dates on the NJIT website. This is a short summary:

Sunday
January 14
First Day of Sunday Classes
Monday
January 15
Martin Luther King's Birthday-No Classes Scheduled
Tuesday
January 16
First Day of Classes
Monday
January 22
Last Day to Add a Course
Tuesday
January 23
W grade posted for all Withdrawals
Monday
January 29
Last Day for a Refund based on a Partial Withdrawal
Tuesday
March 6
Last Day for a Refund based on a Complete Withdrawal
Monday-Sunday
March 12-18
Spring Recess-University Open-No Classes Scheduled
Monday
March 26
Last Day to Withdraw from Cours(s)
Monday
April 2
Summer & Fall Registration Begins
Friday
April 6
Good Friday-No Classes Scheduled
Saturday 
April 7
Saturday Classes Meet
Sunday
April 8
Easter-No Classes Scheduled
Tuesday
May 1
Friday Schedule-Last Day of Class
Wednesday
May 2
Reading Day
Thursday-Wednesday
May 3-9
Final Exam Period
Thursday
May 10
Spring Grades Due in Registrar's Office
Thursday
May 17
Commencement (Tentative Date)

Schedule: This semester is the equivalent of 15 weeks of study. You have to complete and submit 6 assignments (see them below in detail). There is no final examination, the course is assessed based on 6 assignments. The schedule and deadlines for all assignments are below. All assignments should be in electronic format. If there is something not clear, please email, or call, or make an appointment and see me (as specified above). There is a limited number of rework options (typically one per assignment) to assure that you do your best and learn the most, and of course get the fair grade for your efforts. I am keen to help, but I need your help to be able to help you. Your hard work is the best help for all of us to acieve this goal! If you win, we all win!

Class 1 Introduction and overview of the course as well as the subject: Concurrent / Simultaneous Engineering (meaning exactly the same) and PLM, in a traditional and in a modern design and manufacturing enterprise. Object oriented (OO) and globally distributed enterprise models. Systems and integrated processes are explained. Our discussions are supported by DVD videos and virtual factory tours, and have an engineering management focus on how to find and reduce product design and process design related waste; on how to support integrated product / process design concepts and models, how to win over your competitors by following digital design & manufacturing principles and technologies, and how to innovate. Innovation is key in our 'Innovation Economy', in particular in the USA, competing with low labor cost nations on a global basis. If you learn about CE / PLM / Digital Design & Manufacturing, you basically learn how to secure your own job for a very long time!

Student Activities (this is what you should do to get an 'A' in this class, and most importantly learn the subject):

1. Please read this syllabus. Know your deadlines, what is needed, and by when.
2. Review your eLearning Pack companies. Who are they? What are they doing? How can they help you with your new product / process innovation? You must work with them... the boss says so...
3. Review all other resources in your eLearning Pack. See what you have and how do the resources relate to the study program in this class. There are CDs/DVDs supporting each assignment, and there is a book too. Look at them and see what they cover.
4. Start to read the book offered in the eLearning Pack. Most assignments are supported by Chapters in the main Concurrent Engineering 3DeBook. Look at it as a useful resource helping you with assignments and methods. View it electronically using the DVD inside the book; much nicer: all in color, with videos and active code...
5. To prepare for the first assignment start to view some of the DVD videos. The more you can see at this stage the better. You should re-visit these videos later in the course to get a deeper understanding of the methods, principles and technologies demonstrated. They'll offer several new ideas and direction.
6. The first Assignment, labelled Assignment 0, since this is the zero stage, is to invent a new product/process that you will develop (virtually) with the collaborative companies (the 4 companies in your eLearning Pack). Think of something that you are already familiar with. As examples think of customizing an automobile, or inventing a new walking, talking humanoid robot, or the hydroforming process (a great method to bend tubes, designers should know), or 4-axis turning using computer controlled machine tools, or a smart hospital bed that is networked to the Internet, or a new cell phone (see an old model in 3D; a new toy, etc. You'll need Quicktime to play this! Whilst holding down the mouse move your cursor left and right to activate the 3D object; enjoy!) which has camera, email, web-access, music, video, a new smart humanoid robot that will iron your shirts, or clean the house, and the car, or a digital hub in your house for TV, vide, music, security, or telematics solutions for your car, or smart appliances in the kitchen, etc. There are plenty of opportunities! Just think and invent. Can think BIG, don't have to implement it all! I'll give you a lot of fredom to develop some of your ideas following the robust methods I am teaching you in this class; no worries, THINK BIG!

Class 2 Concurrent Engineering and PLM Methods, Tools and Technologies. The Product Development process. Focus on integrating design and manufacturing processes for the purpose of cutting waste, and improving quality. PLM methods and tools for frontloading the product development process.

Submit by the End of This Week! (note, that 'End of Week', for all cases means Friday, 5.00 p.m. of that week)! Assignment No. 0: Design your Own Concurrent Engineering, Digital Design and Digital Manufacturing System Design Challenge with the 4 Collaborative Companies in your eLearning Pack (1 page Executive Summary). This is a short electronic presentation by each student entitled: 'My PLM / Digital Design & Manufacturing challenge, my collaborative companies, and my plans for collaborating with them in order to develop, innovate and bring to market my new product/process design'. Please address briefly all these issues.

You can change the focus later as you develop the project, but you'll need my approval to go ahead. This is why I need the single page executive summary emailed to me. (This is also a good time to start to set up your web page...)

Also, include your project Title, Author (Name, your photo, your class, date, your eLearning Pack serial number and the collaborative companies you have (a MUST!).

I will respond to this by email, comment and hopefully accept your plans. When you have your web page up and running, include this Assignment 0 to have a nice, integrated documentation approach to all of your assignments on the web.

Don't miss the fact, that this is a Concurrent Engineering, PLM and NPI&I - focused class! Make sure, that your assignments reflect this! Also, you must collaborate with teh 4 companies in your eLearning Pack!

Classes 3, and 4 Concurrent Engineering, PLM and NPI&I (New Product Innovation & Introduction) in our rapidly growing research and development world = DVD Video Lectures and full screen, high quality case study videos. Enjoy; you are seeing and experiencing the past and the future...

Submit by the End of This Week!

Project/ Assignment No.1: Concurrent Engineering Video Lectures (20%) (Relevant eLearning Pack Resource: work through the DVD videos). Take notes as you watch them. You'll need these notes in some of the other assignments too!

• In terms of assignment documentation method, please follow the Documentation section of the 3D eBooks in your eLearning Pack.
• Title, Author (Name, Class, Date, your eLearning Pack serial number, and the 4 collab. companies you have ( a MUST!)
• Statement on who has done the work, even if done in a team: EACH individual, and this is true for all assignments, must submit an assignment by himself/ herself!
• Contents
• Introduction and Objectives of the Project
• A brief description of the methodologies applied.
• The Main Body of the project:
  • View and study the CE / PLM Lecture and Software Demo Videos (DVD Labels 1, and 2a to 2d)
  • DVD Label 1: Show me that you have seen and understood these videos, by designing your own 3 questions for each video-module in DVD Label 1 (there are 14 video lectures, or modules in this DVD video, therefore you should create and answer a total of 14 x 3 = 42 questions). These videos are important for you to understand the basic CE principles, as well as help you in developing your plans for a new product innovation and introduction process. They also give you a perspective the way the subject has evolved and matured during the past 20 plus years. Very important!
  • DVD Labels 2a, 2b, 2c, and 2d: Industrial Case-1 (Answer the following questions: What is PLM? What is digital design & manufacture and why is this such a huge opportunity? What are the key PLM methods and technologies illustrated? How is digital design integrated with digital manufacturing in Delmia PLM? What is frontloading, and why is it critical to understand this process? Furthermore, design your own 4 good PLM / Digital Design & Manufacturing - focused questions for EACH DVD Label, meaning for 2a, 2b, 2c, and 2d, and answer them.)
  • DVD Label 3 Industrial Case-2 (This video explains CAD-to-CAD conversion challenges in a PLM environment. Try to answer the following question: How would you, as an engineering manager, resolve transition issues from one CAD / CAM platform to a modern PLM solution? Again, design further 4 good PLM / innovative enterprise - focused questions and answer them)...
  • Each answer should be 3-5 sentences long, but it's really up to you if you want to write more...and even add figures, photos, etc. You are free to explore.
• Summary (i.e. what has been achieved)
• Further work needed / proposed
• References and Bibliography (including the CDs, Internet as a main source of information)
• Appendix (- if necessary)

Typical Mistakes: Why am I loosing grade points in this assignment?

• The assignment's administrative section is missing, and/or is incomplete...
• The above outline is NOT followed
• Only a few videos are discussed ... several questions and answeres are missing... the questions created are not relevant, miss the focus...
• The answers are copied from each other; Sorry, you must innovate and create your OWN questions and answers.

Classes 5 and 6

QFD (Quality Function Deployment); Component-oriented Requirements Analysis is discussed with 3D Virtual Reality examples as an OO Concurrent Engineering / PLM methodology. Note, that we are dealing with the "Product Planning Stage QFD diagram/ matrix. i.e. the very first one.

Student Activities:

1. Carry on reading the book offered in the eLearning Pack.
2. Based on CORA: The CORA eBook (inside your printed text, one of the 3D eBooks in the DVD) educates a requirements analysis method and offers examples and solutions, as well as active code-tools for you to execute (in the form of MS Excel templates). You should understand this and based on the MS-Excel Template, develop your own Requirements Analysis solution for the product you are developing, with the 4 collaborative companies. As outlined in Assignment 0). The example given is a detailed study. Try to fully understand it because it is very important.
3. Study the QFD / Requirements Analysis method and the 3D objects. Consider the requirements analysis aspects when designing your new product.

Class 7

QFD (Quality Function Deployment) / Requirements analysis 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 / CORA (Quality Function Deployment; Component Oriented Requirements / Needs Analysis). In terms of assignment development method, please follow the CORA CD-ROM in your Learning Pack. (Relevant eLearning Pack Resource: Requirements analysis CD-ROM inside the CE book, as described above)

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 in the 3D eBook. Therefore feel free to incorporate digital images, text and even video clips or 3D VR objects provided into your assignment; nevertheless never forget to credit the source of such objects in the bibliography.

Project/ Assignment No. 2: QFD1 /CORA (Quality Function Deployment; Component Oriented Requirements / Needs Analysis) (20%)

• In terms of assignment documentation method, please follow the Appendix of the CORA 3D eBook in your Learning Pack.
• Title, Author (Name, Class, Date, your eLearning Pack serial number, and the 4 collab. companies you have ( a MUST!)
• Statement on who has done the work EACH individual, and this is true for all assignments, must submit an assignment by himself/ herself!
• Contents
• Introduction and Objectives of the Project
• A brief description of the methodologies applied.
• The Main Body of the project:
  • Develop your own CORA product requirements model using the CORA Excel Template.
  • Show your main requirements, and solution processes in this spreadsheet, that you have to customize, based on the CORA Template spreadsheet.
  • In this assignment, also use our Beta ver. Ranky-Taguchi calculator (CD Label 4) for designing an experiment for a given case (samples are in the CD). Read the Word file first, then study the spreadsheet examples, then study the CORA requirements analysis method, and finally calculate at least one of the parameters you need in the CORA spreadsheet using the Ranky-Taguchi calculator. Look for bugs! If you find one I'll give you extra 10% for the entire course! Also, note, that Fanny is French, therefore the English writeup needs more work... it is beta, but will be very good soon...The maths is already very good.
  • When you finish your CORA analysis, make sure you explain the results: What are your decisions based on the CORA analysis, and why? Show me, that you understand what and why... based on teh CORA analysis.
  • Also explain to me how the design specification gained from CORA integrates with the manufacturing plans. (This product and process / manufacturing / assembly process integration is crucial to achieve full PLM!)
  • Also show how your (real, or made up) company can collaborate in designing new hardware/ software / service with the collaborative companies given you in your eLearning Pack (there are 4 companies you have to collaborate with; explain HOW you are planning to do this together with THEM. YOU MUST WORK WITH THEM; sorry; the boss says so...).
• Summary (i.e. what has been achieved)
• Further work needed / proposed
• References and Bibliography (including the CDs, Internet as a main source of information)
• Appendix (if necessary)
  

Typical Mistakes: Why am I loosing grade points in this assignment?

• The assignment's administrative section is missing, and/or incomplete...
• The above outline is NOT followed
• The models / solutions are copied from the samples offered; Sorry, you must innovate and create your OWN designs, and models.
• The analysis of the results is thin, or missing.
• The collaborative companies are not included properly. Sorry, you MUST collaborate!
• The CORA model is incomplete, or inaccurate. Decisions are not explained.
• The Ranky-Taguchi DOE calculator is not being used.

Class 8

FMEA: The Failure Mode and Effect Analysis, or Process Failure Risk 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.

Relevant eLearning Pack Resource: Study the DFRA CD Case Study! Note, that the DFRA CD-ROM is focusing on using the FMEA method for disassembly process failure risk analysis. This CD educates a the method and offers examples and solutions, as well as active code-tools for you to execute (in the form of MS Excel templates). 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.

Class 9

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. (Part 1).

Submit by the End of This Week! Assignment No. 3: Process Failure Mode and Effects / Failure Risk Analysis in the CE Context

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.

Student Activities and relevant eLearning Pack Resources

1. Carry on reading the book offered in the eLearning Pack.
2. The DFRA CD takes you through the entire process. The printed textbook has the eBook in the DVD inside the text.
3. 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?

Please keep this in mind: 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 assignments; nevertheless never forget to credit the source of such objects in the bibliography.

Project/ Assignment No. 3: Process Failure Mode and Effects / Failure Risk Analysis in the CE Context (20%)

• In terms of assignment documentation method, please follow the Appendix of the DFRA CD-ROM in your Learning Pack.
• Title, Author (Name, Class, Date, your eLearning Pack serial number, and the 4 collab. companies you have ( a MUST!)
• Statement on who has done the work EACH individual, and this is true for all assignments, must submit an assignment by himself/ herself!
• Contents
• Introduction and Objectives of the Project
• A brief description of the methodologies applied.
• The Main Body of the project:
  • Develop your FMEA/ DFRA model using the 3D eBook Excel Template, for the product that you are developing, in a collaborative fashion with your eLearning Pack companies. (This is the third eBook inside your DVD, in the printed text you get with the eLearning Pack.)
  • Show your main process failure modes, and solution processes in this spreadsheet, that you have to customize, based on the DFRA Template spreadsheet.
  • In this assignment, also use our Beta ver. Ranky-Weibull calculator (also in the CD: Label 4) for considering the reliability analysis for a given case (samples in the CD). Read the Word file first, then study the spreadsheet examples, then study the DFRA risk analysis method, and finally try to calculate reliability rel;ated risk with the Ranky-Weibull spreadsheet, and then integrate your findings with the rule-based approach in the DFRA spreadsheet. Interesting research task; have fun! The rule-based method is great, but if we can have data we can calculate with the Weibull maths. Show how this could be done using our templates. This is the new research in this exercise. Also, look for bugs in the Ranky-Weibull spreadshheet! If you find one I'll give you extra 10% for the entire course! Also, note, that Fanny is French, therefore the English writeup needs more work... it is beta, but will be very good soon... The maths is good though.
  • Also, show how your (real or made up) company can collaborate with the companies given you in your Learning Pack (there are 4 companies you have to collaborate with; to avoid process failures. Explain HOW you are planning to do this together with THEM. YOU MUST WORK WITH THEM; sorry; the boss says so...).
  • Make sure, that in all cases you explain the resuts clearly. I want to see, that you understand what you should be doing with the FMEA / DFRA spreadsheet results you just created. This is a core engineering management aspect of this assignment.
• Summary (i.e. what has been achieved)
• Further work needed/proposed
• References and Bibliography (including the CDs, Internet as a main source of information)
• Appendix (if necessary)
  

Typical Mistakes: Why am I loosing grade points in this assignment?

• The assignment's administrative section is missing, and/or incomplete...
• The above outline is NOT followed
• The models / solutions are copied from the samples offered; Sorry, you must innovate and create your OWN designs, and models.
• The analysis of the results is thin, or missing.
• The collaborative companies are not included properly. Sorry, you MUST collaborate!
• The DFRA model is incomplete, and/or inaccurate.
• The RAnky-Weibull method / calculator is not used.

Class 10

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. Rapid prototyping methods and solutions (Part 2).

Based on the Rapid Prototyping CD-ROM (inside the textbook, in the DVD): Focus on the engineering related challenges/ questions in this CD. Try to answer 10 selected questions of your choice! Incorporate these answers into the Assignment below!

Class 11

Design for Demanufacturing, disassembly, Virtual Product Disassembly over the web, and other methods discussed with 3D Virtual Reality examples and classroom exercises. Rapid prototyping methods and solutions. Networked Concurrent Engineering systems in digital collaborative factories. Discussion on network modeling methods and tools. PLM (Product Lifecycle Management), NPI & I (New Product Innovation and Introduction).

Student Activities:

1. Carry on reading the book offered in the eLearning Pack.
2. Based on the Rapid Prototyping eBook: Focus on the engineering related challenges/ questions in this eBook.
3. Try to answer 10 selected questions of your choice! Incorporate these answers into the Assignment below!

Submit by the End of This Week! Assignment No. 4: Rapid Prototyping Study (20%)

The students' 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.4: Rapid Prototyping Study

• In terms of assignment documentation method, please follow the Appendix of the Rapid Proto CD-ROM in your Learning Pack.
• Title, Author (Name, Class, Date, your eLearning Pack serial number, and the 4 collab. companies you have ( a MUST!)
• Statement on who has done the work EACH individual, and this is true for all assignments, must submit an assignment by himself/ herself!
• Contents
• Introduction and Objectives of the Project
• A brief description of the methodologies applied.
• The Main Body of the project:
  • Develop/ select/ identify your own company’s Rapid Prototyping methods / model/ strategy using the list of methods offered in the Rapid Proto. 3D multimedia eBook in your eLearning Pack in the textbook DVD,
  • as well as others you can find over the web, for the product that you are developing, in a collaborative fashion with the 4 companies you have to work with...
  • Answer any selected 10 questions in the eBook, by writing approximately 4-6 sentences (whatever you feel appropriate) on each with some optional sketches if necessary.
  • Furthermore, research OTHER rapid proto. methods on the web. Explain the methods, principles, and main application areas in your assignment. (Suggest you look up: http://www.rapidprototyping.fraunhofer.de/frames.shtml.en)
  • Also, show how your (real or made up) company can collaborate in rapid prototyping the new hardware/ software you are designing in a CE / PLM fashion, with the companies given you in your eLearning Pack (there are 4 companies you have to collaborate with; explain HOW you are planning to do this together with THEM. YOU MUST WORK WITH THEM; sorry; the boss says so...).
• Summary (i.e. what has been achieved)
• Further work needed/proposed
• References and Bibliography (including the CDs, Internet as a main source of information)
• Appendix ( if necessary)
  

Typical Mistakes: Why am I loosing grade points in this assignment?

• The assignment's administrative section is missing, and/or incomplete...
• The above outline is NOT followed
• The models / solutions are copied from the samples offered; Sorry, you must innovate and create your OWN designs, and models.
• The collaborative companies are not included properly. Sorry, you MUST collaborate!
• The Rapid Proto model /strategy is incomplete. Did not address Design For Manufacturing, Quality, Assembly, KANRI, KAISEN, MUDA, MURA, MURI, POKA-YOKE, the role of Quality Circles, Design for Demanufacturing, disassembly, Virtual Product Disassembly processes / methods.

Class 12 and 13 (Don't worry, it's almost over...)

Concurrent Engineering / PLM 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.

Student Activities:

1. Carry on reading the book offered in the eLearning Pack.
2. Based on the Rapid Proto eBook: study collaborative teamwork opportunities. (This section links from the documentation methods chapter and has a series of important principles, that you can work with).
3. Search for New Product Innovation and Introduction (NPI & I) methods, tools and technologies over the Internet. Try to collect at least 10 URLs with a short explanation of the method they cover.

Class 14 and 15 (Note, that Classes 14 and 15 are kept for Assignment related project improvements)

Submit This Week! Assignment No. 5: Concurrent Engineering Product Design Assessment and Improvements: New Product Innovation & Introduction (NPI & I) Challenges Part 1: Innovative Toy PLM Design (20% max.) and Part 2: PLM / Digital Design & Digital Manufacturing Transition Plan, Marketing Plan (Press Release of your new product/ process/ service) (20% max.)

Documentation Structure for Assignment #5

1. Author (Name, Class, Date, your eLearning Pack serial number, and the 4 collab. companies you have ( a MUST!)
2. Statement on who has done the work.
3. Contents: List the main topics in this Assignment
4. Part 1: Innovative Toy PLM Design: The Main Body of the assignment: Now that you have understood our approach, focus on designing a newtoy, or cell phone (perhaps based on an old design that everybody understands well). Discuss the product/process innovation and introduction methods and process you would suggest your company to follow, based on what we have learned, based on your projects in this course, and the collaborative companies in your eLearning Pack. You can use any resources, including what we have learned, the library, the web, your company, anything legal...
5. Search for New Product Innovation and Introduction (NPI & I) methods, tools and technologies over the Internet. Try to collect at least 10 URLs with a short explanation of the method they cover.
6. Document your thoughts, methods, models, strategies and technologies that you plan to use in your future work. This essay should cover the above with a CORA requirements model for the new toy design, or cell phone, a design-oriented Failure Risk Analysis model for the new toy design, or cell phone and some explanations on the rapid proto. method/technology one should choose to prototype it. Include all aspects that you can address, i.e. hardware, industrial design, software, service and networking, functionalities, etc. Offer text explanations, plus figures, images, and digital media, as necessary to present your new cellphone design to a (virtual board of directors, i.e. the class and myself, over the web) for venture capital support (sorry, again all on a virtual basis only...).
7. Further work needed / proposed: What other methods could be integrated and HOW? How could you make your new product design to be that of a successful product in the marketplace? (We want to see you how you can innovate, and succeed using the learned and other methods!
8. Part 2: PLM / Digital Design & Digital Manufacturing Transition Plan for a company of your choice: The Main Body of the assignment: Now that you understand CE, PLM / Digital Design & Manufacturing, convert your company into a PLM Consulting Company, that specializes in turning traditional engineering businesses into modern, PLM/ Digital Design & Manufacturing companies. Create a true engineering management solution, covering the following:
   1. A convincing marketing plan for the CEO / CTO that they should move into PLM / Digital Design & Manufacturing. Keep in mind, that many of them will raise the typical arguments, until it is too late not to go under: Our current systems are OK, no need to change... PLM is far above our budgets... We are already doing this, no need to change... We cannot change our CAD systems because all the files are in a different format and we'll loose everything we have designed during the past 10 years... Nobody wants to change our systems... Takes ages to learn a new PLM system, we haven't got the time and money to do this... We are not operating on a global basis, we don't need it... and others. You should advocate the innovation opportunities using a library of reusable objects. Develop your arguments in this direction... This is key for all of us to survive. (One of Toyota's key secret is that they create well designed and tested platforms populated with reusable objects / modules. For each new release they carefully and gradually adjust these reusable objects and change them as the market demands this change. They also test everything in the digital domain first, and develop everything in integration with manufacturing, assembly, quality control, maintenance, etc. in mind... In comparison, the traditional product design company would start from scratch with everything for each product release. As a result, whilst they release on new product at high cost and with mistakes, Toyota will release 3 or more with well tested reusable objects... Now you know!)
   2. A transition strategy and process plan (use CIMpgr). You can assume, that the company already uses CAD / CAM, but most of it is a mix of 2D and 3D tools, and they are not integrated into a PLM level we saw in the DVDs in this course. (This plan should also include a PLM education plan: How would you educate PLM to the average small, medium and large size businesses?)
   3. Create an implementation and test plan
   4. Design a ROI plan (a simple plan will do at tghis stage) - make up all missing data.
9. References and Bibliography (Including books, articles, the Internet as a source of information, CD-ROMs and the CD-ROM serial numbers you have used
10. Appendix (if necessary).
11. We need your FULL documentation electronically (preferred on the web as a URL, linking to your web-friendly files)

11.55 pm, Saturday, May 5, 2007: ABSOLUTELY THE LAST DAY TO SUBMIT any new assignments, or reworked assignments! All submissions MUST be electronic. Please email me the final URL of your course assignment webpage, with the last versions of all assignments in it.

Schedule and due dates: As above. The total course duration is the equivalent of 15 weeks of study. Students will be required to complete each assignment. Assignments totaling 120% max. Grade "A" for this class requires min. 92% total.

Feedback to the Anonymous Total Quality Feedback Form: IE655 (January 21, 2003)

Please rate the following topics planned to be covered in this class by rating each topic between 0 (not important / poor) and 10 (extremely important / excellent!) on the right hand side of the sheet please!

This feedback form will help your instructor to dynamically adjust the breath and the depth of the topics to be covered in this semester in this class to maximize your level of quality satisfaction.

Topics (as per the web-based syllabus) Your rating (0 -> 10)

Web-based syllabus (Rated: Very High)

eLearning Pack (Most students haven't seen it yet)

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 (Rated: Very High).

Object oriented (OO) process and enterprise models are introduced (Rated: High).

Systems and integrated processes are explained using traditional as well as new, OO methods (Rated: High)

Engineering management focus on how to find and reduce waste; how to support integrated product / process design concepts and models. (Rated: Very High)

Concurrent Engineering Methods, Tools and Technologies (Rated: Very High)

Process modeling the digital enterprise (Rated: Very High), with the exception of one: rated very low (2))

Focus on integrating design and manufacturing processes for the purpose of cutting waste, and improving quality (Rated: Very High)

Process modeling methods and examples (Rated: Very High)

Object Oriented Concurrent Engineering Information System Models (CIMpgr, Object Oriented Process Modeling is explained and discussed through exercises and examples) (Rated: Very High, with the exception of one, rated low (3))

QFD (Quality Function Deployment) (Rated: High)

Requirements Analysis is discussed with 3D Virtual Reality examples as an OO Concurrent Engineering methodology (Rated: Very High)

FMEA: The Failure Mode and Effect Analysis, or Process Failure Risk Analysis methodology and its use in CE (Rated: Very High, two rated it Medium)

Interactive FMEA modeling / Disassembly Failure Risk Analysis modeling with the 3D Virtual Reality examples on the DFRA CD-ROM (Rated: Very High)

Design For Manufacturing, Quality, Assembly (Rated: High)

KANRI, KAISEN, MUDA, MURA, MURI, POKA-YOKE (Rated: High, some did not know what this meant, so we are going to discuss it in detail)

The role of Quality Circles, and other methods discussed with 3D Virtual Reality examples and classroom exercises (Rated: High)

Rapid prototyping methods and solutions (Rated: most rated it Very High, nevertheless two rated it low (2-3))

Concurrent Engineering Team management methods and issues (Rated: Very High)

The TOPS method (The Ford Motor Company) (Rated: High, some did not know what this meant)

Virtual teaming methods over the Internet (Rated: High)

A 3D Virtual Reality web-based method and code is discussed in detail (Rated: most High, nevertheless two rated it Low (3))

Design For Environment and related Concurrent Engineering and CE Management issues, the way you see them related to the subject area of Hybrid cars (Rated: High)

Design of Experiments (DOE) Application Example, of YOUR choice, with the documentation and the calculations explained (Rated: High)

Industrial and R&D Case studies for every topic (as listed above) (Rated: Very High)

Any other topic you would like to cover? Please explain: (Received 4 requests)

1. JIT (just-in-time) manufacturing: note, that we'll deal with this briefly, nevertheless the IE673 TQM course deals with this in detail;

2. Information management in product/ process integration (we are going to deal with this in detail, see above).

3. The lean manufacturing approach: note, that this is similar to (1) above, nevertheless we'll deal with this briefly.

4. Using simulation tools/ products to determine product effectiveness; we are going to deal with this in detail, nevertheless due to the depth of the simulation opportunities we won't be able to exhaust the topic in this course.

It is over! Congratulations! You can now analyze and improve many products and services!

PLEASE VIRUS CHECK EVERY SUBMITTED FILE!

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!