IMPORTANT General Notes

1. In this section we'll post notes that effect all students. This will save us all time. Please read and collaborate. Please read this new syllabus carefully. Having read and understood it, if you want to please email your instructor the following (you can copy paste the list below into your email for consistency):
   1. • Your full name (as known to NJIT; not your nick name), the
      • Your major interest / direction in your professional life (in a few words). This helps me to help you.
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).

As always,

Happy Learning for REAL,

Professor Paul G Ranky, PhD

1. Also, if you are asking something, that is clearly described in the syllabus, I will probably not have the time to act as your computer and read it for you...
2. Naturally my email at NJIT can fail too, as it has in the past. In this case either wait until NJIT resolves this, or call if urgent (you have my home telephone number above, in case of an emergency).
3. Last year's statistics shows that over 80 percent of the questions asked by students about this course were actually answered in this combined Welcome Note/ Course Syllabus... therefore PLEASE READ it ... it saves time for all of us, most importantly for you!
4. Due to the fact that I teach and supervise typically over 120 graduate students every semester, I cannot confirm the receipt of your homework assignments, but when you get my comments and the grade you'll see that I am working on your assignments too. It is important that you prepare them as well as you can, on time. PLEASE note, that I will only tolerate lateness if there is a professional reason for it.
5. About improving and resubmitting assignments: Please note, that each assignment must be submitted on time. There is only one resubmission option and that is within the framework of the last assignment, when you have to submit all your assignments again (see later). Within the last assignment, the max. grade is only a portion of what you would have received for the assignment if you had completed it on time at high quality in the first place. So again: watch the resubmssion issue carefully... you MUST complete quality assignments ON time!
6. PLEASE set up your own web page including your photo in the webpage, use NJIT's FREE web server, or your company's, or your own, or other solutions that work... it is your choice what software you use, which service provider, etc... PLEASE submit ALL your assignments electronically. Since I deal with typically over 1000 assignments every semester ALL YOUR ASSIGNMENTS MUST BE submitted electronically. If you do this over the web, it becomes very easy after Assignment 0... you may email me assignment 0 as an attached Word file, nevertheless you should put it onto your web site as soon as you have learned how to create a website. (I'll teach you how to design a webpage in the life class.)
7. PLEASE do NOT use MS-Publisher as a web authoring tool, since according to the last 6 semester's experience it has linking problems even within an entirely MS 'industry standard' (or non-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!
8. Please make sure that your URL works before you send me an email with a full length 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, and then copy-paste the requirements from this syllabus and then add every assignment to this URL as you develop them. This way you won't miss any aspect of any assignment. Also, this will be an extremely valuable knowledge documentation method to learn and resource when you apply for a job! If you don't know how to set up a webpage I will help you during the first week of classes. Please let me know if you need help! (If you are registered as a DL student you can still join my live class for this session in particular, or come and see me.)
9. When you are done, you trigger my grading process by sending me an email with your URL in it.
10. ESCAPE route: every semester about 2-3% of my students decide not to develop a web page... this is a poor decision on their behalf... 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 MS 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...
11. As you post a new assignment PLEASE email me about this with the proper link (the full URL in the email, like this http//www.thisismywebpage.com, so that I can just click on it and I am at your webpage). Please do not put any passwords on your web site. Passwords are not safe anyway and it makes my life very difficult...
12. In your emails, please use the same name you are known to NJIT at the time of registration. Often I see long names with nick names in emails, that are not on my roster, therefore takes me a long time to find you... and the more time I have to waste on stupid searches like this, the less time I have to teach you valuable things... so please do not use your nick name in your emails!
13. We plan to use the Highlander email-to-class system offered by NJIT, therefore pls. READ the email address you have offered to NJIT, ELSE I CANNOT BE IN TOUCH WITH YOU BY EMAIL; since this is the ONLY email my NJIT system knows about you (even if you have 6 others... hope all challenges are clear...)
14. The NJIT Honor Code will be upheld, and any violations will be brought to the immediate attention of the Dean of Students. Students will be made aware of any modifications or deviations from the syllabus throughout the course of the semester. 
15. These are the steps my students suggested in the past to follow when uploading webpages to the NJIT server (Note: I use professional servers and professional software tools; I do not use the NJIT server, therefore if you need help in terms of VPN (Virtual Private Network) links, or how to download software from the NJIT website, or why your webpage does not work with the FTP (File Transfer PRotocol Program NJIT offers) PLEASE contact the NJIT computing helpdesk, NOT me. Also suggest, that you network with other students in the class, or via chatgroups (instant messaging systems); I will help in this as much as I can by emailing these important links to everybody during the first week of class, as soon as I get the class roster from NJIT's Registrar.

    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, lots of free 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 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!

16. One of my students offered this explanation on how to upload webpages to the NJIT server: (new version: October 27, 2005 state; might have changed...) Click to see it in .html

    Also, another student of mine suggests to use Netscape for free webpage design. This is the link: Netscape 7.2 is free for download for both PC and Mac at the following URL:

    http://browser.netscape.com/ns8/download/archive72x.jsp

    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. (Also, 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. Always include the full URL into the email, else it won't link directly).

    Also note, that besides the class discussions (live class), the eLearning pack eBooks have several examples on the architecture of simple and complex web-pages. All of these are in open source, please study them! (Note, that open-source does not mean that you can upload an entire eBook of mine, or video onto a server on the web. This would be a major copyright violation!!!! Try to stay out of legal trouble, USA lawyers are the best... PLEASE!)

17. The 21st Century Engineer must be a professional information searcher, information and NEW 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... You should be able to question, interrogate and take optimal decisions... 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

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 / Green PLM Product / Process Design Challenge in collaboration with the 4 Collaborative Companies in your eLearning Pack (You'll need my 'OK, to go-ahead' to proceed.) Please note, that as in previous semesters we will pecifically address eco-friendly, lean and Sustainable GREEN PLM design aspects in all of our system models and designs in this course. Note: deadlines are strict! Late submissions will not be accepted! Deadline: February 16, 2009
• Classes 3 and 4 Submit by the End of Week 4! Assignment No. 1: What is Concurrent Engineering (CE) and Green PLM (Product Lifecycle Management) and why is this subject important for our future? DVD video exercises (20% max.) Note: deadlines are strict! Late submissions will not be graded! Deadline: March 9, 2009
• 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.) Note: deadlines are strict! Late submissions will not be graded! Deadline: March 23, 2009
• 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.) Note: deadlines are strict! Late submissions will not be graded! Deadline: April 13, 2009
• Class 10
• Classes 11 and 12 Submit by the End of this Session! Assignment No. 4: Sustainable Green Design for Manufacturing / Assembly / Environment Methods and Technologies Study (20% max.) Note: deadlines are strict! Late submissions will not be graded! Deadline: April 27, 2009
• Class 13
• Class 14
• Class 15 Submit by the End of this Session! Assignment No. 5: Concurrent Engineering / Green PLM Product Design Assessment and Improvements: a product/process design of your choice, a green product design review process and marketing plan (Press Release of your new product/process/service), and optionally Video-conference with a class-mate over the Internet using free SKYPE (30% max.) Note: deadlines are strict! Late submissions will not be graded! Deadline: May 8, 2009

NJIT IE 655

Welcome to IE655: one of the most useful green 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. We'll also learn how to create Sustainable GREEN products within a Sustainable GREEN PLM process. Techniques utilized and discussed in detail include lean-six-sigma design systems analysis and integration principles, needs analysis, following QDF (Quality Function Deployment) - like methods and tools, product modeling, system modeling, process risk analysis following FMEA (Failure Mode and Effects Analysis) concepts and tools, Taguchi design of experiments methods and tools, Weibull reliability analysis methods and tools, collaboration and integration methods, rapid prototyping, digital design & digital manufacturing, design for manufacturing / assembly, design for the environment, eco-friendly designs, 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, sustainable green design and manufacture, and product 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) lean-six-sigma 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 and green PLM (Product Lifecycle Management) 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 reduce 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, Digital Design and Digital Manufacturing, Total Quality Management, Decision Analysis Methods 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 (New Product & Process Innovation & Introduction) 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 product, process and service design and manufacturing / assembly industries, as well as to IT/IS (Information Technology and Information Systems Engineering) and even to pure service environments (like running a hotel, or a bank, or a ski resort, or dive operation). 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 often 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, with this course, 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.
• How to collaborate on a design issue with a local and global team via email and video-conferencing, and the web.
• How to develop design reviews and discuss issues over the web in a global team.
• How to create ethical and plesent professional work environments in which positive creative thoughts and energies dominate... and
• 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/DVD-ROMs, and DVD / digital videos. It includes real-world research and industrial case studies documented using 2D and 3D interactive multimedia, 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 product 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 & Digital Manufacturing.

Why is this course needed?
There are many methods and solutions to innovate and develop new green and sustainable quality 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. CE and PLM also underlines the importance of integrated engineering.

As a US-based BMW senior engineer with a PhD degree in engineering stated at the SAE Automotive World Conference in Detroit (April 2007): 'BMW prefers to employ engineers who have both design as well as manufacturing experiences... We, at BMW, firmly believe, that one cannot design quality automobiles without having an integrated engineering approach...' (And of course, this integrated approach is what we communicate in this course as CE and PLM...)

The CE/PLM 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 and PLM focus 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! (See the interesting table offered below by Peter Rayson, TIC, University of Birmingham, UK.)

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

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In broader terms, the aims of CE, Green PLM, or integrated lean, or agile, or adaptive, 3D digital design and digital manufacturing are very clear: get rid of waste, reduce the number of costly changes, eliminate toxic materials and processes as you green your product and manufacturing / assemnbly, integrae product and process engineering better, focus on high quality at low cost, offer product data management and Green PLM within all the companies involved in the product creation and manufacturing processes, organize our knowledge in our minds, and help 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, in global supply chains, 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”.

As you can see from Steve Job's comment, Apple truly understands the importance of culture being part of any integrated product, process and/or service design... several other CEOs only look at cost and then outsource... this is because most CEOs are not engineers and they just don't understand the importance of systems integration and culture being part of all this... not just the short term revenue logic...

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. (In other words, software only is cool, but without an integrated approach with hardware, other software and a strong cultural base it just won't work... just look at the way industry giants have disappeared and the way they'll disappear in this decade...)

All of the above sounds really simple, nothing really new, and as you could say: 'OK, but where are the differential equations... this is easy...'; nevertheless it is not easy to actually deliver the goods... but no worries, we'll learn a lot of this in this class.

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

And then came the Sustainable GREEN PLM era... In a different industry, we can identify similar eager to develop new green 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...)

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

Now 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 Mechanical Engineering (ME), 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, Industrial Design 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, Sustainable GREEN PLM methods, tools and technologies, and management methods, for the purpose of greening and improving products and services, and to learn how to innovate in a cost effective and productive way.

To summarize, the methods taught in this course are relevant not just to innovative product 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.

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 sustainable green and lean project management, total quality, decision analysis, and new product/process/service creation approach. In other words, nothing wasted, all integrated for the same great goals!

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 current semester 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 eTextbook of the course on the DVD. Ranky: Concurrent / Simultaneous Engineering (Methods, Tools and Case Studies) with a Sustainable GREEN PLM focus, ISBN 1-872631-04-5. (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...) 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)
• Also on the same DVD: Industrial Case Videos (the latest and best on PLM); PLEASE NOTE, that most of these videos are encoded using the latest and best quality MPEG4 codec by Apple and an International Consortium of professional companies. They play very well on any PC or Mac, the quality is in most cases as good as a standard definition DVD, or better, BUT the filesize is about 1/5th of the standard DVD MPEG2 file sizes we are used to... this is a HUGE advantage. Therefore, as long as you have a DVD player in the computer, and Apple's cross platfrom QuickTime it will play. You might need to download the latest version of Apple's QT (ver. 7, or later) FREE from: http://www.apple.com and then click on 'Downloads' at the top... (It is a dynamic web page, therefore if you look it up from a PC it will offer the Win compatible download, and from a Mac the Mac version; nice!) At the time of writing the MS Media Player cannot play this modern format. Also as far as I know, most TV-linked, standalone (i.e. not PC/Mac integrated) DVD players still cannot play MPEG4 files... BUT, due to the huge file-size reduction we can have all our videos on only a few DVDs, not 8-10 as in previous semesters... easier for you. These are the full length Case Video file names:
  • AISIN-AutoComponents
  • CalifMotors-Vehicle
  • FordConceptCar
  • PLM-1
  • PLM-2
  • Ranky-Taguchi-Weibull; you can see the future today! Includes the Ranky-Taguchi Design of Experiments files (in Beta). You'll use this together with the CORA method, as explained in the textbook as well as on the Component Oriented Requirements Analysis eBook. 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! ... also includes the 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! You keep all above as a valuabe resource!

PLEASE note, that all above is for your personal educational non-profit use only, not to be put on the Internet or any servers, or make copies, else you might get into serious trouble with the USA copyright law... and as you know USA lawers are some of the best in teh world...

More 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. 900 MHz, with a 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 much 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. 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.

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. (You might recall my motto: Happy Learning for REAL... assignments sound like real-world assignments versus examinations; and exactly what they are...)

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) during office hrs at NJIT.

Class 1 Introduction and overview of the course as well as the subject: Concurrent / Simultaneous Engineering (meaning exactly the same) and green sustainable 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. Deadlines are strict!
2. Review your eLearning Pack companies. Who are they? What are they doing? How can they help you with your new green 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 3DeBook 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 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 with a Sustainable GREEN PLM focus, 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 an existing design, that should be a green product, or 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. Sustainable GREEN PLM methods and tools for frontloading the product development process.

Submit by (see date above): Assignment No. 0: Design your Own Concurrent Engineering, PLM, Digital Design and Digital Manufacturing System Design Challenge with the 4 Collaborative Companies in your eLearning Pack with a Sustainable GREEN PLM focus!

You can submit this assignment as an electronic document written in Word, or PDF, or even better in HTML and published on your own website. Note, that if you haven't got your web site up and running yet, at this stage I'll accept this document as an email attachement in Word. BUT, when you have your website working, I would like to ask you to post this as Assignment 0, with the rest of your assignments on the web site in HTML (not hyperlinked in Word! because HTML is Internet standard, MS Word is NOT...)

This work should be 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 Sustainable GREEN product/ process design'. Please address briefly all these issues using the following structure:

1. Your full name (as known to NJIT's Registrar, not nick names please) and
2. Optionally your photo
3. Your eLearning Pack ID (this is a MUST!):
4. Your virtual company name: this is your company, the 5th company... like ABC Incorporated...
5. The 4 collaborative companies, their names and briefly what they are dealing with. (These companies are represented in your eLearning Packs and every one of these learning packs is different...) You should also explain how you plan to collaborate with them as you develop your new design.
6. Now a bit more about your company (this is the 5th company): As you will see, although this is an educational experience, we'll play the game for real (within our virtual dream worlds...) because I would like you to become Chief Engineers and engineering management-focused CEOs helping to green the world... eventually... and many of you will... just work hard at it... it will happen! So, this is what I need from you, about 100-150 words on each topic as shown below:

• Your company's Strategic Plan - with a CE/PLM with a lean, green sustainable focus: This is a plan that will give direction to your company, unite all employees and allow them to make decisions in context and with priorities that are consistent with your, i.e. the CEO's (Chief Executive Officer and Chief Engineer's) own vision. Employees must be given this because many employees have limited ability for forethought and planning. However, this plan must also be a collaborative work to get as much perspective from your team and have them understand what is behind the decisions. 
• At this stage only an approximate Budget(s) - Think of a startup company and try to estimate how much cash and resources you need to take off. Think of a 1 to 3 year plan. A simple and estimated budget should usually be broken down by department to insure accountability and authority for managers. This allows them to get things done and have the resources they need to grow their departments as necessary. It also sets them up to have the respect of their people and prevents major cash flow "surprises".
• To Be Trecked Metrics - with a CE/PLM and Green focus: These are the metrics tracked over time in your company, that allow daily, weekly, quarterly and annual specific goals to be set and measured. Tracking, that has ratios (not just absolute numbers) are strongly recommended, but these are always specific to a particular company.
• Management By Objectives - with a CE/PLM and Green focus: Your company needs a set of specific milestones and goals for monthly, quarterly and annual objectives. Without these there is no way everyone in the organization is pulling in the same direction and therefore lots of time and money will be wasted. Most executives and managers should be able to generate these and also review them with the team as monthly staff meetings to avoid communications issues. Good managers spend 50% of their time improving the business, not working in the day-to-day details. This is what creates competitive advantage and a rising company value and multiple.
• Key Processes - with a Sustainable GREEN PLM/ CE focus: The key processes in your company must be agreed to as the business gets its value proposition and delivery down, especially when these processes are part of the core value and competitive advantage. These include your sales process, your R&D, your digital design and manufacture, PLM, etc. processes and your customer delivery process(es). These are often very ad hoc early on, but they must be more formalized as the business grows, as it's complexity increases and as customer legacy issues hinder forward progress. IMPORTANT here: Conformance to eco-standards, meaning: Does the product conform to national / international greenhouse emission standards? What is the carbon footpront of the product, process or service? How can this be reduced? Is this a sustainable lean and green product / process? You must convince me, I represent your venture capitalists / angels who will support your startup!

Note, that according to Bob Norton, CEO: ...if you have these five systems in place and operating well, in the REAL world, you are prepared to scale your business at 100%, 200% or even more rapid growth. Without these it is likely you will have many problems growing.  The hidden costs of this will make you uncompetitive and cost you market share, customers and first mover advantages. Bob also suggests, that there are these five things that need to be in place for a company to move into high growth mode without betting the company and without all kinds of problems arising...  These things come from experience and the best practices developed over a century of 'good' management. They are proven, not "management of the month club" fads that come and go. 
 
Would you want a newly graduated doctor to do brain surgery on you or your family? Not likely! This is because you recognize the difference between education and experience, between theory and real practice and wisdom. You recognize the difference between reading about flying and actually flying a plane! Who would try to fly a plane alone after just reading a few books on flying!?  So how come most CEOs who have not run a larger high growth business think they can do it alone and reinvent all the needed systems and best practices themselves on the fly!?  Well, most likely because we CEOs must have extreme confidence (often viewed as arrogance by others) to even try to start a company. We are risk takers and willing to tackle large problems with our intellect, however, we must get experience, guidance and input from others who have "been there and done that" to avoid many pitfalls that can kill a company, or stop its growth completely...

Most early-stage companies have the first major growth problems at a level of about 15-25 employees and between $1million and $2million in revenue. This is the zone in which it is critical to begin to transition from raw entrepreneurship to professional management practices. Many CEOs and founders have not had the high growth experience at this Stage 3 to Stage 4 development phase and inevitably major problems will occur. It is easy for the "wheels to fall off the wagon" as you accelerate the business. Small percentage growth of 10% to 30% can require significant changes as it becomes very significant absolute growth. Usually at this point the CEO can not keep track of everything and needs to depend more on the management team. This means you need systems and procedures that keep the owners and CEO comfortable, and also give management and others room to grow their responsibilities...

... and this is exactly what we'll be learning about in this course with a strong engineering management focus... Now back to reality...our course: Note, that just as in the real world, you can change the focus of your project(s) later as you develop them, 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...)

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 the 4 companies in your eLearning Pack!

Again, this is the way the rework of assignments works: you submit your assignment on deadline (or before) and within a few days I'll grade it and email you the grade with comments. Then you can start to improve the assignment based on my comments. After this do not resubmit it, only at the end of semester when all assignments are to be reworked and resubmitted anyway. Then I can reward you (hopefully) for all improvements you have made during the semester on all your assignments. The web page control is in YOUR hands, therefore you work on it when you can, as many times as you can. All I need is deadlines to be kept! Fair and mimics real world action.

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 high quality case study videos. Enjoy; you are seeing and experiencing the past and the future...

Submit by (see date above): Assignment No.1: Concurrent Engineering Video Lectures and 3DeBook reading / study (20%) (Relevant eLearning Pack Resource: work through the DVD videos and eBook chapters). Take notes as you watch the videos. You'll need these notes in some of the other assignments too!

1. In terms of assignment documentation method, please follow the Documentation section of the 3D eBook in your eLearning Pack.
2. Title, Author (Name, Class, Date, your eLearning Pack ID number, and the 4 collab. companies you have ( a MUST!)
3. 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!
4. Contents
5. Introduction and Objectives of the Project
6. A brief description of the methodologies applied.
7. The Main Body of the project:
   1. View and study the CE / PLM Lecture and Software Demo Videos (in the DVD):
      • These are the full length Case Video file names:
        • AISIN-AutoComponents
        • CalifMotors-Vehicle
        • FordConceptCar
        • PLM-1
        • PLM-2
   2. Show me, that you have seen and understood the a Sustainable GREEN CE/PLM focus in these videos, by answering your own 5 questions for each video. (Answer your own questions with about 3-4 sentences each.)
   3. Based on the 3DeBook in the DVD, answer the following questions:
      1. What is CE and PLM?
      2. What is the difference between CE and PLM?
      3. What is green sustainable PLM?
      4. What is digital design & manufacture and why is this such a huge opportunity?
      5. How is digital design integrated with digital manufacturing in Delmia PLM?
      6. What is frontloading, and why is it critical to understand this process?
      7. Read Chapters 1, 2 and 3 of the 3DeBook. Find 5 questions in EACH of these Chapters and answer them. Each answer should be min. 3-4 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.
8. Summary (i.e. what has been achieved)
9. Further work needed / proposed
10. References and Bibliography (including the CDs, Internet as a main source of information)
11. 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 3DeBook offered in the eLearning Pack.
2. Watch the videos again with a customer requirements analysis focus: What customer requirements / needs are these products / processes satisfy?
3. Based on CORA: The CORA chapter in the eBook 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.
4. 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 (see date above): 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 chapter in the 3DeBook)

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.

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

1. In terms of assignment documentation method, please follow the Appendix of the CORA 3D eBook in your Learning Pack.
2. Title, Author (Name, Class, Date, your eLearning Pack serial number, and the 4 collab. companies you have ( a MUST!)
3. Statement on who has done the work EACH individual, and this is true for all assignments, must submit an assignment by himself/ herself!
4. Contents
5. Introduction and Objectives of the Project
6. A brief description of the methodologies applied.
7. The Main Body of the project:
   1. Read Chapter Six in the 3D eBook: Review and explain in a few sentences each image what the the customer requirements were / could have been based on the images offered (image files: IMG_1122 to IMG_1174 section).
   2. Based on Chapters 7 and 8, develop your own CORA product requirements model using the CORA Excel Template. Focus on creating a sustainable green design!
   3. Show your main requirements, and solution processes in this spreadsheet, that you have to customize, based on the CORA Template spreadsheet.
   4. In this assignment, also use our Beta ver. Ranky-Taguchi calculator (in the same DVD in a separate directory) for designing an experiment for a given case. 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 still in beta, but will be very good soon...The maths is already very good.
   5. When you finish your CORA spreadsheet calculations, make sure you analyze and explain the results:
      1. What is your analysis of the calciulated results, and what are your decisions based on the CORA analysis, and why?
      2. Show me, that you understand what you should do and why... all based on the CORA spreadsheet.
      3. Also find the top three largest AIR numbers in the CORA matrix and explain what are you going to do with the findings? This analysis of the results is critical! I would like to see that you understand the results of CORA and then you can manage your design team, based on the results! Many students miss this, don't be one of those!
      4. 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 green PLM!)
   6. Also show how your (real, or made up, i.e. the 5th) company can collaborate in designing new hardware/ software / service with a Sustainable GREEN PLM focus with the collaborative companies. (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...).
8. Summary (i.e. what has been achieved)
9. Further work needed / proposed
10. References and Bibliography (including the CDs, Internet as a main source of information)
11. 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 CORA results is thin, or missing, or not explained. You must explain what you plan to do with teh CORA results and why.
• The sustainable green focus is 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 / Disassembly Process Failure Risk Analysis methodology and its use in CE.

You are developing this for a product / process, or service for your company with a CE/PLM focus! In order to complete this assignment you must read Chapter 9 in the 3DeBook.

Relevant eLearning Pack Resource: Study the DFRA Case Study! Note, that the DFRA method is focusing on using the FMEA method for disassembly process failure risk analysis. This eBook 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 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 (see date above): Assignment No. 3: Process Failure Mode and Effects / Failure Risk Analysis: Risk-based Design, 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 eBook / textbook offered in the eLearning Pack.
2. The videos illustrate several risky processes.
3. The DFRA chapter in the CE eBook takes you through the entire process.
4. 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: I am interested in seeing that you understand the methods... I 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 DVD-ROMs and in the book. Therefore feel free to incorporate digital images, text and even video clips or 3D VR objects provided 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%)

1. In terms of assignment documentation method, please follow the Appendix of the eBook in your Learning Pack.
2. Title, Author (Name, Class, Date, your eLearning Pack ID/serial number, and the 4 collab. companies you have ( a MUST!)
3. Statement on who has done the work EACH individual, and this is true for all assignments, must submit an assignment by himself/ herself!
4. Contents
5. Introduction and Objectives of the Project
6. A brief description of the methodologies applied.
7. The Main Body of the project:
   1. Develop your FMEA/ DFRA (the same) model using the 3D eBook Excel Template, for the product, that you are developing, in a collaborative fashion with your eLearning Pack companies.
   2. Show your main process failure modes, and solution processes in this spreadsheet, that you have to customize, based on the DFRA Template spreadsheet. Note: if a product / process fails it is not sustainable!
   3. Explain in detail what your engineering management decisions will be based on the calculated results in the PFRA spreadsheet. This is VERY important!
   4. In Chapter 4 in the CE 3DeBook, review image set IMG_1684 to IMG_1704 and describe potential failure modes. It is a product you probably have never seen, therefore this should be an interesting challenge! I am expecting you to write about 1 page on this analysis.
   5. In this assignment, we also use our Beta ver. Ranky-Weibull calculator (also in the DVD) 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.
   6. 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...).
   7. 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.
8. Summary (i.e. what has been achieved)
9. Further work needed/proposed
10. References and Bibliography (including the CDs, Internet as a main source of information)
11. 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 calculated results is thin, or missing.
• The collaborative companies are not included properly. Sorry, you MUST collaborate!
• The PFRA/DFRA model is incomplete, and/or inaccurate.
• The Ranky-Weibull method / calculator is not used.

Class 10

Design For Manufacturing, Design For Green Sustainable 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).

Focus on the engineering related challenges/ questions, but most importantly on lean, sustainable green design. 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 (see date above): Assignment No. 4: Sustainable Green Design for Manufacturing / Assembly / Environment Methods and Technologies 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: Sustainable Green Design for Manufacturing / Assembly / Environment Methods and Technologies Study

1. In terms of assignment documentation method, please follow the Appendix of the eBook in your Learning Pack.
2. Title, Author (Name, Class, Date, your eLearning Pack serial number, and the 4 collab. companies you have ( a MUST!)
3. Statement on who has done the work EACH individual, and this is true for all assignments, must submit an assignment by himself/ herself!
4. Contents
5. Introduction and Objectives of the Project
6. A brief description of the methodologies applied.
7. The Main Body of the project:
   1. Develop/ select/ identify your own company’s Sustainable Green Design for Manufacturing / Assembly / Environment Methods and Technologies methods / model/ strategy using the list of methods offered in the 3D multimedia eBook in your eLearning Pack,
   2. Also, incorporate other green design and green manufacturing methods and tools you can find on the web, for the product that you are developing, in a collaborative fashion with the 4 companies you have to work with...
   3. Answer any selected 10 questions in Chapter 3 of the eBook, by writing approximately 3-4 sentences on each with some optional sketches if necessary. Address Design For Green, Manufacturing, Quality, Assembly, KANRI, KAISEN, MUDA, MURA, MURI, POKA-YOKE, the role of Quality Circles, Design for Demanufacturing, disassembly, Virtual Product Disassembly processes / methods.
   4. Furthermore, research OTHER sustainable green product design, green PLM methods on the web. Explain the methods, principles, and main application areas in your assignment.
   5. Also, show how your (real or made up) company can collaborate globally in a CE / PLM environment, 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...).
8. Summary (i.e. what has been achieved)
9. Further work needed/proposed
10. References and Bibliography (including the CDs, Internet as a main source of information)
11. 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 green PLM model /strategy is incomplete. Did not address Design For Green, 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 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 Sustainable Green 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 by (see date above): Assignment No. 5: Concurrent Engineering Product Design Review / Assessment and Improvements: New Product Innovation & Introduction (NPI & I) Challenges Part 1: Innovative PLM Design (20% max.) and Part 2: PLM / Green and Sustainable 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: 10% of 30%: Innovative Green PLM Design: The Main Body of the assignment: Now that you have understood our green CE/PLM approach, focus on finding an existing non-sustainable green design and then changing that design to a new sustainable green product of your choice, like a new toy, automobile, machine, or... cell phone (perhaps based on an old design that everybody understands well). Please note, that copy-paste jobs from the Internet will not be accepted! You have to come up with novel ideas!
5. 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...
6. Search for New GREEN 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.
7. 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 a new product, such as a 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...).
8. 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!
9. Part 2: 10% of 30%: PLM / Digital Design & Digital Manufacturing and Sustainable Green 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 lean and sustainable green design 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... Green 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.
10. Part 3: Optionally (for extra 10% of 30%) conduct a Video Conferencing (VC) session using SKYPE, or whatever other software you wish to use (free over the web) VC with one of your classmates and discuss each others' designs. Try to create a collaborative sustainable green product design review team spirit and document your findings... This is what you should document professionally:
11. 1. 1. 1. The purpose of the video-conferencing session is to conduct a virtual product design review? What is a product design review? How did you prepare your files for this web-based VC product design review?
          2. What were the most important steps in your product design review process?
          3. What software did you use for VC and how? (Must include 3-4 screen prints of the VC session as a proof.)
          4. What did you discuss and achieve during the VC session? (Offer a script of your discussions in professional English, not in 'hej dude whatsup' language...)
          5. How do you like this video-conferencing approach for collaborative CE/PLM problem solving?
          6. What were the main challenges?
          7. What worked well, and what did not, and why?
          8. In comparison to a face-to-face visit, versus VC, what is the estimated carbon footprint saving to the environment? How did you calculate this result? (Hint: search the web, there are some really useful carbon footprint calculators for free!)
12. References and Bibliography (Including books, articles, the Internet as a source of information, DVD-ROMs and the serial numbers you have used
13. Appendix (if necessary).
14. We need your FULL documentation electronically (preferred on the web as a URL, linking to your web-friendly files) 11.59 pm, May 8, 2009 = ABSOLUTELY THE LAST DAY TO SUBMIT any assignments! All submissions MUST be electronic = by email / with a web URL in it. Schedule and due dates: As above. The total course duration is 15 weeks. Students will be required to complete each assignment. Assignments totaling 110% max. Grade "A" for this class requires min. 90% total. Note, that we don't have a Midterm or a Final exam, because of the integrated nature, the computational requirements, and the research contents of the customized assignments, BUT you must complete each assignment on time. I want to give you an 'A', BUT YOU must do the work at a high quality. Thank you for helping me to be able to help you! Your success is my success too!
15. One more time, the NJIT Grade Scale: