Knowledge based enterprisinjg strategy for lean product develoment

Brian Prasad

Knowledge-based Enterprising (KBE) Strategy for Lean Product

Development (LPD)

Biren (Brian) Prasad, Ph.D. President, Knowledge Solution,

Irvine, CA

http://www.KnowledgeSol.com/

Keynote Talk at

The 27th International Conference on

CAD/CAM, Robotics and Factories of the Future

Conference (CARS & FoOF 2014),

22-24 July 2014, London, UK

Brian Prasad http://www.KnowledgeSol.com/

Mission

Our mission is to provide unequaled value through superior quality, performance

technical innovation speed and responsiveness, cost

savings via lean product development & premier

customer service via knowledge-based

developments

to our customers.

Innovation

Vision

Continuous Improvement

Vision

Knowledge Solution - Company


Product Development

Process

Functional Requirements

Engineered Product

Content

Time $ Cost

A Typical Product Development– What it is?


A typical Product-development process

Value-added activity

Type I waste Partial value-added

Type II waste Non value-added

TRADITIONAL

Value-added & Creative efforts

Repetitive tasks

Re-do’s Reinventing solutions Repeating mistakes

CE

With KBE KBAD

Further reduction in development effort

Innovate Automate

Value activity

Reuse

Apply Best practices

Apply Analysis

Insert New Ideas

Creative Efforts

Reduction in development

effort

Eliminate Continuous Improvements

Minimize

With Continuous Improvement

Repetitive tasks Value-added activity

Minimize

Creative Efforts

KBE: Knowledge –Based Enterprising or Engineering KBAD: Knowledge-Based Application Development

Knowledge–based Enterprising (KBE) Strategy for Lean Product Development – What it is?


A typical design scenario

Expert Engineers

Expert Analysts

Expert Designers

Product Engineers

Product Analysts

Product Designers

Project Managers

Function Managers

Knowledge –based Enterprising (KBE) Strategy for LPD – What it is?


What’s wrong with this?

• Knowledge is fragmented

• Subject matter experts (SME) often scarce and busy

• Less uniformity and consistency

• Time-intensive, manpower dependent

• When people retire, information is lost

• Often design is done via trial and error— case-based reasoning

Knowledge –based Enterprising (KBE) Strategy for LPD – What it is?


Expert Engineers

Expert Analysts

Expert Designers

Product Engineers

Product Analysts

Product Designers

Project Managers

Function Managers

KBE Strategy for Lean Product Development: Knowledge-centric approach


Modular

Procedural

Tightly-coupled

open

Level of integration

co

ncu

rre

nt

se

ria

l

Process path

KBE Strategy for Lean Product Development: Enrichment of knowledge…

is a continuum


KBE Strategy for LPD: Let’s consider this situation

BalanceTube

LVDT

SecondaryPiston (SPiston)

CenterGland (CG)

EndGland (EG)

RodEnd (RE)

PrimaryPiston (PPiston)

RampWasher

CEBearing

CGRetainer

EGRetainer

EGNut

REBearing

Cylinder


Procedural Strategy: Serial, tightly-coupled KBE system

Tandem SPiston

Tandem CenterGland

Tandem PPiston

Tandem Cylinder

Tandem EndGland

Tandem EGRetainer

Tandem CGRetainer

Tandem RodEnd

Tandem EGNut

Tandem REBearing

Tandem CGBearing

Tandem RampWasher

Tandem BalanceTube

Tandem LVDT

… Table

Design Table

Specs Table

Material Table

Analysis Tools

Modular

Procedural


Drawbacks of procedural KBE Strategy for LPD

• Part and product specific

• Hard-coded interfaces

• Cumbersome to maintain

• Incompatible API’s

• External parameter linking issues

• Very sensitive to interface changes (parameters, rules, features)

• Expansions are complex and error prone

• Inflexible

Modular

Procedural

Procedural KBE Strategy- Drawbacks?


Product Assembly

Completed Assembly

Detail Parts

SmartPart

Modular KBE Strategy: Rule-based System

Control Structure

High Level Requirements

Detail Requirements

An assembly of parametric parts, where dependence of one part to another is controlled by a “control structure logic”—whose primary function is to link relationships and attributes throughout a product hierarchy resulting in a product assembly that is associative.

Modular

Procedural


Modular KBE Strategy for LPD: System Approach

PERFORMANCE SPECIFIED

product concept (initial)

materials / attributes / features / parameters

develop system concept

decompose systems into subsystems

decompose subsystems into

components

decompose components into

parts

design each part

design pairs of parts

design pair of parts into components

design pair of components into

subsystems

design pair of subsystems into

system

design system concept

product concept

(working)

PERFORMANCE VERIFIED

Level 5

Level 4

Level 3

Level 2

Level 1

Level 0

Modular

Procedural


Modular KBE Strategy for LPD

Product Lifecycle Management (PLM) Implementation


Result of Modular KBE Strategy for LPD: Open, Concurrent LPD System

Product Definition

Configurator

Product Solution Configurator

SmartPart Configurator

Modular

Procedural

Apply Intra-Part Relations

Apply System Specs

Build System

Solution

Apply Inter-

Component

Relations

Apply Assembly Constraints

Build Sub-system

Solution

Build Component

Solution

Instantiate Chosen

Component

Templates

Build chosen

Component

Templates

Build Assembly Constraints

Choose a Sub-System

Configuration

Choose a System

Configuration

Choose a Component

Configuration

Build Intra-Part Rules & Relations

Build System Specs

Build Inter-

Component

Relations


Merits of modular lean product development

• Product-Independent • Architecture

• Part-Independent • Concept

• Tool-Independent • Method

Modular

Procedural

Product Definition Configurator

Product Solution Configurator


Modular KBE Strategy for LPD?


A CATIA V5 implementation

• System Architecture • JustOne system model and common tree

structure

• Generative Rule Bodies • Rule bodies create more rules dynamically on

the tree; asleep until awaken • Retrieve templates; no generative geometry

• Internal Linking • Two generalized automation methods to

pass/exchange information intrapart and interpart

Modular KBE Strategy for LPD?


Modular KBE Strategy Implementation: Specs Definitions (Excel Inputs)


Parameters

TypePart

CATParts

TypePartSpecs

TypePartSizing

TypePartGeometry

CATProduct

OpenLocked

Restricted

Type: Tandem

Modular KBE Strategy Implementation: SmartParts Creation

Parameters

TandemPiston

CATProduct

OpenLocked

Restricted

CATParts

TandemPistonSpecs

TandemPistonSizing

TandemPistonGeometry

Parameters

TandemGland

CATProduct

OpenLocked

Restricted

CATParts

TandemGlandSpecs

TandemGlandSizing

TandemGlandGeometry


Modular KBE Strategy Implementation: Achieving a Product Solution


Modular KBE Strategy Implementation: Inter- & Intrapart communications


Build a Component

Templates

Apply Intra-Part Relations

Apply System Specs

Build Assembly Constraints

Choose a Sub-System

Configuration

Build System

Solution Choose a System

Configuration

Choose a Component

Configuration

Build Intra-Part Rules & Relations

Apply Inter-

Component

Relations

Apply Assembly Constraints

Build System Specs

Build Sub-system

Solution

Build Component

Solution

Build Inter-

Component

Relations

Instantiate Component

Templates


Aggregation

Product Solution Configurator Product Definition

Configurator

Modular KBE Strategy Implementation: Demo


Demo–Salient points

• Initialize parameters • SmartParts pulled and Rules added • Specs parameters & constraints passed from

“systems” to “subsystems”, to “components,” to “parts” during “decomposition” and vice versa during “aggregation”

• SmartParts were “instantiated” and constraints satisfied

• Solution is reconfigurable for changing spec requirements

Modular KBE Strategy Implementation


Modular KBE Strategy Implementation:

…directly from spec

• Good for early program stages (Quick evaluation of various “alternate designs” scenarios)

• Gets you 80% there and you can finish the rest (20%) in native CATIA mode

Engineered design…



• Good for early program stages (Quick evaluation of various “alternate designs” scenarios)

• Gets you 80% there and you can finish the rest (20%) in native CATIA mode


• Unbalanced tandem actuator with 4100 psi supply pressure and 9.49 inch stroke.




• Balanced simplex actuator with 3050 psi supply pressure and 3.89 inch stroke.




Key Benefits

• Knowledge resides in one system and reused widely across the enterprise

• Order of magnitude savings (1:10 ~ 1:100)

• Promotes collaboration & knowledge sharing

• Product independent architecture

• Experts now become knowledge-keepers

• Promotes innovations and creativity

• Good for preliminary studies & portfolio mgt

• Knowledge inside, Lean inside, standards inside, analysis inside, best practices inside

Modular KBE Strategy for Lean Product Development (LPD)


Keys to maximizing productivity gains …

• KBE has its own life. Think about integration and interfaces. They are big deal for KBE.

• Holistic view of product development process • Employ a modular, open, and concurrent

strategy for building KBE systems • Think engineering centric versus geometry-

centric; analysis driven, geometry is a by-product

• Follow a knowledge management framework for applying KBE



Questions?

Contact: Biren (Brian) Prasad, Ph.D.

[email protected] [email protected]

Tel: (714) 396 9424

Knowledge Solution A PLM-LPD Service Company

Irvine, CA


mailto:[email protected]

Knowledge based enterprisinjg strategy for lean product develoment

Technology

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