Product Architecture
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Product Architecture
Chapter 9EIN 6392, summer 2012
Product Design for Manufacturability and Automation
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Product Design and DevelopmentKarl T. Ulrich and Steven D. Eppinger2nd edition, Irwin McGraw-Hill, 2000.
Chapter Table of Contents 1. Introduction2. Development Processes and Organizations3. Product Planning4. Identifying Customer Needs5. Product Specifications6. Concept Generation7. Concept Selection8. Concept Testing9. Product Architecture10. Industrial Design11. Design for Manufacturing12. Prototyping13. Product Development Economics 14. Managing Projects
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Planning
Product Development Process
ConceptDevelopment
System-LevelDesign
DetailDesign
Testing andRefinement
ProductionRamp-Up
Product architecture is determined early in the development process.
Platform decision
Concept decision
Decomposition decision
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Outline Definition Modularity Steps for creating the architecture Related system level design issues
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Definition – Product Architecture
A scheme by which the functional elements of the product are arranged (or assigned) into physical building blocks (chunks) and by which the blocks interact.
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Product Architecture: DefinitionThe arrangement of functional elements into physical chunks which become the building blocks for the product or family of products.
Product
module
module
module
module
module
module
module
module
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Fundamental Decisions Integral vs. modular architecture? What type of modularity? How to assign functions to chunks? How to assign chunks to teams?
Which chunks to outsource?
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Practical Concerns Planning is essential to achieve the
desired variety and product change capability.
Coordination is difficult, particularly across teams, companies, or great distances.
Special attention must be paid to handle complex interactions between chunks (system engineering methods).
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Product Architecture: Conclusions Architecture choices define the sub-
systems and modules of the product platform or family.
Architecture determines: ease of production variety feasibility of customer modification system-level production costs
Key Concepts: modular vs. integral architecture clustering into chunks planning product families
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Considerations at product architecturing How will it affect the ability to offer
product variety? How will it affect the product cost? How will it affect the design lead
time? How will it affect the development
process management?
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Modular vs. integrated architecture
Modular Chunks implement one or a few functional elements in
their entirety (each functional element is implemented by exactly one physical chunks)
The interactions between chunks are well defined and are generally fundamental to the primary functions of the products.
Integrated Functional elements of the product are implemented
using more than one chunk A single chunk implements many functions. The interaction between chunks are ill defined and
may be incidental to the primary functions of the products.
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Factors affecting architecture modularity
Product changes Product variety Component standardization Product performance Manufacturability Product development management
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Factors affecting architecture modularity (product changes)
For modular architecture Allows to minimize the physical changes required to achieve a
functional changeReasons for product changes upgrades add-ons adaptation (adapt to different operation environments) wear (e.g., razors, tires, bearings) consumption (for example, toner cartridges, battery in cameras) flexibility in use (for users to reconfigure to exhibit different capabilities) re-use in creating subsequent products
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Factors affecting architecture modularity (product variety) The range of products (models)
concurrently available in the market Modular can vary without adding
tremendous complexity to the manufacturing system.
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Factors affecting architecture modularity
Component standardization Use the same components in multiple products Increase production volumes
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Factors affecting architecture modularity
Product performance (for integrated design) Allow optimizing the performance for an individual
integrated architecture. Allow function sharing
Implementing multiple functions using a single physical element.
Allow for redundancy to be eliminated through function sharing and geometric nesting
Thus could lower the manufacturing cost
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Factors affecting architecture modularity
Manufacturability DFM can be performed on the chunk-level but
not across several chunks. For example, minimize the total number of part
counters. Thus, it is more applicable to an integrated
design.
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Factors affecting architecture modularity
Product development management Better for modular architecture
Each modular chunk is assigned to an individual or a small group
Known and relatively limited functional interactions with other chunks.
Not as easy for integrated architecture Detailed designs will require close
coordination among different groups.
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Architecture Design Process create a schematic of the product cluster the elements of the schematic create a rough geometric layout identify the fundamental and incidental
interactions.
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Creating a product schematic Create a schematic diagram
representing the (physical or functional) elements of the product, using blocks, arrows, and other notations. Flow of forces or energy Flow of material Flow of signal or data
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Cluster the elements of the schematic
Factors for considering clustering Geometric integration and precision Function sharing Capability of vendors Similarity of design or production
technology Localization of design (or part) change Accommodating variety Enabling standardization Portability of the interfaces
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Creating a rough geometric layout A geometric system layout in
2D or 3D drawings, 2D or 3D graphics, or Physical models.
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Identify the fundamental and incidental interactions Fundamental interactions
Those which connect the building blocks, such as energy flows, material flows, and data flows.
Incidental interactions Those that arise because of geometric
arrangements of the building blocks, such as thermal expansion or heat dissipation.
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Differentiation Postponement (delayed differentiation) The timing of differentiation in the
supply chain Modular components vs. final assembly for
each model in the inventory. Two principles
1. Differentiating elements must be concentrated in one or a few chunks
2. The product and production process must be designed so that the differentiating chunks can be added to the product near the end of the supply chain.
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Platform planning Trade-off decision between
Differentiation plan Difference in product attributes from
customer’s viewpoint Commonality plan
The components which the product versions commonly share. Therefore, their physicals are the same across the products in the platform.
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Guidelines for managing platform trade-off Platform planning decision should be
informed by quantitative estimates of cost and revenue implications.
Iteration is beneficial. The nature of trade-off between
differentiation and commonality is not fixed. The product architecture dictates the nature of the trade-
off. The team may consider alternative architectures to
enhance both differentiation and commonality.
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Related system-level design issues A recursive process
Defining secondary systems Establishing the architecture of the chunks Creating detailed interface specifications
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Trailer Example:Integral Architecture
upper half
lower half
nose piece
cargo hangingstraps
spring slotcovers
wheels
protect cargofrom weather
connect to vehicle
minimizeair drag
supportcargo loads
suspendtrailer structure
transfer loadsto road
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Trailer Example:Modular Architecture
box
hitch
fairing
bed
springs
wheels
protect cargofrom weather
connect to vehicle
minimizeair drag
supportcargo loads
suspendtrailer structure
transfer loadsto road
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What is this?
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Nail Clippers?
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Modular Product Architectures
Chunks implement one or a few functions entirely. Interactions between chunks are well defined. Modular architecture has advantages in simplicity
and reusability for a product family or platform.
Swiss Army Knife Sony Walkman
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Platform Architecture of the Sony Walkman
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Integral Product Architectures Functional elements are implemented by multiple
chunks, or a chunk may implement many functions. Interactions between chunks are poorly defined. Integral architecture generally increases performance
and reduces costs for any specific product model.
High-Performance Wheels Compact Camera
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Choosing the Product Architecture
Architecture decisions relate to product planning and concept development decisions:
Product Change (copier toner, camera lenses)Product Variety (computers, automobiles) Standardization (motors, bearings, fasteners)Performance (racing bikes, fighter planes)Manufacturing Cost (disk drives, razors)Project Management (team capacity, skills)System Engineering (decomposition, integration)
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Ford Taurus Integrated Control Panel
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Modular or Integral Architecture?
Motorola StarTACCellular Phone
RollerbladeIn-Line Skates
FordExplorer
AppleiBook
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The concepts of integral and modular apply at several levels:
system sub-system component
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Product Architecture = Decomposition + Interactions
Interactions within chunks
Interactions across chunks
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Establishing the Architecture
To establish a modular architecture, Create a schematic of the product,
and Cluster the elements of the
schematic to achieve the types of product variety desired.
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Product Architecture Example:Hewlett-Packard DeskJet Printer
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DeskJet Printer Schematic
Flow of forces or energyFlow of materialFlow of signals or data
StoreOutput
StoreBlankPaper
EnclosePrinter
ProvideStructuralSupport
PrintCartridge
PositionCartridgeIn X-Axis
PositionPaper
In Y-Axis
SupplyDC
Power“Pick”Paper
ControlPrinter
CommandPrinter
Connectto
Host
CommunicatewithHost
DisplayStatus
AcceptUser
Inputs
Functionalor PhysicalElements
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Cluster Elements into Chunks
StoreOutput
StoreBlankPaper
EnclosePrinter
ProvideStructuralSupport
PrintCartridge
PositionCartridgeIn X-Axis
PositionPaper
In Y-Axis
SupplyDC
Power“Pick”Paper
ControlPrinter
CommandPrinter
Connectto
Host
CommunicatewithHost
DisplayStatus
AcceptUser
Inputs
Paper Tray PrintMechanism
Logic Board
Chassis
Enclosure
User Interface Board
Host DriverSoftware
Power Cordand “Brick”
Functionalor PhysicalElements
Chunks
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Geometric Layout
printmechanism
paper tray
user interface board
printcartridge
logicboard
chassis
chassis
paperroller
print cartridge
paper tray
enclosure
logic board
height
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Incidental Interactions
Enclosure
Paper Tray
Chassis
PrintMechanism
User InterfaceBoard
LogicBoard
Power Cordand “Brick”
Host DriverSoftware
Styling
Vibration
Thermal Distortion
Thermal Distortion
RF InterferenceRF
Shielding
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System Team AssignmentBased on Product Architecture
F G E D I A C B1 K1 J P N Q R B2 K2 O L M H S T U VCrankshaft F F l l l l l l l l l l l l
Flywheel G l G l l l lConnecting Rods E l E l l l l l l
Pistons D l l l D l l l l l l l l lLubrication I l l l l I l l l l l l l l l
Engine Block A l l l l l A l l l l l l l l l lCamshaft/Valve Train C l l l l C l l l l l l
Cylinder Heads B1 l l l l l B1 l l l l l lIntake Manifold K1 l l l l K1 l l l l l
Water Pump/Cooling J l l l l l l J l l l l l l l l l
Fuel System P l P l l l l l l l l l l
Air Cleaner N l N l l l l l lThrottle Body Q l l l Q l l l l l l l l l
EVAP R l l R l l l
Cylinder Heads B2 l l l B2 l l l l l l l lIntake Manifold K2 l l l l l l K2 l l l l l l l
A.I.R. O l l l l l l O l l l l l lExhaust L l l l l l l l l L l l l l l l
E.G.R. M l l l l l l l l M l l l l lAccessory Drive H l l l l l l l l l l l l l l l l H l l l l
Ignition S l l l l l l l l l l l l l l l l S l l lE.C.M. T l l l l l l l l l l l l l l l l l l T l l
Electrical System U l l l l l l l l l l l l l l l l l l l U lEngine Assembly V l l l l l l l l l l l l l l l l l l l l l l V
Frequency of PDT Interactionsl Daily l Weekly l Monthly
Team 1
Team 2
Team 3
Team 4
Integration Team
From “Innovation at the Speed of Information”, S. Eppinger, HBR, January 2001.
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Planning a Modular Product Line:Commonality Table
Chunks
Number of Types
Family Student SOHO (small office, home office)
Print cartridge 2 “Manet” Cartridge “Picasso” Cartridge “Picasso” Cartridge
Print Mechanism 2 "Aurora" Series Narrow "Aurora" series "Aurora" series
Paper tray 2 Front-in Front-out Front-in Front-out Tall Front-in Front-out
Logic board 2 “Next gen” board with parallel port
“Next gen” board “Next gen” board
Enclosure 3 Home style Youth style “Soft office” style
Driver software 5 Version A-PC Version A-Mac
Version B-PC Version B-Mac
Version C
Differentiation versus Commonality
Trade off product variety and production complexity
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Product Model Lifetime
From Sanderson and Uzumeri, The Innovation Imperative, Irwin 1997.
0 1 2 3 4 5Survival Time (years)
1.0
0.8
0.6
0.4
0.2
0
FractionSurviving Sony
AIWAToshibaPanasonic
Sony1.97 yr
Others1.18 yr
Average Life
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Types of Modularity
Swapping Modularity Sharing Modularity
Sectional Modularity Bus Modularity
Fabricate-to-Fit Modularity Mix Modularity
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Audio System Exercise:Where are the Chunks?
CassetteTuner Front Controls
Power Amplifier
CD Changer
Rear Controls
Cellular Phone
Cellular Antenna
Antenna Motor
AM/FM Antenna
Rear Headphones
LF Speaker
LR Speaker
RR Speaker
RF Speaker
Microphone
Display
104.1 FM