book

Designing Complex Products with Systems Engineering Processes and Techniques, 2nd Edition

Name: Designing Complex Products with Systems Engineering Processes and Techniques, 2nd Edition
Author: Vivek D. Bhise
ISBN: 9781000835793

by Vivek D. Bhise

February 2023

Intermediate to advanced

584 pages

17h 26m

English

CRC Press

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Cover Page
Half Title page
Title Page
Copyright Page
Contents
Preface for the First Edition
Preface for This Second Edition
Website Materials
Acknowledgments
Author

Part I Systems Engineering Concepts, Issues, and Methods in Product Design
1 Introduction to Products, Processes, and Product Development
Introduction and ObjectivesUnderstanding Products, Customers, Processes, and SystemsWhat Is a Product?Who Is the Customer?What Are Customer Needs?What Is a Process?Designing a Complex ProductDefinition of a SystemSystems, Subsystems, and ComponentsSystems Work with Other SystemsProduct Families and Component SharingProduct DevelopmentLife Cycle Stages of a ProductConcluding RemarksReferences
2 Systems Engineering and Other Disciplines in Product Design
IntroductionSystems Engineering FundamentalsWhat Is Systems Engineering?Managing a Complex ProductSystems Engineering Processes in Product DevelopmentSystems Engineering ProcessFive Loops in the Systems Engineering ProcessMajor Tasks in the Systems Engineering ProcessSubsystems and Components DevelopmentExample of Cascading a Requirement from the Product Level to a Component LevelIterative Nature of the Loops within the Systems Engineering ProcessIncremental and Iterative Development ApproachSystems Engineering “V” ModelNASA Description of the Systems Engineering ProcessManaging the Systems Engineering ProcessRelationship between Systems Engineering and Program ManagementRole of Systems EngineersIntegrating Engineering Specialties into the Systems Engineering ProcessRole of Computer-Assisted Technologies in Product DesignCAD and CAEModel-Based Systems EngineeringImportance of Systems EngineeringAdvantages and Disadvantages of the Systems Engineering ProcessSome Challenges in Complex Product DevelopmentConcluding RemarksReferences
3 Decision-Making and Risks in Product Programs
IntroductionProblem-Solving ApproachesDecision-MakingAlternatives, Outcomes, Payoffs, and RisksMaximum Expected Value PrincipleOther PrinciplesTechniques Used in Decision-MakingAnalytical Hierarchical MethodWeighted Total Score for Concept SelectionInformational Needs in Decision-MakingDecision-Making in Product DesignKey Decisions in Product Life CycleTrade-Offs during Design StagesRisks in Product Development and Product UsesDefinition of Risk and Types of Risks in Product DevelopmentTypes of Risks during Product UsesRisk AnalysisRisk MatrixRisk Priority Number and NomographsProblems in Risk MeasurementsImportance of Early Decisions during Product DevelopmentConcluding RemarksReferences
4 Product Attributes, Requirements, and Allocation of Functions
IntroductionAttributes and RequirementsWhat Is an Attribute?Importance of AttributesWhat Is a Requirement?Attribute RequirementsWhy “Specify” Requirements?How Are Requirements Developed?Characteristics of a Good RequirementTypes of RequirementsCustomer RequirementsFunctional RequirementsPerformance RequirementsInterface RequirementsReliability RequirementsEnvironmental RequirementsHuman Factors RequirementsSafety RequirementsSecurity RequirementsDesigned-to-Conform versus Manufactured-to-Conform RequirementsWhere Are Requirements Stored?Requirements Allocation and AnalysisRequirements AllocationRequirements AnalysisAttributes DevelopmentCascading Attribute Requirements to Lower LevelsDividing the Product into Manageable LevelsRelating Attribute Structure to SystemsAn Example: Attributes, System Decomposition, and Requirements for Vehicle Exterior Lighting SystemAn Example: Cascading of Vehicle Level Sub-attribute Requirements into Powertrain Subsystem RequirementsAn Example: Attributes, Requirements, and Trade-Offs in Suspension Systems of a Sports CarFactors Affecting RequirementsRole of Standards in Setting RequirementsTypes of StandardsAdvantages of StandardsDisadvantages of StandardsProblems with StandardsStandards Development ProcessConcluding RemarksReferences
5 Understanding and Managing Interfaces
IntroductionInterface Definition, Types, and RequirementsWhat Is an Interface?Types of InterfacesInterface RequirementsVisualizing InterfacesInterface DiagramInterface Matrix and N-Squared DiagramExamples of Interface Diagrams and Interface MatricesLaptop Computer InterfacesAutomotive Fuel System InterfacesIllustration of Use of Information Contained in Interface MatrixClustering and Sequencing of Matrix DataTeamwork in Interface ManagementEstablishment of Interface ControlConcluding RemarksReferences
6 Detailed Engineering Design during Product Development
IntroductionEngineering DesignSix Product ExamplesIllustration of Wind Turbine Design Using Systems Engineering “V” ModelLeft Side of the “V”—Design and EngineeringRight Side of the “V”—Verification, Manufacturing, and AssemblyRight Side of the Diagram—Operation and DisposalActivities in Engineering DesignConcluding RemarksReferences
7 Product Evaluation, Verification, and Validation
Objectives and IntroductionWhy Evaluate, Verify, and Validate?Testing, Verification, and ValidationDistinctions between Product Verification and Product ValidationOverview on Evaluation IssuesTypes of EvaluationsEvaluation Methods: An OverviewMethods of Data Collection and AnalysisObservation MethodsCommunication MethodsExperimentation MethodsObjective Measures and Data Analysis MethodsSubjective Methods and Data AnalysisRating on a ScaleAnalysis of 10-Point Ratings DataPaired Comparison-Based MethodsEvaluations during Product DevelopmentVerification Plan and TestsValidation Plan and TestsConcluding RemarksReferences
8 Program Planning and Management
IntroductionProgram versus Project ManagementProgram Management FunctionsDevelopment of Detailed Project PlansProject ManagementSteps in Project PlanningTools Used in Project PlanningGantt ChartCritical Path MethodProgram (or Project) Evaluation and Review TechniqueWork Breakdown StructureProject Management SoftwareOther ToolsSystems Engineering Management PlanContents of SEMPChecklist for Critical InformationRole of Systems EngineersValue of Systems Engineering Management PlanComplexity in Program ManagementTime ManagementCost ManagementChallenges in Program ManagementConcluding RemarksReferences
9 Costs and Benefits Considerations and Models
IntroductionTypes of CostsNonrecurring and Recurring CostsRevenues Buildup over Time as the Product Is SoldMake versus Buy DecisionsFixed versus Variable CostsQuality CostsManufacturing CostsSafety CostsProduct Termination CostsTotal Life Cycle CostsEffect of Time on CostsBenefits EstimationProject Financial PlanAn Example: Automotive Product Program Cash FlowEffect of Interest and/or InflationProduct Pricing ApproachesTraditional Costs-Plus ApproachMarket Price-Minus Profit ApproachSoftware ApplicationsTrade-Offs and RisksConcluding RemarksReferences
Part II Quality, Human Factors, Safety, and Sustainability Approaches
10 Quality Management and Six-Sigma Initiatives
IntroductionDefinition of QualityKey Concepts in Quality ManagementQuality Gurus and Their FindingsProduct Quality MeasurementsCustomer Satisfaction and the Kano Model of QualityQuality InitiativesTotal Quality ManagementISO 9000Malcolm Baldridge Award CriteriaSix-Sigma MethodologiesOverview of Tools Used in Quality ManagementConcluding RemarksReferences
11 Human Factors Engineering in Product Design
IntroductionHuman Factors EngineeringWhat Is It?Human Factors Engineering ApproachHuman Factors Research StudiesHuman Factors Engineer’s Responsibilities in Designing Complex ProductsImportance of Human Factors EngineeringCharacteristics of Ergonomically Designed ProductsWhy Apply Human Factors Engineering?Human Factors Engineering Is Not CommonsenseA Brief Overview of Human Characteristics and CapabilitiesPhysical CapabilitiesInformation Processing CapabilitiesOther Factors Affecting Human CapabilitiesPercentile ValuesHuman ErrorsDefinition of an ErrorTypes of Human ErrorsHuman InterfaceUser Performance MeasurementsTypes and Categories of User Performance MeasuresCharacteristics of Effective Performance MeasuresHuman Factors Methods: An OverviewConsiderations in the Applications of Human Factors GuidelinesConcluding RemarksReferences
12 Safety Engineering in Product Design
IntroductionBackground: Safety EngineeringDefinition of Safety EngineeringSafety ProblemsImportance and Need of Safety Engineering3Es of Safety Engineering and CountermeasuresMethods Used in Safety EngineeringHistoric BackgroundDefinition of an AccidentAccident Causation TheoriesSafety Performance MeasuresWhy Measure Safety Performance?Currently Used Accident MeasuresAccident-Based Incident RatesAdvantages and Disadvantages of Current Accident-Based MeasuresNon-accident MeasuresSafety Analysis MethodologiesTwo Possibilities: Accident versus HazardAccident Analysis MethodsHazard Analysis MethodsProduct Safety and LiabilityTerms and Principles Used in Product LitigationsProduct DefectsWarningsSafety CostsSecurity Considerations in Product DesignConcluding RemarksReferences
13 Design for Sustainability
IntroductionWhat Is Sustainability?What Is a Sustainable Product?Life Cycle ConsiderationTools/Methods Used for Sustainability AnalysesDesign for EnvironmentDesign for DisassemblyDFD and DFA GuidelinesUse of FastenersRecycling and Material RecoverySelection and Use of MaterialsProduct Design Guidelines for RecyclingDesign for Active DisassemblyConcluding RemarksReferences
Part III Tools Used in Product Development, Quality, Human Factors, and Safety Engineering
14 Methods and Toolbox
IntroductionOverview of MethodsClassification of MethodsObservation MethodsCommunication MethodsExperimentation MethodsData Presentation MethodsMethods in Product Development, Quality, Human Factors, Safety, and Program ManagementIntegration of Tools in ApplicationsConcluding RemarksReferences
15 Product Development Tools
IntroductionBenchmarking and BreakthroughBenchmarkingBreakthroughDifferences between Benchmarking and BreakthroughPugh DiagramAn Example of Pugh Diagram ApplicationQuality Function DeploymentAn Example of the Quality Function Deployment ChartCascading Quality Function DeploymentsAdvantages and Disadvantages of Quality Function DeploymentFailure Modes and Effects AnalysisAn Example of a Failure Modes and Effects AnalysisFailure Modes and Effects and Criticality AnalysisOther Product Development ToolsBusiness PlanProgram Status ChartStandardsModel-Based Systems EngineeringComputer-Aided Design ToolsPrototyping and SimulationPhysical Mock-UpsTechnology Assessment ToolsConcluding RemarksReferences
16 Design for Manufacturing and Assembly
IntroductionDesign, Functioning, Manufacturing, and AssemblyPrinciples of DFMAMaterials, Manufacturing and Assembly Considerations: An Example of IC Engine PistonManufacturing and Assembly ConsiderationsManufacturing and Assmbly CostsAssembly Engineer’s Recommendations to Component Designers for Assembly Cost ReductionsMethods to Estimate Assembly TimeMethods-Time MeasurementBoothroyd et al. Assembly Evaluation MethodsBoothroyd et al. Manual Assembly Evaluation MethodOther Boothroyd et al. Assembly Evaluation MethodsAn Example of Applications of MTM-1 vs. Boothroyd’s Manual Assembly Time Estimating MethodsSimilarities between MTM-1 and Boothroyd et al. Manual Assembly MethodsDissimilarities between MTM-1 and Boothroyd et al. MethodsBoothroyd et al. Methods for Estimating Assembly Times for High-Speed Automatic Assembly and Robotic AssemblyHigh-Speed Automatic AssemblyRobotic AssemblyConcluding RemarksReferences
17 Traditional and New Quality Tools
IntroductionTraditional Quality ToolsPareto ChartCause-and-Effect DiagramCheck SheetHistogramScatter DiagramStratificationControl ChartsSome Examples of Control ChartsNew Quality ToolsRelations DiagramAffinity DiagramSystematic DiagramMatrix DiagramMatrix Data AnalysisProcess Decision Program ChartArrow DiagramsExperiment DesignAn Example: Experiment to Select a Display with the Highest LuminanceMultivariate Experiment DesignsTaguchi’s Three-Step Product Design ApproachTaguchi’s Product Robustness and Quadratic CostsTaguchi ExperimentsConcluding RemarksReferences
18 Human Factors Engineering Tools
IntroductionDatabases on Human Characteristics and CapabilitiesAnthropometric and Biomechanical Human ModelsHuman Factors Checklists and ScorecardsChecklistTask AnalysisAn Example: Task Analysis for Opening a Liftgate and Removing a JackHuman Performance Evaluation ModelsLaboratory, Simulator, and Field StudiesHuman Performance Measurement MethodsRange of Human Performance MeasuresTypes and Categories of Human Performance MeasuresExamples of Behavioral Human Performance MeasuresMethods to Measure Human Operator WorkloadProduct PsychophysicsConcluding RemarksReferences
19 Safety Engineering Tools
IntroductionHazard Identification and Risk Reduction ToolsHazard AnalysisGeneral Hazard AnalysisDetailed Hazard AnalysisMethods Safety AnalysisChecklists to Uncover HazardsRisk AnalysisSystems Safety Analysis ToolsFailure Modes and Effects AnalysisFault Tree AnalysisAccident Data Analysis ToolsPurpose of Accident Data CollectionFlow of Accident Data CollectionAccident Data Reporting ThresholdsAccident InvestigationsAccident Data Sources and UsersSafety Performance Monitoring, Evaluation, and ControlInterview and Observational Techniques for Non-Accident Measurement of Safety PerformanceCritical Incident TechniqueBehavioral SamplingControl ChartsBefore versus after StudiesCost–Benefit AnalysisReliability AnalysesDefinitions of Reliability and MaintainabilityReliability of a Series SystemReliability of a Parallel SystemReliability of Hybrid SystemsDesigning for ReliabilityApproaches for Reliability ImprovementsA Reliability Engineer’s TasksConcluding RemarksReferences
20 Cost–Benefit Analysis
IntroductionCost–Benefit Analysis: What Is It?Why Use Cost–Benefit Analysis?Steps Involved in Cost–Benefit AnalysisSome Examples of Problems for Application of Cost–Benefit AnalysisCost–Benefit Analysis of Residential Solar Panels: An ExampleProblemCost–Benefit Analysis and CalculationsExercising Cost–Benefit Model for Sensitivity AnalysisRisks and Uncertainties in Cost–Benefit AnalysisUncertaintiesControversial AspectsConcluding RemarksReferences
21 Life Cycle Analyses
IntroductionWhat Is Product Life Cycle?Life Cycle AnalysisObjectives of LCALCA Impact CategoriesCarbon FootprintFour Phases of Life Cycle AssessmentLife Cycle Cost AnalysisObjectives of LCCASome Examples of LCA and LCCA ApplicationsExamples of LCAExamples of LCCAConcluding RemarksReferences
Part IV Applications, Case Studies, and Integration
22 Applications of Systems Engineering Tools: A Case Study on an Automotive Powertrain System
IntroductionAutomotive Powertrain ProjectProject ObjectivesProject StepsSystems, Subsystems, and Sub-SubsystemsEngine Sub-SubsystemTransmission Sub-SubsystemsDrivetrain Sub-SubsystemsFastenersCascading Vehicle Attribute Requirements to Powertrain RequirementsTrade-Offs in Powertrain DevelopmentConcluding RemarksReference
23 Case Studies and Integration
IntroductionCase Study 1: Motorcycle SystemsObjectivesProject DescriptionMotorcycle Attributes to Systems RelationshipsCase Study 2: Benchmarking and Evaluation of Steering WheelsObjectivesProject DescriptionBenchmarking StudyEvaluation in a Driving SimulatorCase Study 3: Pugh Analysis of an Automotive ConceptObjectiveAnalysis of the ProblemCase Study 4: Cyclone Grinder DevelopmentObjectiveProject DescriptionCustomer Requirements for the GrinderFunctional Requirements for the GrinderSystems and Components of the GrinderGrinder Development Project ScheduleKey Concepts for Successful Cyclone Grinder DesignRisk ManagementKey ObservationsCase Study 5: smart Car Design and ProductionObjectivesProject IntroductionSmart Car’s Customer NeedsBenchmarking of the smart CarKey Product Design Development IssuesKey Business and Supply Chain IssuesCase Study 6: Problems during Boeing 777 DevelopmentObjectiveProject Description and Uncovered ProblemsCase Study 7: Boeing 787 Dreamliner Design and ProductionObjectiveProject and Product DescriptionProduction IssuesCase Study 8: Flexible Assembly Line for Laptop ComputersObjectivesBackgroundAssembly Line ConfigurationCase Study 9: Specifications for an Electric CarObjectiveProject BackgroundApplication of the Matrix Data AnalysisConcluding RemarksReferences
24 Case Studies in Cost–Benefit Analysis
IntroductionCase Study 1: Cost–Benefit Analysis of Automotive Product Development ProgramsCase Study 2: JEDI Model Applications for Comparison of Costs and Economic Benefits of Wind Turbine Power Plant with Natural Gas Power PlantCase Study 3: Evaluation of Five Electric Power Generation AlternativesMethodologyCase Study 4: NHTSA/EPA Cost–Benefit Analysis: Increases in Vehicle Costs, Fuel Savings, and Avoided PollutionIncrease in Vehicle Price vs. Fuel SavingsCase Study 5: Manufacturing and Assembly Line: Robotic Assembly of an Automotive Differential Gear CarrierBaseline Manual AssemblyRobotic Assembly MethodRow and Column Codes for ComponentsAssumptions Regarding Parts and Assembly ConsiderationsCost–Benefit AnalysisLife Cycle Cost AnalysisConcluding RemarksReferences
25 Challenges and Future Issues in Systems Engineering
IntroductionChallenges in Systems EngineeringNeed for Tools in Complex Product DevelopmentTools to Manage Multifunctional and Multiple RequirementsCoordination of Global Design TeamsCommonalityModularityCAD and CAE IntegrationErgonomic Needs in Designing ProductsFuture Technological ChallengesBright Future for Systems EngineersCharacteristics of a Good Systems EngineerTeaching Systems EngineeringObjectives of the ProjectsProject WorkBrief Descriptions of the ProjectsConcluding RemarksReferences
Appendix 1 Product Development Case Studies
ObjectivesMethod
Appendix 2 Benchmarking, Quality Function Deployment, and Design Specifications
ObjectivesProcedure
Appendix 3 Vehicle Systems Analyses: Requirements, Interfaces, Trade-Offs, and Verification
ObjectivesMethod
Appendix 4 Business Plan and Systems Engineering Management Plan for the Proposed Vehicle
ObjectivesContents of the Report
Appendix 5 Conceptual Design of the Proposed Vehicle
ObjectivesProcedure
Appendix 6 Vehicle Assembly Process Plan
ObjectivesContents of the Report
Appendix 7 Term Project: Final Report
ObjectivesContents of the Report
Appendix 8 Calculations of Centerline and Control Limits for Control Charts
Notations Common to Both Variables and Attributes Control ChartsNotations for Variables Control ChartsProcess Capability MeasurementsNotations for Attributes Control Charts3-Sigma Control Upper and Lower Limits and CenterlinesX-Bar and R ChartsX-Bar and S ChartsX and RM ChartsP Chart (For Constant Subgroup Size of n)P Chart (For Variable Subgroup Size of nj)NP ChartU Chart (For Subgroup Size of nj)C Chart (For Constant Subgroup Size of n)References
Index

Content preview from Designing Complex Products with Systems Engineering Processes and Techniques, 2nd Edition

21 Life Cycle Analyses

Introduction

One of the major considerations in implementing systems engineering is to have life cycle consideration in developing systems or products. This means that during the development of a system or a product the design team must consider and evaluate the entire life cycle of the system (or product) from its concept development to its disposal (after retirement), i.e., often called the “cradle-to-grave” considerations or life cycle analyses (LCA). Typically, the present value of costs incurred during the entire product program from the product concept generation to the retirement of the product is added, and the sum is subtracted from the present value of the total revenues generated by the product sales (number ...

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Designing Complex Products with Systems Engineering Processes and Techniques, 2nd Edition

by Vivek D. Bhise

21 Life Cycle Analyses

Introduction

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