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The advantages of the various rapid prototyping (RP) and rapid tooling (RT) technologies to reduce the time and/or cost of prototypes and tooling are discussed. The difficulty is in large part due to an inherene conflict resulting from the way in which one measure and evaluate employees' performance in design versus those who work in manufacturing....
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Context 1
... generic cycle may include the following phases: concept, concept design review, production design review, production (tooling), and first shipment authorization (Hanson, 1998;Hewson, 1998). As a product progresses through these phases, the costs associated with ECOs increases rapidly (see figure 2). ...
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Citations
... Consequently, the behavior and performance of NPDs may be different during testing than the pilot commissioning of the product. This difference often causes additional cost and time in the late stages of NPD, where changes cost the most [8] since the NPD must be frequently adjusted outside of the commission site or re-manufactured at the OEMs location. To increase the chances of earning more money on the final product, prototyping efforts must be efficient and have a high success rate. ...
When simulating manufacturing systems and the production of components, sufficient realistic behaviour is needed to use the simulation as a decision-making tool for optimising and verifying the design. To simulate, design, and optimise fish processing with the singular simulation of fish, a physics engine with soft body support and advanced interaction between bodies is beneficial. This paper explores the use of Omniverse as a simulation platform and Isaac Sim as a simulation tool. A digital simulation and representation of a fish processing line is developed and compared with a physical build production line for fish processing.
... One such direction is to create products that can resolve or answer customer complaints about a criterion by looking at customer reviews with negative sentiments. Determining the direction of product development is hoped to reduce product development costs because it can save time for testing hypotheses and reduce the cost of design changes (cost of change) in later phases of product development (Folkestad & Johnson, 2001;Pedersen et al., 2016). ...
The research aims to provide the decision-maker with a framework for determining customer requirements during product development. The proposed framework is based on sentiment analysis and supervised multilabel classification techniques. Therefore, the proposed technique can categorise customer reviews based on the “product design criteria” label and the “sentiment of the review” label. To achieve the research goal, the research presented in this article uses the existing product development framework presented in the literature. The modification is conducted especially in the conceptual stage of product development, in which the voice of the customer or a customer review is obtained from the scraping, and a multilabel classification technique is performed to categorise customer reviews. The proposed framework is tested by using the set data on women’s clothing reviews from an e-commerce site downloaded from www.kaggle.com based on data by Agarap (2018). The result shows that the proposed framework can categorise customer reviews. The research presented in this paper has contributed by proposing a technique based on sentiment analysis and multilabel classification that can be used to categorise customers during product development. The research presented in this paper answers one of the concerns in the categorisation of needs raised by Shabestari et al. (2019), namely, the unclear rules or main attributes of a requirement that make these needs fall into certain categories. Categorising customer requirements allows decision-makers to determine the direction of product development to meet customer needs.
... Since Hardware is not required, SiL Tests can anticipate issues that would only be discovered late in development when physical parts are available. As defined by James Folkestad and Russell Johnson, cost of design changes significantly increases at late development phases [6]. ...
... In addition to all of the aforementioned challenges, the later significant changes to the product have to be made within the development process of electric powertrains, the more expensive the implementation becomes [9]. Therefore, a high degree of automation in combination with validated simulation models is crucial to assure powertrain requirements are met before the first prototype is built and thus to minimise the total development costs. ...
Within the BMWK-funded project eTestHiL, a follow-up project of Concept ELV2 (funded by BMWi), a novel electrically driven axle (e-axle) is developed together with a suitable chassis design for a heavy-duty truck. This paper begins with the discussion of requirement sources for heavy duty vehicles, followed up by different transmission concepts for e-axles. A method for pre-selection of electric machines is also presented. After defining powertrain topologies for further investigation, their benefits and drawbacks are discussed from the point of transmission efficiency. The analysis also includes a preliminary comparison of single versus dual motor concepts and different operation strategies of the latter. Lastly, the measurement data of the Concept ELV2 e-axle – which was created using the same approach as in this paper – is presented to show both the validation of the prototype and the calculation method for transmission losses as well.
... To be more resource efficient, frontloading information gathering and knowledge transfer in a project is preferred. The later problems arise in a project, the more expensive they are to handle, as the cost of design changes increase rapidly when made late in the development process (Folkestad & Johnson, 2001). To make sure the adequate knowledge is available for ongoing projects, several activities need to take place outside of the project environment (Stenholm, 2018). ...
... It can be used as a guideline in narrowing down the options and directing the direction the product should take to meet customers' expectations. Although customer expectations can be fulfilled in a later phase by tailoring the specifications according to customers' wants (Moos, 2014), integrating the expectations in the idea generation phase will incur less cost of change (Folkestad & Johnson, 2001). In the idea generation phase of the illustrated case, the ideas focusing on underbody durability and aesthetics should be prioritized. ...
This paper discusses the role of text mining and sentiment analysis in collecting and analyzing customers’ verbatim/voice of the customer for product design and development. In the illustration case of designing car underbody, the data were collected from a car online forum discussion website and processed using text mining techniques with “underbody” as a keyword. The result of the analysis finds there are worries regarding underbody durability against rust and damages. This finding is used as a reference point for the car underbody design process.
... Another important aspect is timing: it is extremely important to understand users' preferences as soon as possible (see Figure 1). The earlier design changes occur in product development, the less their impact costs (Folkestad & Johnson, 2001). User tests are useful to understand how the consumers will perceive the product, to depict their emotions, and finally to assess their preferences. ...
... Cost of design changes in relation to the product development phase. (Folkestad & Johnson, 2001) Products need to increase their perceived value to stand out from competitors'; companies must look for new strategies in order to assess innovation and create new successful products. For a long time innovation has been merely identified with the act of researching new technologies. ...
Affective Design is gaining much attention from academic research and companies. In this paper, a research framework for assessing Innovation through Affective Design is presented. Moreover, Affective Design is correlated to Participatory Design through some definitions. The importance of an Affective approach during the earliest phases of design process is motivated. This study introduces Affective Design as a powerful approach in order to manage interactive Virtual Prototyping (iVP) methodology. The paper deals with issues regarding the great variability that iVP offers: the questions raised find answer in the notion of Accordance, which is defined on the basis of Product Semantics. A tool to implement iVP methodology with this approach is here presented. Finally, the results of a pilot study, qualitatively tested to assess the tool usability, are described.
... However, at the same time it brings new questions about acceptability to the forefront. Given the lack of current research on perceptions towards waste-derived bio-based plastics and that design changes are considerably less expensive in the earlier stages of product development ( Folkestad and Johnson, 2001 ), it is important to engage with stakeholders even during the research and development phase. This paper will qualitatively explore opinions and perceptions towards a range of feedstocks and, for the first time in literature, perceptions towards bio-based plastics from slaughterhouse wastes. ...
Bio-based plastics are produced from bio-based raw materials such as sugar cane, potatoes, corn, and agricultural and slaughterhouse waste. The evolution of the bio-based plastics market is affected by the stakeholders involved owing to their role in production processes, environmental guidelines and purchasing decisions. It is therefore imperative to understand the perceptions of stakeholders in order to inform the development of the bio-based plastics sector. This novel exploratory study investigates the perceptions and opinions of three stakeholder groups: environmental professionals and plastic processors; university students; and consumers in Belfast, Northern Ireland. During the focus groups (25 participants in total), samples of bio-based plastics, including starch-based monolayer and multilayer, and polyethylene terephthalate (PET), were presented. A qualitative analysis using the framework method revealed that environmental professionals and plastic processors were aware of both the benefits of bio-based plastics, such as a reduction in use of fossil fuels; and the challenges, which include the utilisation of agricultural land for biomass substrates and possible contamination of current conventional plastic recycling streams. Although there was a general lack of knowledge among students and consumers about bio-plastics, they conveyed their beliefs that the use of agricultural waste will lead to closed-loop systems, resulting in a balanced approach to production and waste management. Among students and consumers, concern was raised about contamination of food by bio-based packaging prepared from slaughterhouse waste. However, these participants supported the use of slaughterhouse waste in the production of bio-based plastics for non-food contact items. The students and consumers and some of the environmental professionals and plastic processors were reluctant to pay more for bio-based plastics. The results indicate that manufacturers of bio-based plastics could benefit by informing consumers on the environmental impacts of beginning-of-life parameters, such as production processes and feedstocks, by using life cycle assessment parameters. This should be incorporated into information provided on labelling using standards from neutral organisations. This research could inform future communication strategies around bio-based plastics with both the public and industry.
... Cost of design changes plotted in relation to the product development phase as illustrated by Folkestad and Johnson, 2001. 12 Figure 1.5 ...
Design changes are an inevitable part of any product development process. In complex engineered products, changes can cause a cascading effect on other components, commonly known as the “knock-on effect of change”. Managing changes, therefore, has become an important part of design projects. Such changes can propagate through many facets of design and by many different mechanisms. Of particular interest in this dissertation, margins in design play an important role in determining whether a change propagates or gets absorbed. A literature review identifies the underlying concepts of change propagation through a metamodel. The review reveals a lack of study on the mechanisms of change propagation, which greatly dictates how the changes propagate or whether they get absorbed. Based on the insights gained from the literature review, empirical experiments were conducted using student participants. Data from the experiments was collected and analysed using a modelling approach based on a conceptual framework. The analysis of data gave rise to a list of five change propagation mechanisms. The study concluded that margins in a design are one of the most influential factors which determine the nature of propagation when a change is triggered. This dissertation introduces a method called the Margin Value Method to analyse an engineering design, localise the excess margin, and quantify it considering change absorption potential in relation to design performance deterioration. Margin in design may be desirable to mitigate risk and absorb future changes, but at the same time, may be undesirable if the over-specification deteriorates the design’s performance. The Margin Value Method provides guidance for improving a design by prioritising excess margin that provides relatively little advantage at high cost, and could therefore be eliminated to improve design performance. Two case studies using the method are presented.
... Moveover, this approach to prototyping acquires value only in the later stages of the design process, when the idea has grown mature and solid. It would be totally out of scope to create a definite, realistic prototype at the early stages, with high costs, when changes in the design are still very probable and less expensive than at later stages [Folkestad, James and Johnson 2001]. At the same time, early prototyping is extremely important also for commercial purposes as it allows companies to better match end-users desires and needs [Coughlan, Fulton-Suri and Canales 2007]. ...
