Agile, Reconfigurable Manufacturing

Short Course at University of Valladolid RECONFIGURABLE MANUFACTURING – Product, Process, & Business Integration Summer 2004 Instructor: Zbigniew J. Pasek, Ph. D., University of Michigan

Course Rationale and Objectives: Globalization creates both an opportunity and a challenge for manufacturing companies. For established companies the opportunity is to sell products in any place on the globe, and enhance the sales with the aid of the Internet. The challenge is to succeed in a turbulent business environment, in which competitors have similar opportunities. Globalization and the Internet originate another type of opportunity – to form start-up companies for durable goods that are utilizing the Internet to enhance their sales (entrepreneurship). Since the core of such start-ups is the innovative product, this course emphasizes creativity in designing products and touches on preparing simple business plans. There is a third possibility that unifies the two previous opportunities – to form a new subsidiary (or a division) inside a large corporation to produce a new product within the company’s line of products. The challenge is similar to that in forming a start-up, but it is easier in the finance aspect –– if the product is appealing, the corporation will invest the resources. This course aims at analyzing the technical and business dimensions of different manufacturing paradigms, and emphasizing the integration between engineering and business:  Developing innovative products having the variety to satisfy customers’ tastes and preferences in different regional segments  Developing a new type of reconfigurable manufacturing systems that have a production capacity adaptable to market demand  Developing responsive business models that take advantage of market opportunities and enhance customer relationships.

Course Topics 1. Manufacturing Paradigms Mass production, lean production, mass customization and personalized productio. Models and principles of these paradigms.

2. Product Design in Global Environment Creativity in product design. Design for Mass-Customization. Modular architecture in product design.

3. Manufacturing Systems Dedicated, flexible, and reconfigurable systems and machines. Analysis of system configurations.

4. Business Issues Agile, reconfigurable enterprises. Responsive business models. Workforce empowerment. Finance models. Preparation of simple business plans.

Materials 1. Coursepack 2. Class slides 3. Occasional reading

1 Course Requirements We work in teams of four (4) students; whenever possible each coming from a different background (e.g., engineering, business, industrial experience, etc.). The instructors assign the teams.  Before the first class, please fill the course form that enables us to form teams.  The team assignment is to form a start-up company that produces a new innovative product that fits mass-customization markets at a global scale. The team should (1) Describe the products and its design, (2) Elaborate on the manufacturing system that produces the product, and (3) Prepare a simple business plan that includes (a) market analysis, (b) product design, (c) layout of the production system, (d) strategic plan and company organization, and (e) finance issues. This is the team main class project (70% of the grade). Additional requirements include:  Reading before class; part of the grade is given on class participation  “Paradoxical Products” for creative thinking (tentative).  Three team assignments (tentative).

Course Final Grade 70% - Team Project 10 % - Product Design: Presentation, Report, Response to comments 10 % - Product Manufacturing: Presentation, Report, Response to comments 10 % - Final Project Presentation 10 % - Grades given by team mates. 30 % - Final Project Report. 10 % - Class Participation: Presence and discussion. 20 % - Additional Assignments Schedule Date Description Chapter Day 1 Course Overview & Organization 1 Introduction to Reconfigurable Systems Day 2 Product Development Strategy 2 Customer Surveys and Product Specifications Customized, Personalized & Reconfigurable Products Day 3 Product Design Presentations Mass Production & Lean Production 4 Analysis of Mass Customization 5 Traditional Manufacturing Systems 6 Day 4 Reconfigurable Manufacturing Systems 7 Reconfigurable Machines 8 System Configuration Analysis 9 Day 5 Product Manufacturing Presentations Responsive Business Models 10 Financial Models Day 6 Business plans Globalization & manufacturing strategies Day 7 Final Project Presentations Class Summary 12