ToolsTools && TrendsTrends inin ProductProduct DevelopmentDevelopment

1 PercentPercent ofof CurrentCurrent SalesSales ContributedContributed byby NewNew ProductsProducts

70%

60% High Tech All Firms Low Tech

50%

40%

30%

20%

10%

0% Bottom Third Middle Third Top Third Most Successful

Self Reported Standing in Industry 2 DecayDecay CurveCurve

100

90

80

70

60 1990 1995 50

40

30

20

10

0

Ideas Tested Launched Success

3 DesignDesign ProcessesProcesses

4 NPDNPD ProcessesProcesses inin UseUse inin thethe USUS

Other

3rd Gen. Stage Gate STAGE GATE PROCESSES 56 % Facilitated Stage Gate 1 Stage Gate

Functional, sequential

Informal

None

0% 5% 10% 15% 20% 25% 30%

5 ProcessProcess TasksTasks ……

►► ProductProduct LineLine PlanningPlanning ƒƒ Portfolio,Portfolio, CompetitionCompetition ►► StrategyStrategy DevelopmentDevelopment ƒƒ TargetTarget Market,Market, Needs,Needs, AttractivenessAttractiveness ►► Idea/ConceptIdea/Concept GenerationGeneration ƒƒ OpportunitiesOpportunities andand SolutionsSolutions ►► IdeaIdea ScreeningScreening ƒƒ Sort,Sort, Rank,Rank, EliminateEliminate

6 …… ProcessProcess TasksTasks

► BusinessBusiness AnalysisAnalysis ƒ Business Case, Development Contract ► DevelopmentDevelopment ƒ Convert Concept into Working Product ► TestTest && ValidationValidation ƒ Product Use, Market ► ManufacturingManufacturing DevelopmentDevelopment ƒ Developing and Piloting Manufacturing Process ► CommercializationCommercialization ƒ Launch of Full-Scale Production and Sales

7 TasksTasks IncludedIncluded inin ProcessesProcesses

Commercilization

Manufacturing Development

Test & Validation

Development

Business Analysis

Screening

Idea Generation

Project Strategy

Product Line Planning

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

8 ProjectsProjects CompletingCompleting TasksTasks

Commercialization

Manufacturing Development

Test & Validation

Development

Business Analysis

Screening

Idea Generation

Project Strategy

Product Line Planning

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

9 AverageAverage TimeTime SpentSpent onon TasksTasks

Product Line Planning

Project Strategy

Idea Generation

Screening

Business Analysis

Development

Test & Validation

Manufacturing Development

Commercialization

0 5 10 15 20 25 30 35 weeks 10 PercentagePercentage ofof ProjectsProjects UsingUsing MultifunctionalMultifunctional TeamsTeams

New-to-World

New-to-Firm

Major Revision

Cost Reduction

Repositioning

Minor Improvement

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

11 ToolsTools

12 PerceivedPerceived ImportanceImportance andand UseUse ofof MarketingMarketing ResearchResearch ToolsTools

Importance Voice of Customer Degree of Use 5

4 Pre-Test Markets Customer Site Visits 3

2

1

Test Markets 0 Concept Tests

Conjoint Analysis Focus Groups

Beta Testing

13 PerceivedPerceived ImportanceImportance andand UseUse ofof EngineeringEngineering ToolsTools

5 Importance Rapid Prototyping Degree of Use 4

Virtual Design 3 Concurrent Engineering

2

1 Perfomance Simulation Design for Manufacturing 0

FMEA CAD

Value Analysis CAE

14 PerceivedPerceived ImportanceImportance andand UseUse ofof OrganizationOrganization ToolsTools

5 Importance CPM PERT GANNT Degree of Use 4 Champions 3 Leaderless Teams 2

1 Process Owner Colocated Teams 0

QFD Team Building Drill

Matrix Organization Heavyweight Manager

Self Directed Teams 15 PerceivedPerceived Importance:Importance: TopTop 55

►► VoiceVoice ofof thethe CustomerCustomer (4.2)(4.2) ►► CustomerCustomer SiteSite VisitsVisits (3.9)(3.9) ►► RapidRapid PrototypingPrototyping (3.9)(3.9) ►► ProjectProject SchedulingScheduling ToolsTools (3.9)(3.9) ►► ProductProduct ChampionsChampions (3.9)(3.9)

16 FrequencyFrequency ofof Use:Use: TopTop 55

►► ProjectProject SchedulingScheduling ToolsTools (3.7)(3.7) ►► VoiceVoice ofof CustomerCustomer (3.6)(3.6) ►► CustomerCustomer SiteSite VisitsVisits (3.5)(3.5) ►► ComputerComputer--AidedAided DesignDesign (3.4)(3.4) ►► MatrixMatrix OrganizationsOrganizations (3.2)(3.2)

17 PerformancePerformance

18 PastPast andand FutureFuture ImpactImpact ofof NewNew ProductsProducts

45.0%

40.0%

Past 5 Years 35.0% Next 5 Years

30.0%

25.0%

20.0%

15.0% Percent of Total

10.0%

5.0%

0.0%

New Product Sales New Product Profits 19 ProductProduct SuccessSuccess

►►SuccessfulSuccessful ProductsProducts (subjective)(subjective) 55.955.9 %%

►► ProfitableProfitable 51.751.7 %%

►► StillStill onon marketmarket afterafter 55 yearsyears 74.174.1 %%

20 PerformancePerformance CriteriaCriteria

Customer Acceptance Financial Performance Technical Performance

Repositioning

Incremenatal Improvement

Next Generation

New Product Line

New To World

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

21 AverageAverage LengthLength ofof DevelopmentDevelopment ProjectsProjects

Incremenatal Improvement

Next Generation

New Product Line

New To World

0 5 10 15 20 25 30 35 40 45

WEEKS 22 FurtherFurther ReadingReading

►► RosenauRosenau etet al.al. ““TheThe PDMAPDMA HandbookHandbook ofof NewNew ProductProduct DevelopmentDevelopment”” ƒƒ DataData SourceSource forfor precedingpreceding slidesslides

►► Cooper,Cooper, RobertRobert G.G. ““WinningWinning atat NewNew ProductsProducts”” ƒƒ StageStage--GateGate ProcessesProcesses

23 ToolsTools ForFor Innovation:Innovation: TheThe DesignDesign StructureStructure MatrixMatrix

ThomasThomas A.A. RoemerRoemer SpringSpring 06,06, PD&DPD&D

24 OutlineOutline

► Overview ƒ Traditional Project Management Tools and Product Development ► Design Structure Matrix (DSM) Basics ƒ How to create ƒ Classification ► The Iteration Problem: ƒ Increasing Development Speed ƒ Sequencing, Partitioning and Simulation ► The Integration Problem: ƒ DSM Clustering ƒ Organizational Structures & Product Architectures

25 ClassicalClassical ProjectProject ManagementManagement ToolsTools

y

t ►►GanttGantt ChartsCharts i

v

i

t

Ac ►►GraphGraph--based:based: PERT,PERT, CPM,CPM, IDEFIDEF Time

26 CharacteristicsCharacteristics

► ComplexComplex DepictionDepiction ► FocusFocus onon WorkWork FlowsFlows ƒ DSM focuses on Information Flows ► IgnoreIgnore IterationsIterations && ReworkRework ƒ Test results, Planned design reviews, Design mistakes, Coupled nature of the process ► DecompositionDecomposition && IntegrationIntegration ƒ Assume optimal Decomposition & Structure ƒ Integration of Tasks not addressed

27 DesignDesign IterationIteration

► Iteration:Iteration: TheThe repetitionrepetition ofof taskstasks duedue toto newnew information.information. ƒ Changes in input information (upstream) ƒ Update of shared assumptions (concurrent) ƒ Discovery of errors (downstream) ► FundamentalFundamental inin ProductProduct developmentdevelopment ƒ Often times hidden ► UnderstandingUnderstanding IterationsIterations requiresrequires ƒ Visibility of information flows

28 AA GraphGraph andand itsits DSMDSM

B E ABCDEFGH I A A X B B X A C I CXC F D D X E E FX F X D G G G HXX H IXI

H

29 CreatingCreating aa DSMDSM

► DesignDesign manualsmanuals ► ProcessProcess sheetssheets ► StructuredStructured expertexpert interviewsinterviews ƒ Interview engineers and managers ƒ Determine list of tasks or parameters ƒ Ask about inputs, outputs, strengths of interaction, etc ƒ Enter marks in matrix ƒ Check with engineers and managers ► QuestionnairesQuestionnaires

30 FourFour TypesTypes ofof DSMsDSMs

Iteration

Activity based DSM Sequencing Parameter based DSM Partitioning Simulation

Integration Team based DSM Clustering Product Architecture DSM

31 IterationIteration FocusedFocused ToolsTools

Concepts,Concepts, Examples,Examples, SolutionSolution ApproachesApproaches

32 SequencingSequencing TasksTasks inin ProjectsProjects

Possible Relationships between Tasks

A A

A B

B B

Dependent Independent Interdependent (Series) (Parallel) (Coupled)

33 DSM:DSM: InformationInformation ExchangeExchange ModelModel

Interpretation: ABCDEFGHIJKL ► Rows: Required Information A • ƒ D needs input from E, F & L. B • ► Columns: Provided Information C • D • ƒ B transfers info to C,F,G,J & K. E • Note: F • ► Information flows are easier to G • capture than work flows. H • I • ► Inputs are easier to capture than J • outputs. K • L •

34 DSM:DSM: PartitionedPartitioned oror SequencedSequenced

BGCDA KLJ I HEF

B • Series Task C • Sequence A • Parallel K • L • Coupled J • F • I • E • D • H • G •

35 SequencingSequencing AlgorithmAlgorithm

► Step 1: Schedule tasks with empty rows first ► Step 2: Delete the row and column for that task ► Step 3: Repeat (Go to step 1) ► Step 4: Schedule tasks with empty columns last ► Step 5: Delete the row and column for that task ► Step 6: Repeat (Go to step 4) ► Step 7: All the tasks that are left unscheduled are coupled. Group them into blocks around the diagonal

36 Example:Example: BrakeBrake SystemSystem DesignDesign

12345678910111213 Customer_Requirements 1 1 Wheel Torque 2 2 X Pedal Mech. Advantage 3 X 3 XX X X X System_Level_Parameters 4 X 4 Rotor Diameter 5 XXXX5 XX XX X ABS Modular Display 6 X 6 X Front_Lining_Coef._of_Friction 7 XXX 7 XX X Piston-Rear Size 8 XX 8 X Caliper Compliance 9 XX 9 XX Piston- Front Size 10 XX X10 Rear Lining Coef of Friction 11 XXX X X11 X Booster - Max. Stroke 12 12 X Booster Reaction Ratio 13 XXXX XXXXXX13

37 PartitionedPartitioned DSM:DSM: BrakeBrake DesignDesign

1 4 210831171351296 Customer_Requirements 1 1 System_Level_Parameters 4 X 4 Wheel Torque 2 X 2 Piston- Front Size 10 XX10 X Piston-Rear Size 8 XXX8 Pedal Mech. Advantage 3 XX XX3 XX Rear Lining Coef of Friction 11 XXXX11 XX Front_Lining_Coef._of_Friction 7 XXXX7 XX Booster Reaction Ratio 13 XXXXXXX13 X Rotor Diameter 5 XXXXXXXXX5 Booster - Max. Stroke 12 X 12 Caliper Compliance 9 XXX X 9 ABS Modular Display 6 X 6

38 SemiconductorSemiconductor DesignDesign ExampleExample

SEE SDMFDC SWHWDDB FDL I RD FVRCCDDGVR SCD PFSFVAECDDDLCCL I MDTCC FV PD Set customer target • xx ³ Estimate sales volumes x • xx ³ Establish pricing direction x • x ³ Schedule project timeline • x Concurrent Activity Blocks Development methods x • x xxx Generational Learning Feedback Macro targets/constraints xx • xxxx Financial analysis xxxxx• Develop program map x • x Potential Iterative Loops Create initial QFD matrix x xxx• Set technical requirements xxxx• x Write customer specification xx xxx• ³³³³ ³ ³ ³ ³ High-level modeling xx xx• xxx Write target specification xxx x xxxxx• xx Develop test plan xx xxx • x Develop validation plan xx x x• Build base prototype xxxxxx• Functional modeling xxxxx• xxxxxxxx ³³³³³ ³³³³ ³ Develop product modules x xxxxxx xx• ³ Lay out integration x xxxxxx x x• Integration modeling x x xxx x x• xxx Random testing xx • xxx Develop test parameters x x xxxxx• xxx Finalize schematics x x xxx• xx ³ ³ ³ ³ ³ Validation simulation x x x xxxx• xx Reliability modeling x xxxx• x Complete product layout xx xxx• xx Continuity verification xxx xxx• Design rule check xx x • Design package xxx x x • ³ ³ ³ ³³³ ³ Generate masks x xxx • x³ Verify masks in fab xx x• Run wafers x • x³ Sort wafers x • Create test programs x • Debug products x x xxx• ³³ ³ ³³³ ³ Package products xxx• Functionality testing xxx• Send samples to customers xx x x • Feedback from customers x • Verify sample functionality Sequential Activities x • Approve packaged products xxxx• Environmental validation xx x x • Complete product validation x x xxx• Develop tech. publications xx • xx Develop service courses x x • x Determine marketing name xxxx x x Parallel Activity Blocks • Licensing strategy xxx • Create demonstration xx xx xx• Confirm quality goals xx x xx • Life testing xx x • xx Infant mortality testing xx x x• x Mfg. process stabilization x xx• ³³ Develop field support plan x x • Thermal testing xxx • Confirm process standards x • xx Confirm package standards xx xxx• x Final certification x xxx xxxxxxx• Volume production xxx• x Prepare distribution network xx xxxxx x • Deliver product to customers x xxxxx x x x• 39 TaskTask SequencingSequencing ExampleExample

Space Shuttle Main Engine

40 EngineEngine ComponentsComponents

41 DependencyDependency RelationsRelations inin ConceptualConceptual DesignDesign BlockBlock

ACTIVITIES 1 2 3 4 5 6 7 8 9 101112131415161718 19 20 21 22 23 24 25 26 27 SSP Engine Balance 1 4 0.15 0.1 0.1

CMT Make Preliminary Material Selections 2 1 0.1 0.1 0.1 0.1 0.1

CST Assess Pump Housing 3 8 1

Design Pump Housing 4 0.5 0.2 4 1 1 0.1 1 0.1

CST Assess Turbine Housing 5 4 1

CST Compare Design Annulus Area… 6 1 1

CAX Determine Optimum Turbine St aging 7 1 0.1 0.1 6 0.1 1 0.2 0.1

CST Compare Design Pit chline Velocit ies… 8 1

CST Compare Design Impeller Tip Speed… 9 1 1

CHX Determine Pumping Components 10 1 0.1 0.2 0.1 6 0.2

CDE Design Pumping Elements 11 0.5 1 8 0.3 0.1

CST Evaluat e Rotor Sizing 12 1 1 1

CDE Incorporate Bearing Dimensions 13 2 1

CDE Design Rotor 14 0.2 1 1 2 1 0.1 1 0.2 0.1

CBR Det ermine Bearing Geometry 15 0.1 1 0.2 4 10.10.1

CDE Posit ion Bearings and Select ion 16 0.2 1 1 0.2 2

CDE Design Turbine 17 0.2 1 0.3 0.1 4

CDE Integrate Rot or and Structure Layout 18 1 1 8 0.1 1

CDE Incorporat e Seal Dimensions 19 1 1

CSL Def ine Seal System 20 0.2 0.1 1 1 0.3 4

CSL Define Individual Sealing Elements 21 0.1 0.2 1 2 0.1 0.1

CDE Develop Thrust Balance 22 0.2 1 6

CRD Build Finite Element Model 23 0.1 0.3 1 1

CRD Define Linear Rot ordynamic Behavior 24 1 1 1 1 1 2

CRD Evaluate Design 25 1 1

CDE Analyze Weight 26 10.24

Design Turbine Housing 27 0.5 0.1 1 1 0.2 1 0.1 4

42 BlockBlock DecompositionDecomposition

min∑ yna ijijij i,j = index for activities, i,j = 1,2,…,N; ∈Aij m = index for stages, m = 1,2,…,M; s.t. M A = the set of directed arcs in the design graph; ∑ im ,1 ∀= ix m=1 aij = the level of dependency of activity i on j

N ⎧ if1 activity i is toassigned stage m ∑ im , ∀≤ mCx xim = ⎨ i=1 ⎩0 otherwise ⎧ if0 arc ij is a feed back between stages M yij = ⎨ ⎩1 otherwise im ∑ ijjh ,0 ∀≤−− ,, mjiyxx mh += 1 ⎧W (a large number) aij = 1if nij = ⎨ ⎩1 otherwise yx ijim {},1,0, ∀∈ i ,, mj

43 ResultingResulting StructureStructure forfor ConceptualConceptual DesignDesign BlockBlock

ACTIVITIES 1 10 9 2 7 8 17 11 12 6 16 20 21 19 15 13 4 3 27 14 18 22 5 23 24 25 26

SSP Engine Balance 1 4 0.1 0.15 0.1

CHX Det ermine Pumping Component s 10 1 6 0.1 0.1 0.2 0.2

CST Compare Design Impeller Tip Speed… 911

MT Make Preliminary Mat erial Select ions 2 0.1 1 0.1 0.1 0.1 0.1

CAX Det ermine Optimum Turbine St aging 7 1 1 0.1 6 0.1 0.2 0.1 0.1

ST Compare Design Pit chline Velocit ies… 8 1

CDE Design Turbine 17 0.2 1 4 0.3 0.1

CDE Design Pumping Element s 11 1 0.5 8 0.3 0.1

CST Evaluat e Rot or Sizing 12 1 1 1

CST Compare Design Annulus Area… 6 1 1

CDE Posit ion Bearings and Select ion 16 1 0.2 1 2 0.2

CSL Def ine Seal System 20 1 0.2 1 4 0.3 0.1

CSL Def ine Individual Sealing Element s 21 0.1 1 2 0.1 0.2 0.1

CDE Incorporat e Seal Dimensions 19 1 1

CBR Det ermine Bearing Geomet ry 15 1 1 4 0.1 0.1 0.2 0.1

CDE Incorporat e Bearing Dimensions 13 1 2

Design Pump Housing 4 1 0.5 1 1 4 0.2 0.1 0.1

CST Assess Pump Housing 3 1 8

Design Turbine Housing 27 0.5 1 1 1 4 0.2 0.1 0.1

CDE Design Rot or 14 0.2 1 1 1 1 2 0.1 0.2 0.1

DE Int egrat e Rot or and St ruct ure Layout 18 1118 0.1

CDE Develop Thrust Balance 22 0.2 1 6

CST Assess Turbine Housing 5 1 4

CRD Build Finit e Element Model 23 0.1 10.31

RD Def ine Linear Rot ordynamic Behavior 24 1 1 1 1 1 2

CRD Evaluat e Design 25 1 1

CDE Analyze Weight 26 10.24

44 STCSTC’’ss ExistingExisting ProcessProcess

Conceptual Design

Negotiation

Detail Design

Manufacturing & Testing

Program Office Project Team

Functional Departments

45 ProposedProposed ProcessProcess

Conceptual Design

Negotiation

Detail Design

Manufacturing & Testing

Core Design Team Program Office Functional Departments

46 PilotPilot ProjectProject PerformancePerformance

Conceptual Design

Detail Design Fabrication & Test As-Is 9d 39 days 68 days

27% Savings To-Be 20 days 25 days 40 days

0 10 20 30 40 50 60 70 80 90 100 110 Project Completion Time [days]

47 DSMDSM SimulationSimulation Task A X Task B X Task C X ► TaskTask AA requiresrequires inputinput fromfrom tasktask CC ► PerformPerform AA byby assumingassuming aa valuevalue forfor CC’’ss outputoutput ► DeliverDeliver AA’’ss outputoutput toto BB ► DeliverDeliver BB’’ss outputoutput toto CC ► FeedFeed CC’’ss outputoutput backback toto AA ƒ Check initial assumption (made by A) ► UpdateUpdate assumptionassumption andand repeatrepeat tasktask A.A.

48 SimulatingSimulating ReworkRework

Task A R Task B X Task C X

R is the probability that Task A will be repeated once task C has finished its work.

R = 0.0 : There is 0 chance that A will be repeated based on results of task C. R = 1.0 : There is 100% probability that A will be repeated based on results of task C.

49 SimulatingSimulating 22ndnd OrderOrder ReworkRework

Task A X Task B R2 Task C X

Second Order rework is the rework associated with forward information flows that is triggered by feedback marks.

First order rework: Output of task C causes task A to do some rework 2nd order rework: Consequently there is a chance tasks depending on A (e.g. task B) will also be repeated.

50 SimulatingSimulating ReworkRework ImpactImpact

Task A I Task B X Task C X

I = 0.0 : If task A is reworked due to task C results, then 0% of task A’s initial duration will be repeated

I = 1.0 : If task A is reworked due to task C results, then 100% of task A’s initial duration will be repeated

51 SimulationSimulation ResultsResults

Impact Rework .5 Information Flow .5.5 .9 .5 .9.9 X .5 .5.5 .9 .5 XX ► DSM contains rework .5.9 .5 .9.9 X .9 .9X XX .9 X probabilities and XX impacts Target 1.0 ► Cost and time add up 0.8 ► Many runs produce a 0.6 distribution of total time 0.4 and cost 0.2 ► Different task 0.0 120 126 132 138 144 150 156 162 168 174 180 sequences can be tried Schedule (days)

Source: “Modeling and Analyzing Complex System Development Cost, Schedule, and Performance” Tyson R. Browning PhD Thesis, MIT A&A Dept., Dec 99 52 GanttGantt ChartChart withwith IterationIteration

2 3 4 5 6

y 7 8 9 Activit 10 11 12 13 14 0 20 40 60 80 10014 120 140 16013 13 15 Elapsed Time (Days) 16 17

► Typical Gantt chart shows monotone progress ► Actual project behavior includes tasks stopping, restarting, repeating and impacting other tasks Source: “Modeling and Analyzing Complex System Development Cost, Schedule, and Performance” Tyson R. Browning PhD Thesis, MIT A&A Dept., Dec 99 53 LessonsLessons Learned:Learned: IterationIteration

► Development is inherently iterative ► Understanding of coupling is essential ► Iterations improve quality but consumes time ► Iteration can be accelerated through ƒ Information technology (faster iterations) ƒ Coordination techniques (faster iterations) ƒ Decreased coupling (fewer iterations) ► Two Types of Iteration ƒ Planned Iterations (getting it right the first time) ƒ Unplanned iterations (fixing it when it’s not right)

54 IntegrationIntegration FocusedFocused ToolsTools

Concepts,Concepts, Examples,Examples, SolutionSolution ApproachesApproaches

55 TeamTeam SelectionSelection

► TeamTeam assignmentassignment isis oftenoften opportunisticopportunistic ƒ “We just grab whoever is available.” ► NotNot easyeasy toto telltell whowho shouldshould bebe onon aa teamteam ► TraditionTradition groupsgroups peoplepeople byby functionfunction ► InfoInfo flowflow suggestssuggests differentdifferent groupingsgroupings ► InfoInfo gatheredgathered byby askingasking peoplepeople toto recordrecord theirtheir interactioninteraction frequencyfrequency withwith othersothers

56 ClusteringClustering aa DSMDSM

A B C D E F G A FEDBCG A A A A B B F F C C E E D D D D E E B B F F C C G G G G

No Dependency Low Hi

57 AlternativeAlternative ArrangementArrangement OverlappedOverlapped TeamsTeams

A FEDBCG A FEDBCG A A A A F F F F E E E E D D D D B B B B C C C C G G G G

No Dependency Low Hi

58 GMGM’’ss PowertrainPowertrain DivisionDivision

► 2222 DevelopmentDevelopment TeamsTeams intointo fourfour SystemSystem TeamsTeams ƒ Short block: block, crankshaft, pistons, conn. rods, flywheel, lubrication ƒ Valve train: cylinder head, camshaft and valve mechanism, water pump and cooling ƒ Induction: intake manifold, accessory drive, air cleaner, throttle body, fuel system ƒ Emissions & electrical: Exhaust, EGR, EVAP, electrical system, electronics, ignition

59 Existing PD System Teams

AFGDE I BCJ KPHNOQLMRSTUV Engine BlockA A z z z z zzzzz z zz zzz CrankshaftF z F zzzzzzz zzz z FlywheelG z z G z Team 1 zz Pistons D z z z D zzz zzz z z z Connecting RodsE z zzE z zz z Team 2 LubricationI z z z z z I z z zz zzz z Cylinder HeadsB z z z z B zzz z z z z Camshaft/Valve TrainC z zzz z C zz Team 3 z zz Water Pump/CoolingJ z z z z z J z z z zzz zz Intake ManifoldK z z z z z K z zz z

Fuel SystemP z P z zzz zz zz

Accessory DriveH z z z z z zzzH z zzzzzzzzz Air CleanerN z z N z z z A.I.R. O zzz z O z z z z z z Team 4 Throttle BodyQ zzzz z Q z z z z z ExhaustL zzzz zzz L z zzz z E.G.R.M z z zz zzz M z z z z EVAPR z z R z z IgnitionS zzzzzzzz z z z z z z S zzz E.C.M.T z z z zzzz z z z zzz z zzT z z Electrical SystemU z z z z z z z zzz zzz zzzzU z Engine AssemblyV zzz z z zzz z zzz zzzzz z z z V

Level of Dependence z High z Average z Low

60 Proposed PD System Teams

Crankshaft F F zzzzz zz z zz z z Flywheel G z G zzTeam 1 zz Connecting Rods E z E z zz zz z Pistons D z z z D z z z z z zz z z Lubrication I z zzz I z z zz zzzz z Team 2 Engine Block A z zzzz A zz z z zzzz z z Camshaft/Valve Train C zzz z C z zz zzz Cylinder Heads B1 z z z zzB1 zz z z Team 3 z z Intake Manifold K1 z z z z K1 z z zz z Water Pump/Cooling J z z z z z z J zzz z z z z z z Fuel System P z P zzzz z zzzzz Air Cleaner N z N z z z z z z Throttle Body Q zzz Q z z z z zz z z z Team 4 EVAP R z z R z z z Cylinder Heads B2 z z z B2 z z z z z z z z Intake Manifold K2 zz z zzzK2 z zzz zz z A.I.R. O zzz z zzO z z z z z z Exhaust L zz zz z z z z L z z zz z z E.G.R. M zzzzz z z z M zzz z z Accessory Drive H z z z z zzzz z z z zzz zzH zzzz Ignition S zz zzzzz z z z z z z z z z S zzz E.C.M. T Systemz zz zIntegrationzzz zz z zTeamz zz z z z z T z z Electrical System U z z z z z z zzzz zzzzz zzzz U z Engine Assembly V z zzzzz z zz z z z z zz zzzzz z z V

Level of Dependence z High z Average z Low

61 LessonsLessons Learned:Learned: IntegrationIntegration

► LargeLarge developmentdevelopment effortsefforts requirerequire multiplemultiple activitiesactivities toto bebe performedperformed inin parallel.parallel. ► TheThe manymany subsystemssubsystems mustmust bebe integratedintegrated toto achieveachieve anan overalloverall systemsystem solution.solution. ► MappingMapping thethe informationinformation dependencedependence revealsreveals anan underlyingunderlying structurestructure forfor systemsystem engineering.engineering. ► OrganizationsOrganizations andand architecturesarchitectures cancan bebe designeddesigned basedbased uponupon thisthis structure.structure.

62 ConclusionsConclusions

► TheThe DSMDSM supportssupports aa majormajor needneed inin productproduct development:development: ƒ documenting information that is exchanged ► ItIt providesprovides visuallyvisually powerfulpowerful meansmeans forfor designing,designing, upgrading,upgrading, andand communicatingcommunicating productproduct developmentdevelopment activitiesactivities ► ItIt hashas beenbeen usedused inin industryindustry successfullysuccessfully

63 AdditionalAdditional MaterialMaterial

► EppingerEppinger,, S.D.,S.D., "Innovation"Innovation atat thethe SpeedSpeed ofof Information,"Information," HarvardHarvard BusinessBusiness Review,Review, January,January, 33--11,11, 2001.2001.

64 MIT OpenCourseWare https://ocw.mit.edu

15.783J / 2.739J Product Design and Development Spring 2006

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