End to End Digitalization Solution for Electronic Manufacturing

The Cambridge Engineering Selector (CES) is a tool that focuses on material, process, and shape combinations of product design. The Resource Consumption Model (RCM) is a tool that focuses on production process resources, resource costs, production volume, production capacity, and manufacturing cycle time. Both tools help identify viable manufacturing process alternatives to meet stated manufacturing objectives.

Highly accelerated life testing has been heavily promoted at Sandia (and elsewhere) as a means to rapidly identify product weaknesses caused by flaws in the product's design or manufacturing process. During product development, a small number of units are forced to fail at high stress. The failed units are then examined to determine the root causes of failure. The identification of the root causes of product failures exposed by highly accelerated life testing can instigate changes to the product's design and/or manufacturing process that result in a product with increased reliability. It is widely viewed that this qualitative use of highly accelerated life testing (often associated with the acronym HALT) can be useful. However, highly accelerated life testing has also been proposed as a quantitative means for "demonstrating" the reliability of a product where unreliability is associated with loss of margin via an identified and dominating failure mechanism. It is assumed that the dominant failure mechanism can be accelerated by changing the level of a stress factor that is assumed to be related to the dominant failure mode. In extreme cases, a minimal number of units (often from a pre-production lot) are subjected to a single highly accelerated stress relative to normal use. If no (or, sufficiently few) units fail at this high stress level, some might claim that a certain level of reliability has been demonstrated (relative to normal use conditions). Underlying this claim are assumptions regarding the level of knowledge associated with the relationship between the stress level and the probability of failure. The primary purpose of this document is to discuss (from a statistical perspective) the efficacy of using accelerated life testing protocols (and, in particular, "highly accelerated" protocols) to make quantitative inferences concerning the performance of a product (e.g., reliability) when in fact there is lack-of-knowledge and uncertainty concerning the assumed relationship between the stress level and performance. In addition, this document contains recommendations for conducting more informative accelerated tests.

New product design and new product process design are important attributes in order a company to survive and sustain in competitive market. However, many new products which have been developed from research and development cannot compete in world market due to product performance issue. In addition, design of new product is unable to cope with the process design and machine capability in manufacturing process. The aims of this study is to identify the relationship between new product design and new product process design on new product performance in manufacturing industry. Random sampling and survey have been used by distributing questionnaire to 400 respondents for final study. Finally 80 respondents had replied with the respond rate of 20%. The study result shows that the extent level in new product design and new product process design are moderate and high level respectively. Furthermore, there is a significant relationship between new product process design and organisational performance (r(80) = 0.570, p < 0.05) in SMEs. However, there are no significant relationships between new product design and organisational performance (r(80) = 0.092, p > 0.05). The study is important for SMEs to gain insight on the effect of new product design and new product process design towards organizational performance.

Gap Analysis and Optimization of Process Involved in Product Design and Development by Integrating Enterprise Resource Planning & Product Lifecycle Management

The modelling of nominal product geometry by computer-aided design tools has gained immense attention in industry during the last decades and is nowadays an integral part of the virtual product development process. However, the established geometry representation schemes for CAD imply severe drawbacks regarding the modelling of geometric part deviations, which are inevitably observed on every manufactured artefact. As a response, the concept of Skin Model Shapes, which stems from international standards for geometric product specification and verification, has been developed as a novel approach for the consideration of product shape variability. It employs discrete geometry methods and computational techniques, such as point clouds, surface meshes and geometric processing, to model shape variability and to facilitate the communication of geometric product information throughout the product design, manufacturing, and inspection processes. This paper highlights the foundations of this concept, demonstrates its potentials for the representation of product geometry considering geometric variations along the product lifecycle, and illustrates main applications in the context of computer aided product and process development. In this regard, a focus is laid upon recent results and contributions, such as contact modelling, tolerance analysis, and motion tolerancing based on Skin Model Shapes. Furthermore, challenges for future research, such as the application to complex shapes and compliant parts, as well as the consideration of novel manufacturing processes, are discussed.

Along with the rapid development of computer technology and CIMS technology, virtual prototyping in product design and manufacturing process are playing an increasingly important role. Based on the analysis the function of virtual prototype, the development platform architecture of virtual prototype for mechanical products is proposed in this paper. Furthermore, the integrated framework process, which is support the pump design, testing, operation, is analyzed in detail. The running case of virtual prototyping environment of pump assembly shows that the application of virtual prototyping technology provides a new idea and means for new product development and product performance improvement.

Cost management and quality analysis methods currently contribute to the decision support in product design and manufacturing process. One of the objectives is to evaluate a process plan in order to choose the most efficient solution in economic and qualitative terms. This study proposes a methodology based on Failure Mode and Effect Analysis (FMEA) with the financial aspects of risk, and Activity-Based Costing (ABC) in the purpose of economical evaluating the process plan. It shows how ABC and cost-based FMEA concepts can be adapted to measure quality-related costs and prioritize quality improvement efforts. Information modeling for this methodology is provided; and a case example is presented to illustrate its application.

PurposeThe purpose of this study was to identify the major quality features of wearable technology embedded products that have the greatest impact on consumer satisfaction using the Kano model, an organized approach to specify consumer requirements and expectation through a preference classification technique.Design/methodology/approachUsing a quantitative research method, an online survey was conducted with a convenience sample of US consumers aged between 19 years old and over. A total of otal 471 useable data were obtained and used for the data analysis.FindingsThis study identified that the 11 quality features of wearables belong to one-dimensional quality category among the five Kano categories, although the impact of each quality feature's performance on consumer satisfaction varies. The results also showed that the performance level of durability, long battery life, usability, product safety, comfortability and reasonable price has the greatest impact on consumer satisfaction of wearables.Research limitations/implicationsThis study has implications for future research by integrating the Kano model with other design and product development related theoretical models when designing, developing and evaluating various wearable products.Originality/valueThis study quantified the key quality features of wearables using the Kano model, which can be a great measurement tool for future researchers to adopt in their studies. The findings of this study help designers, developers and producers of wearables to prioritize the quality features during the product design, development and manufacturing process.

In product design and manufacturing process planning, we prefer the “best” product design out of all feasible designs, which is called the optimal design. Optimization techniques have become the major quantitative tools in engineering design and decision-making process. Process optimization is a process that adjusts a current process to optimize some specified sets of parameters without violating constraints. The most common goals are minimizing cost while maximizing profit and efficiency. This chapter introduces the formulation of a design problem as an optimization statement incorporated with the design constraints. Essential computational methods for solving the optimization statements with demonstrated examples are also discussed.

Quality Function Deployment (QFD) has long been used as a successful design methodology in the heavy industrial and automotive industries. QFD helps designers utilize the ‘voice of the customer’, or customer requirements, to determine which engineering metrics or product specifications are the most essential [1]. This prioritization helps designers know what part of the product or process is most beneficial to focus on during design, resulting in products that better meet customer requirements and generate increased commercial success. QFD and most other design methodologies have rarely been applied to MEMS products [2]. In the case of QFD, the structure of the most common format of the tool dictates that engineering metrics should be related to parts characteristics in the second step of applying QFD. This causes difficulties in using the tool for MEMS as most MEMS do not have physical ‘parts’ that are assembled into a final device. Rather, MEMS have product specifications and a manufacturing process used to create the product. Generally there is a tight link between product and process in MEMS. This link has been utilized in creating a modified version of QFD that relates engineering metrics to design concepts, including product conceptualization and manufacturing process. The modified QFD utilizes aspects of Pugh Concept Selection, and differs from typical QFD primarily in consideration of product idea and manufacturing process in the early phases of product definition. The modified QFD was applied to a MEMS project whose goal was to develop a handheld device that allows users to control the selection and release of a variety of stored scents. The technique was also applied to a microscale heat exchanger for integrated circuits. The scent dispenser and heat exchanger were designed and prototyped at Stanford University in 2005 and 2006, respectively. The modified version of QFD gave insight early in the product definition phase on which design concept to pursue to prototype. Use of this and other design methodologies in the MEMS field could shorten the time it takes to progress through product development to volume manufacturing, and increase confidence in the marketability of the chosen design and manufacturing process. A case study demonstrating the effects of using modified QFD Phase II to assist in finding a good fit between technical capabilities and market application was performed by the author on an acoustic sensor technology [3].

This paper presents a novel integrated system of rapid product development for reducing the time and cost of product development. The system is composed of four building blocks — digital prototype, virtual prototype, physical prototype and rapid tooling manufacturing system. It can aid effectively in product design, analysis, prototype, mould, and manufacturing process development by integrating closely the various advanced manufacturing technologies which involve the 3D CAD, CAE, reverse engineering, rapid prototyping and rapid tooling. Furthermore, two actual examples are provided to illustrate the application of this integrated system. The results indicate that the system has a high potential to reduce further the cycle and cost of product development.

&lt;div class="htmlview paragraph"&gt;The concept of design for six sigma (DFSS) offers a framework to design a product and process right the first time. In general, Taguchi's robust design method has been widely adapted in design optimization, which is a critical phase in any DFSS projects. The objective of the paper is to develop an advanced strategy in selecting an optimized product design and manufacturing process that should be insensitive to various multivariate variation patterns of the multi-stage manufacturing system. A Monte Carlo variation simulation based method is presented that integrates Mohalanobis Distance (MD) method, a discriminant analysis technique, to analyze the manufacturing variation patterns detected by using the multivariate statistical tool, such as principal component analysis (PCA). The proposed method will be explained with an example of an automotive assembly.&lt;/div&gt;

The electronic product design and manufacturing process are in constant evolution, posing very challenging situations for engineering validation and production test. Parts miniaturization, growing complexity, and high frequency are just a few of the main causes of not having available test points. This will result in a limited access to the electrical nets, resulting in a scares possibility to utilize traditional bed-of-nails in-circuit testers. To overcome these limitations, new-generation flying probe test system technology offers a number of innovative solutions. Modern flying probers are comprehensive multidisciplinary test equipment representing a paradigm shift towards the Multi-Domain Test. They are able to combine in a single test equipment different technologies, including real ICT, Power-On test, RF test (also on 5G devices), optical test, 3D laser inspection and thermal verification to reach the most comprehensive test coverage. In this way, state-of-the-art flying probers perform a complete, high-throughput production test even on the most advanced and miniaturized assemblies - overcoming the accessibility limits of bed-of-nails systems - letting escape none of the possible defects. Moreover, it will be possible to perform parallel device flashing by using the OBP (On Board Programming) for an unequalled throughput capability. The system operating software is developed to comply with the Industry 4.0 requirements and adopt the most advanced data security protection. Far from being simple MDA testers!

In the last two decades, lean product development and design processes, which have rapidly penetrated the automotive industry companies with all their functions and spread globally, have come to life with measurements, benchmarks and flow maps on value creation or value addition in new product project stages. In the literature review, two customer-oriented approaches, namely lean product development and user experience design, have been widely adopted within the discipline of new product design. However, the lack of comparative efficiency measurements or studies addressing their integration in scientific publications constitutes the primary motivation of this research. Furthermore, the selection of the research scope and boundaries is based on convenience sampling, enabled by direct qualitative research with companies managerial or design positions in the Turkish automotive supplier industry. The main objective of this study is to conduct a comparative analysis aimed at integrating user experience activities with lean product development process flows, and to reveal metric values that enhance efficiency through overall system optimization. On the other hand, the most important recommendation of the study is that the basic process will benefit positively by including user experience activities, which are the most important application of customer-oriented design approaches, into the highly efficient lean product development flow. Therefore, the study conducted with the mixed research method was completed under the preference of quantitative face-to-face interview method in the in-depth questioning of the qualitative numerical data obtained by the questionnaire method. User experience activities, which are newer and less widespread than lean product development processes, have also revealed the frequency of project-based, customer-oriented design activities, along with the demographic organizational structure of the participating companies in the automotive industry, such as the age of establishment, number of employees, number of designers, etc.

This chapter presents the overview of concurrent design process of green composite products with special focus on conceptual design stage of natural fiber composites product development. Design of green composites product especially during the early product development stage requires three main aspects in product design which are materials, design and manufacturing process to satisfy lower cost, high quality and fast development time requirements in order to ensure successful product launch into the market. In this chapter, the concurrent design process of green composite products are discussed involving several main stages in product development such as green composite materials selection for both natural fiber and matrix constituents, conceptual design development and concept design selection of green composite products, and green composites manufacturing process selection. In addition, discussion on life cycle assessment of green composites is also included in order to provide further insight of the sustainability design requirements to the overall product development process.