Documente Academic
Documente Profesional
Documente Cultură
Modularity and
and
Product
Product Architecting
Architecting
ME 546 - Designing Product Families - IE 546
Timothy W. Simpson
Professor of Mechanical & Industrial
Engineering and Engineering Design
The Pennsylvania State University
University Park, PA 16802
phone: (814) 863-7136
email: tws8@psu.edu
http://www.mne.psu.edu/simpson/courses/me546
PENNSTATE
T. W. SIMPSON
Recall:
Recall: Pines
Pines Five
Five Steps
Steps to
to Mass
Mass
Customization
Customization
Provide Quick
Response
5
4
Modularize
3
2
1
Customize Services
T. W. SIMPSON
Overview
Overview of
of Todays
Todays Lecture
Lecture
MODULARITY IS THE KEY enabler for successful
product family design and product platforms.
What is product architecture? What types exist?
What is modular design? What is its role in product
family and product platform design?
What is an interface? What is a module?
What are the different types of modularity?
What is a function? What is a function structure?
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T. W. SIMPSON
Architecture
Architecture
Beach
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Source - www.coolhouseplans.com
Contemporary
T. W. SIMPSON
System Architecture
System Boundary
T. W. SIMPSON
Architecture:
Architecture: Definition
Definition
Architecture
Consists of:
Function
Related by Concept
To Form
Function
Form
Concept
T. W. SIMPSON
Function-ConceptForm
Function: provide for
1) meeting place
2) visible main speaker
3) processions
Concept: church (Basilica)
Form
raised
T. W. SIMPSON
Product
Product Architecture
Architecture
Product architecture is:
Sources:
Ulrich, K., 1995, "The Role of Product Architecture in the Manufacturing Firm," Research Policy, Vol. 24(3), pp. 419-440.
Ulrich, K. T. and Eppinger, S. D., 2000, Product Design and Development (2nd Ed.), McGraw-Hill, NY, NY.
PENNSTATE
T. W. SIMPSON
Example:
Example: Coffee
Coffee
Maker
Maker
Overall
Function
Brew
Coffee
Electricity
Supporting
Sub-Functions
Auxiliary
Functions
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Water
Ground
Coffee
Coffee
Beans
Store
Water
Heat
Water
Heat
Coffee
Store
Grounds
Mix Coffee
and Water
Store
Coffee
Grind
Beans
Coffee
Shut-off
Heater
T. W. SIMPSON
How
How to
to Create
Create aa Function
Function Structure
Structure
1.
2.
3.
4.
5.
Source: Pahl, G. and Beitz, W., 1996, Engineering Design: A Systematic Approach (2nd Rev. Ed.), Springer-Verlag,
New York.
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T. W. SIMPSON
Morphological
Morphological
Matrix
Matrix
Search for solution principles to
fulfill sub-functions
T. W. SIMPSON
Heat
Coffee
Filter
Heat
Water
S11
Si1
Store
Store
Grounds Water
Brew
Coffee
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Morphological
Morphological Matrix
Matrix for
for Coffee
Coffee
Maker
Maker
S12
Osmosis Dissolve
S1j
S1m
Ionize
Stir
Si2
Sij
Sn1
Sim
Sn2
Snj
Snm
T. W. SIMPSON
Modular
Modular and
and Integral
Integral Architectures
Architectures Defined
Defined
After we identify solutions for each function, we can
combine them to identify modules in the architecture
Modularity is defined as (Ulrich and Tung, 1991):
1. there is a one-to-one correspondence between functional
elements and physical structures ...AND...
2. unintended interactions between modules are minimized
(i.e., component interfaces are de-coupled).
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Coupled
Coupled vs.
vs. Uncoupled
Uncoupled
Designs
Designs
Axiom: Maintain the interdependence of functional
requirements (N. P. Suh, Principles of Design, 1990)
Coupled
Design
Uncoupled
Design
Reference:
Billy Fredriksson, Holistic systems engineering in product development, Griffin , Saab-Scania, Nov. 1994/95
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T. W. SIMPSON
Types
Types of
of Modularity:
Modularity: Slot
Slot
In a slot architecture, each module
has a different interface with the
overall system.
Examples:
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T. W. SIMPSON
Types
Types of
of Modularity:
Modularity: Bus
Bus
In a bus architecture, there is a
common bus to which modules
connect via the same interface.
Examples:
PENNSTATE
T. W. SIMPSON
Types
Types of
of Modularity:
Modularity: Sectional
Sectional
In a sectional architecture, all
interfaces are the same type but
there is no single element to
which modules attach.
What are advantages and
disadvantages of a sectional
approach?
Examples:
Legos
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Sectional
Sectional Modularity
Modularity at
at
Nippondenso
Nippondenso
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T. W.
ST.IMPSON,
W. SIMPSON
2001
Products,
Products, Modules,
Modules, and
and Attributes
Attributes
Products
Product 1
Modules
A1
B1
C1
Different
products
Product 2
Types
Typesof
of
Modules:
Modules:
D1
Common
Common
A1
A1
A1
Variant
Variant
C1,C2
C1,C2
B2
C2
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Module
Attributes
Unique
Unique
B1,
B1,B2,
B2,D1
D1
T. W. SIMPSON
Example:
Example: B&D
B&D Versapack
Versapack Toolkit
Toolkit
Common
Variant
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Variant
Unique
T. W. SIMPSON
Creating
Creating aa Module-Based
Module-Based Product
Product Family
Family
1. Decompose products into their representative functions
2. Develop modules with one-to-one (or many-to-one)
correspondence with functions
3. Group common functional modules into a common
product platform
4. Standardize interfaces to
facilitate addition, removal,
and substitution of modules
Product
Family
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Common
Functions
Product
Platform
Specific
Function 1
Specific
Function 2
Specific
Function k
Derivative
Product 1
Derivative
Product 2
Derivative
Product k
T. W. SIMPSON
Example:
Example: Braun
Braun Family
Family of
of Coffee
Coffee
Makers
Makers
Electricity
Water
Ground
Coffee
Store
Water
Heat
Water
Heat
Coffee
Store
Grounds
Mix Coffee
and Water
Store
Coffee
Common
Function
Brew
Coffee
Coffee
Basic
Model
Water
Filter
Thermos
Karafe
Adjustable
Heater
Frothing
Attachment
KF130
KF145
KF170
KF180
KF185
KF190
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T. W. SIMPSON
Developing
Developing Modular
ModularArchitectures
Architectures
What are some rules of thumb you, as an engineer, might
follow to develop a modular product architecture?
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T. W. SIMPSON
Some
Some Heuristics
Heuristics for
for Module
Module
Development
Development
Stone, et al. (1998) developed
a set of three heuristics to
identify product modules from a function structure:
Dominant Flow:
examines flows through a function structure, following flows until
they either exit from the system or are transformed
the sub-functions through which these flows are traced define a
module
Branching Flows:
examines flows that branch into or converge from parallel
function chains
each branch of a flow can become a module; modules interface
at point where flow branches or converges
Conversion-Transmission:
examines flows that are converted from one type to another
develop a module which converts an energy or material flow into
another form and then transmits it
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T. W. SIMPSON
Some
Some Heuristics
Heuristics for
for Module
Module
Development
Development
Zamirowski and Otto (1999) define two heuristics to aid
in module identification within a product family:
Shared Functions:
functional groups which share similar flows and functions
and appear multiple times within a product family should
be grouped into a single module
this module can then be reused across the product family
Unique Functions:
identify functions that are unique to a single product or
subset of products
group functions into modules to facilitate product variety
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T. W. SIMPSON
Advantages
Advantages of
of Modular
ModularArchitectures
Architectures
Facilitates product change and product variety
modules can easily be upgraded, degraded, and added-on
modules can easily be reused or replaced
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T. W. SIMPSON
Disadvantages
Disadvantages of
of Modular
ModularArchitectures
Architectures
Easier to reverse engineer
Modular products tend to sub-optimal
Assembly costs are slightly higher
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T. W. SIMPSON
Advantages
Advantages of
of Integral
Integral Architectures
Architectures
Facilitates the optimization of holistic performance
characteristics and those that are driven by the size,
shape, and mass of a product [UE00]
Minimizes redundancy through function sharing
Minimizes number of parts which much be assembled
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T. W. SIMPSON
Disadvantages
Disadvantages of
of Integral
Integral Architectures
Architectures
Difficult to upgrade and reconfigure
Adjusting or fine-tuning a single function can be more
complex and difficult
Components and modules cannot be easily replaced if
worn or broken
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T. W. SIMPSON
Modular
Modular vs.
vs. Integral
Integral Architectures
Architectures
As product functionality overshoots customer needs,
modular architectures become more competitive
Performance
Compete through
superior functionality
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Compete through
speed, customization,
and convenience
Time
Adapted from:
C. Christensen and M. Verlinden, 2002, "Disruption, Disintegration, and the Dissipation of Differentiability,"
Industrial and Corporate Change, vol. 11(5), pp. 955-993.
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T. W. SIMPSON