According to W. Edwards Deming, American companies require nothing less than a transformation of management style and of governmental relations with industry. In Out of the Crisis, originally published in 1982, Deming offers a theory of management based on his famous 14 Points for Management. Management's failure to plan for the future, he claims, brings about loss of market, which brings about loss of jobs. Management must be judged not only by the quarterly dividend, but by innovative plans to stay in business, protect investment, ensure future dividends, and provide more jobs through improved product and service. In simple, direct language, he explains the principles of management transformation and how to apply them.

Out of the Crisis

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The New Economics for Industry, Government, Education

Kaizen: The key to Japan‚s competitive success

Revolutionizing product development

As companies strive to develop artefacts intended for services instead of traditional sell-off, new challenges in the product development process arise to promote continuous improvement and increasing market profits. This creates a focus on product life-cycle components as companies then make life-cycle commitments, where they are responsible for the function availability during the extent of the life-cycle, i.e. functional products. One of these life-cycle components is manufacturing; therefore, companies search for new approaches of success during manufacturability evaluation already in engineering design. Efforts have been done to support early engineering design, as this phase sets constraints and opportunities for manufacturing. These efforts have turned into design for manufacturing methods and guidelines. A further step to improve the life-cycle focus during early engineering design is to reuse results and use experience from earlier projects. However, because results and experiences created during project work are often not documented for reuse, only remembered by some people, there is a need for design support. Knowledge engineering (KE) is a methodology for creating knowledge-based systems, e.g. systems that enable reuse of earlier results and make available both explicit and tacit corporate knowledge, enabling the automated generation and evaluation of new engineering design solutions during early product development. There are a variety of KE-approaches, such as knowledge-based engineering, case-based reasoning and programming, which have been used in research to develop design for manufacturing methods and applications. There are, however, opportunities for research where several approaches and their interdependencies, to create a transparent picture of how KE can be used to support engineering design, are investigated. The aim of the research presented in this thesis is to create new methods for design for manufacturing, by using several approaches of KE, and find the beneficial and less beneficial aspects of these methods in comparison to each other and earlier research. This thesis presents methods and applications for design for manufacturing using KE. KE has been employed in several ways, namely rule-based, rule-, programmingand finite element analysis (FEA)-based, and ruleand plan-based, which are tested and compared with each other. Results show that KE can be used to generate information about manufacturing in several ways. The rule-based way is suitable for supporting life-cycle commitments, as engineering design and manufacturing can be integrated with maintenance and performance predictions during early engineering design, though limited to the firing of production rules. The rule-, programmingand FEA-based way can be used to integrate computer-aided design tools and virtual manufacturing for non-linear stress and displacement analysis. This way may also bridge the gap between engineering designers and computational experts, even though this way requires a larger effort to program than the rule-based. The ruleand planbased way can enable design for manufacturing in two fashions – based on earlier manufacturing plans and based on rules. Because earlier manufacturing plans, together with programming algorithms, can handle knowledge that may be more intricate to capture as rules, as opposed to the time demanding routine work that is often automated by means of rules, several opportunities for designing for manufacturing exist.

Methods and Applications

As functional (total care) products emerge in the jet engine industry, the need for product life-cycle models capable of definition and evaluation of life cycle properties increases, since functional products (FP) includes both hardware and service. Recent life-cycle models are intended for hardware products and mostly handle design and manufacturing knowledge. The aim of this article is to present a design approach that extends the evaluation capabilities beyond classical hardware design and manufacturing evaluation. The focus has been to introduce evaluation of manufacturing and post-manufacturing activities in evaluation of conceptual designs. For this purpose, a model has been proposed to handle the information flow between teams when developing structural jet engine components. A case study, in which the proposed model was used in cooperation with a jet engine component manufacturer, is presented. Aspects concerning design, manufacturing, performance, and maintenance of jet engine flanges were included in the example by means of a knowledge based engineering (KBE)-system coupled to databases and spreadsheets. The model is more suitable than recent work for the development of hardware parts of functional products (HFP), since knowledge from more product development disciplines is included. As the engineer changes the design and directly assesses the life-cycle cost (LCC) and how the changes impact the interface to other jet engine components, more knowledge on the impact of design decisions is available at hand for the engineering designer than without the model.

https://www.tobiasclarsson.com/wp-content/uploads/SandbergLarssonEtAl-FunctionalProductLifeycleSimulationModelForCostEstimationInConceptualDesignOfJetEngineComponents-2005.pdf

Functional Product Life-cycle Simulation Model for Cost Estimation in Conceptual Design of Jet Engine Components

This report gives an introduction to Knowledge Based Engineering (KBE) in product development. KBE can be seen as a tool for capturing knowledge and reusing it. The concept of KBE is therefore very ...

Knowledge Based Engineering - In Product Development

In construction projects, a large number of deviations are usually found during inspections and adjusted in a reactive manner. For projects to become proactive, root causes need to be identified and eliminated as a part of a process of continuous improvement (CI). Plan-do-check-act (PDCA) methods are part of CI and have been used with success within the manufacturing industry for decades. Research studies of PDCA in construction are less common, which could be explained by the past dominance of the project-based nature of construction compared to the process-based nature of manufacture. Industrialized construction, however, has changed this picture somewhat, and it is of interest to find out how well it works for less industrialized activities in construction. A PDCA method was tested in two cases selected from one medium-sized Swedish industrialized housebuilder, which uses a building system based on offsite manufactured modules. Empirical results are based on systematic data gathered through interviews ...

A study of a plan-do-check-act method used in less industrialized activities: two cases from industrialized housebuilding

Virtual design tools and methods can aid in creating decision bases, but it is a challenge to balance all the trade-offs between different disciplines in building design. Optimization methods are at hand, but the question is how to connect and coordinate the updating of the domain models of each discipline and centralize the product definition into one source instead of having several unconnected product definitions. Building information modelling (BIM) features the idea of centralizing the product definition to a BIM-model and creating interoperability between models from different domains and previous research reports on different applications in a number of fields within construction. Recent research features BIM-based optimization, but there is still a question of knowing how to design a BIM-based process using neutral file formats to enable multidisciplinary optimization of life-cycle energy and cost. This paper proposes a framework for neutral BIM-based multidisciplinary optimization. The framework consists of (1) a centralized master model, from which different discipline-specific domain models are generated and evaluated; and (2) an optimization algorithm controlling the optimization loop. Based on the proposed framework, a prototype was developed and used in a case study of a Swedish multifamily residential building to test the framework’s applicability in generating and optimizing multiple models based on the BIM-model. The prototype was developed to enhance the building’s sustainability performance by optimizing the trade-off between the building’s life-cycle energy (LCE) and life-cycle cost (LCC) when choosing material for the envelope. The results of the case study demonstrated the applicability of the framework and prototype in optimizing the trade-off between conflicting objectives, such as LCE and LCC, during the design process.

https://www.mdpi.com/2071-1050/11/1/286/pdf

Multidisciplinary Optimization of Life-Cycle Energy and Cost Using a BIM-Based Master Model

SUMMARY: Swedish prefabricators of domestic buildings need to become more effective and efficient; the aim of this paper is to investigate the usefulness of rule-based IT support tools for this purpose. The current sales and design process at a timber volume element prefabricator is presented and evaluated regarding information management and standardisation. It was found that information management during early design is often ad hoc and person dependent; therefore searching for information that could lead to reuse of past solutions is rather time demanding. There is a need for standardisation due to a mentality of designing one-of-a-kind buildings. Knowledge-based engineering is seen as an enabler to enhance the current situation and an IT support procedure is suggested. A demonstrator stair tool was tested, which lets the seller discuss needs with the customer and then use the tool to assess cost and manufacturability. It is argued that the IT support procedure can enable; automation of activities and availability of down stream knowledge in virtual format and a connection between instances of the same geometry. If design flaws can be found early on, downstream waste activities can be reduced. Standardisation could be realised through modularisation, which the implementation of the IT support tool procedure could gain from.

/pdf/knowledge-based-engineering-in-construction-the-3tajynkx0x.pdf

Marcus Sandberg

Papers

Functional Product Life-cycle Simulation Model for Cost Estimation in Conceptual Design of Jet Engine Components

Knowledge Based Engineering - In Product Development

A study of a plan-do-check-act method used in less industrialized activities: two cases from industrialized housebuilding

Multidisciplinary Optimization of Life-Cycle Energy and Cost Using a BIM-Based Master Model

Knowledge-based engineering in construction: the prefabricated timber housing case