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2.008 Design & Manufacturing II

Spring 2002

Systems Design

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- HW#1 due today. - No HW today. - Reading, Kalpakjian, P177-199- Monday 2/16, Holiday- Tuesday 2/17, Monday’s lecture & lab group A- Wednesday 2/18, Yo-Yo case study

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Super bowl 2002

BIG PICTURE

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Systems DesignIs Pats a good team?

Is MIT a good school?

Am I a good teacher?

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A University (Manufacturing System)

High schoolsColleges

Etc.

Faculty, staff, academic programs

Graduate schools

IndustryGovernment

Societyadministration

Suppliers CustomersManufacturing system

graduationadmission F So J Se

FundamentalKnowledgeHands-onknowledge

Image removed due to copyright considerations.

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Good Design lecture room ?

Boston T ?

Honda Civic ?

Logan Airport ?

Government ?

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Design Domains“What” to “How”, “Top” to “Bottom”

What HowFunctionalRequirements

Design Parameters

No impromptu designs!!

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Light

50 µm

Active Matrix

PiezoelectricActuator

Mirror

TMA(thinfilm micromirror array)

Mirror Array on

Piezoelectric

Actuator Array

Daewoo Electronics

Case study

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TMA

Projection Lens

Light Source

Modulation Stop

TMAMirror

Source Stop

No TiltingNo Tilting

Max. TiltingMax. Tilting

Black

White

Increase of tilting angle

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Evolution of TMA Pixels

00 02 04 06 084

8

12

16

20

24

Opt

ical

Effi

cien

cy(%

)

Year

1st1st2nd2nd

3rd3rd

Daewoo Electronics

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Functional Requirements of TMA

1st GenerationFR1= light reflectionFR2= mirror tilting

DP1= cantilever top surfaceDP2= PZT sandwich

FR1FR2

DP1DP2

= X XX X

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Image by 1st Gen. TMA –96’ 12

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Functional Requirements of TMA

2nd GenerationFR1= light reflectionFR2= mirror tilting

DP1= cantilever top surfaceDP2= PZT sandwich

FR1

FR2

DP1

DP2

= X OX X

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Image by the 2nd Gen. TFAMA - 1997.07

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Functional Requirements of TMA

3rd GenerationFR1= light reflectionFR2= mirror tilting

DP1= cantilever top surfaceDP2= PZT sandwich

FR1

FR2

DP1

DP2

= X OO X

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VGA640 X 480307,200 pixels

50 µm

Human Hair

XGA1024 X 768

786,432 pixels

TMA

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Image by the 3rd Gen. TMA -1997.12

150 in. Screen150 in. Screen

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XGA Image, Nov. 1999

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Good Designin small scale products?

“What” to “How”, “Top” to “Bottom”

What HowFunctionalRequirements

Design Parameters

Design Axioms

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Example: Shower Faucet

Functional Requirements- Temperature- Flow rate

θh

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Independence AxiomMaintain the independence of FRs.

Shower faucet example

FR1FR2

DP1DP2

= X XX X

FR1= TemperatureFR2= Flow rate

DP1= Hot waterDP2= Cold Water

FR1FR2

DP1DP2

= X OO X

FR1= TemperatureFR2= Flow rate

DP1= Horizontal AngleDP2= Vertical Angle

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Information AxiomMinimize the information content of the design

Design range

System range

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Functional RequirementsAl Cans12 FRs

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Systems View–Four Design Domains

CustomerDomain

FunctionalDomain

Physical Domain

ProcessDomain

?

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Isolated domains

High walls

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Concurrent Engineering

CustomerDomain

FunctionalDomain

Physical Domain

ProcessDomain

Lower walls-Car program manager-Project Manager

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Four domains

People resources

Programs offices

FunctionsCustomer satisfaction

Organization

ResourcesBusiness structure

Business goals

ROIBusiness

SubroutinesInput variables

Output of programs

Attributesdesired

Software

ProcessesMicro-structure

PropertiesPerformancesMaretials

PVDPFRCAManufacturingsystems

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Systems DesignCustomer SatisfactionConcurrent DesignDesign for Manufacturing, Assembly and “X”Quality Control, Six SigmaHouse of Quality, Takuchi methodAxiomatic Design

Any of these efforts in MEMS/Nano?

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Principles of Design

AxiomsDoes scale matter?

Multi-scale Systems design, 2.76Culpepper & Kim, Fall 2004

Axiomatic Design, 2.8821. N.P. Suh, Principles of Design, Oxford, 19902. N. P. Suh, Axiomatic Design: Advances and

Applications, Oxford, 20013. N. P. Suh, Complexity: Theory and Applications,

Oxford, 2004

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Manufacturing

Unit Manufacturing

Processes

Assembly and Joining

Design forManufacture

MarketResearch

ConceptualDesign

Factory, Systems & Enterprise

•Welding•Bolting•Bonding•Soldering

•Machining•Injection molding•Casting•Stamping•Chemical vapor deposition

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Manufacturing System

ManufacturingSupportsystem

FacilitiesFactory

equipments

Raw materials Finished productsFactory operationsProcessingMaterial handlinginspection

Design

Manufacturingplanning

Manufacturing control

Marketing

Value add process

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Manufacturing

Transformation of materials and information into goods for the satisfaction of human needs

Big Picture ?

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History

1. Greek “manu factus”: made by hand

2. Early mode: piece by piece by skilled artisan

3. In 1750 - 1800: Industrial revolution Early machine toolConcept of factory

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History (cont)4. 1800’s Process specialization

Division of laborEli Whitney, etc., Interchangeable parts

5. Early 1900: Optimization (Manufacturing systems)F.W. TaylorEconomy of scaleCost reduction for high volume productionHenry Ford’s Model T

6. 1950’s: Numerical control (Information technology)AutomationLean manufacturing, JIT6 sigma, ppm

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Post-Industrial-Revolution History of Manufacturing Technologies

The Industrial Revolution (1770-1830): Introduction of steam power to replace waterpower and animal-muscle power.

Decline in yearly hours worked per person: From 3000 hours to 1500 hours in Europe and to 1600 hours in North America.

Increase in labor productivity.

Increase in GDP per worker: 7 fold in U.S.A., 10 fold in Germany, and 20 fold in Japan.

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Automotive Manufacturing Industry

The Ford Motor Co. has been the most studied and documented car manufacturing enterprise.

The 1909 Model T car was easy to operate and maintain.

By 1920, Ford was building half the cars in the world

(more than 500K per year).

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Automotive Manufacturing Industry (cont.)

54,94746,85629,74510,5774,80025655N/AWorld1,9721,5692,1837851761431.6U.K.

2,8322,05045S. Korea

9,90511,2274,67432N/AJapan

1,7011,2671,5921274051N/AItaly

5,6873,9903,739304551341Germany3,0323,1552,45935717738202France

3,0562,2371,353388161Canada

13,02410,86410,2068,0054,265187233U.S.A.

19991993196819501925191019051899Table. Motor vehicle production numbers per year per country (in thous.)

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Manufacturing Industry$4 Trillion, shipments, 1997

1997 Economic Census, U.S. Census BureauWhole Sale $4 T, Retail $2.5 T

459 SIC industries (NAICS)

http://libraries.mit.edu/subjects/course.html

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Gross State Product

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US Gross State Product, 1992

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Big Picture

Information Technology (digital)

Globalization

New Manufacturing Technology

New Materials

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Key Issues• Engineering disciplines

• Materials• Manufacturing processes• Manufacturing equipment• Design for manufacturing (DFM)

• Management disciplines• Work force• Societal obligation• For-profit organization• 2.96

• Integration• Manufacturing systems

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Processes of 2.008

Metalcomponents

Plasticcomponents

Silicon

Joiningprocesses

Removal

Squeezing

Melting

Injection molding

Thermo forming

Welding

Soldering/brazing

Gluing

Milling, turning, drilling

Forging, stamping

Casting

DepositionEtching

CVD, PVD

Wet, dry

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Manufacturing Attributes for Decision Making

CostRateQualityFlexibility

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Material removal –the oldestCost:

Expensive $100 -$10,000

Quality:Very high

Flexibility:Any shape under the sun

Rate:Slow

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Metal squeezingCost:

Cheap, $0.1 - $100Quality:

reasonableFlexibility:

Shapes limited constant cross-section

Rate:Fast (cycle time in sec), high volume

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MeltingCost:

Expensive $100 - $10,000Quality:

Requires post finishingDie casting

Flexibility:Very flexible, good for large parts

Rate:Very slow

Machine tool surface plate, gray iron 14,500 lbs

16V engine block

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Plastics processingCost:

Expensive mold and die, over $10,000

Quality:Very high

Flexibility:Opening for ejection

Rate:Very fast

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JoiningCost:

Cheap, but expensive labor

Quality:Wide range

Flexibility:Manual vs automated

Rate:Slow in general

Very Large Crude Carrier (VLCC)

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Thinfilm fabricationCost:

Very expensive $Millions

Quality:Very high

Flexibility:Any shape in 2-D

Rate:Slow

300mm dual stage lithography system capable of 110nm resolution

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Typical Cost BreakdownSelling Price

Admin, sales24%

Profit19%

R&D5%

Manufacturing38%

Engineering14%

Manufacturing Costs

Direct labor12%

Parts, Material

50%Indirect labor26%

Plant Machinery

12%

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Performance Measures

Capital costProduction rate or capacityCycle timeLead timeMachine utilizationWork-in-processOn-time deliveries