knowledge based enterprisinjg strategy for lean product develoment
TRANSCRIPT
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Brian Prasad
Knowledge-based Enterprising (KBE) Strategy for Lean Product
Development (LPD)
Biren (Brian) Prasad, Ph.D. President, Knowledge Solution,
Irvine, CA
http://www.KnowledgeSol.com/
Keynote Talk at
The 27th International Conference on
CAD/CAM, Robotics and Factories of the Future
Conference (CARS & FoOF 2014),
22-24 July 2014, London, UK
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Brian Prasad http://www.KnowledgeSol.com/
Mission
Our mission is to provide unequaled value through superior quality, performance
technical innovation speed and responsiveness, cost
savings via lean product development & premier
customer service via knowledge-based
developments
to our customers.
Innovation
Vision
Continuous Improvement
Vision
Knowledge Solution - Company
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Brian Prasad http://www.KnowledgeSol.com/
Product Development
Process
Functional Requirements
Engineered Product
Content
Time $ Cost
A Typical Product Development– What it is?
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Brian Prasad http://www.KnowledgeSol.com/
A typical Product-development process
Value-added activity
Type I waste Partial value-added
Type II waste Non value-added
TRADITIONAL
Value-added & Creative efforts
Repetitive tasks
Re-do’s Reinventing solutions Repeating mistakes
CE
With KBE KBAD
Further reduction in development effort
Innovate Automate
Value activity
Reuse
Apply Best practices
Apply Analysis
Insert New Ideas
Creative Efforts
Reduction in development
effort
Eliminate Continuous Improvements
Minimize
With Continuous Improvement
Repetitive tasks Value-added activity
Minimize
Creative Efforts
KBE: Knowledge –Based Enterprising or Engineering KBAD: Knowledge-Based Application Development
Knowledge–based Enterprising (KBE) Strategy for Lean Product Development – What it is?
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Brian Prasad http://www.KnowledgeSol.com/
A typical design scenario
Expert Engineers
Expert Analysts
Expert Designers
Product Engineers
Product Analysts
Product Designers
Project Managers
Function Managers
Knowledge –based Enterprising (KBE) Strategy for LPD – What it is?
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Brian Prasad http://www.KnowledgeSol.com/
What’s wrong with this?
• Knowledge is fragmented
• Subject matter experts (SME) often scarce and busy
• Less uniformity and consistency
• Time-intensive, manpower dependent
• When people retire, information is lost
• Often design is done via trial and error— case-based reasoning
Knowledge –based Enterprising (KBE) Strategy for LPD – What it is?
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Brian Prasad http://www.KnowledgeSol.com/
Expert Engineers
Expert Analysts
Expert Designers
Product Engineers
Product Analysts
Product Designers
Project Managers
Function Managers
KBE Strategy for Lean Product Development: Knowledge-centric approach
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Brian Prasad http://www.KnowledgeSol.com/
Modular
Procedural
Tightly-coupled
open
Level of integration
co
ncu
rre
nt
se
ria
l
Process path
KBE Strategy for Lean Product Development: Enrichment of knowledge…
is a continuum
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Brian Prasad http://www.KnowledgeSol.com/
KBE Strategy for LPD: Let’s consider this situation
BalanceTube
LVDT
SecondaryPiston (SPiston)
CenterGland (CG)
EndGland (EG)
RodEnd (RE)
PrimaryPiston (PPiston)
RampWasher
CEBearing
CGRetainer
EGRetainer
EGNut
REBearing
Cylinder
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Brian Prasad http://www.KnowledgeSol.com/
Procedural Strategy: Serial, tightly-coupled KBE system
Tandem SPiston
Tandem CenterGland
Tandem PPiston
Tandem Cylinder
Tandem EndGland
Tandem EGRetainer
Tandem CGRetainer
Tandem RodEnd
Tandem EGNut
Tandem REBearing
Tandem CGBearing
Tandem RampWasher
Tandem BalanceTube
Tandem LVDT
… Table
Design Table
Specs Table
Material Table
Analysis Tools
Modular
Procedural
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Brian Prasad http://www.KnowledgeSol.com/
Drawbacks of procedural KBE Strategy for LPD
• Part and product specific
• Hard-coded interfaces
• Cumbersome to maintain
• Incompatible API’s
• External parameter linking issues
• Very sensitive to interface changes (parameters, rules, features)
• Expansions are complex and error prone
• Inflexible
Modular
Procedural
Procedural KBE Strategy- Drawbacks?
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Brian Prasad http://www.KnowledgeSol.com/
Product Assembly
Completed Assembly
Detail Parts
SmartPart
Modular KBE Strategy: Rule-based System
Control Structure
High Level Requirements
Detail Requirements
An assembly of parametric parts, where dependence of one part to another is controlled by a “control structure logic”—whose primary function is to link relationships and attributes throughout a product hierarchy resulting in a product assembly that is associative.
Modular
Procedural
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Brian Prasad http://www.KnowledgeSol.com/
Modular KBE Strategy for LPD: System Approach
PERFORMANCE SPECIFIED
product concept (initial)
materials / attributes / features / parameters
develop system concept
decompose systems into subsystems
decompose subsystems into
components
decompose components into
parts
design each part
design pairs of parts
design pair of parts into components
design pair of components into
subsystems
design pair of subsystems into
system
design system concept
product concept
(working)
PERFORMANCE VERIFIED
Level 5
Level 4
Level 3
Level 2
Level 1
Level 0
Modular
Procedural
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Brian Prasad http://www.KnowledgeSol.com/
Modular KBE Strategy for LPD
Product Lifecycle Management (PLM) Implementation
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Brian Prasad http://www.KnowledgeSol.com/
Result of Modular KBE Strategy for LPD: Open, Concurrent LPD System
Product Definition
Configurator
Product Solution Configurator
SmartPart Configurator
Modular
Procedural
Apply Intra-Part Relations
Apply System Specs
Build System
Solution
Apply Inter-
Component
Relations
Apply Assembly Constraints
Build Sub-system
Solution
Build Component
Solution
Instantiate Chosen
Component
Templates
Build chosen
Component
Templates
Build Assembly Constraints
Choose a Sub-System
Configuration
Choose a System
Configuration
Choose a Component
Configuration
Build Intra-Part Rules & Relations
Build System Specs
Build Inter-
Component
Relations
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Brian Prasad http://www.KnowledgeSol.com/
Merits of modular lean product development
• Product-Independent • Architecture
• Part-Independent • Concept
• Tool-Independent • Method
Modular
Procedural
Product Definition Configurator
Product Solution Configurator
SmartPart Configurator
Modular KBE Strategy for LPD?
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Brian Prasad http://www.KnowledgeSol.com/
A CATIA V5 implementation
• System Architecture • JustOne system model and common tree
structure
• Generative Rule Bodies • Rule bodies create more rules dynamically on
the tree; asleep until awaken • Retrieve templates; no generative geometry
• Internal Linking • Two generalized automation methods to
pass/exchange information intrapart and interpart
Modular KBE Strategy for LPD?
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Brian Prasad http://www.KnowledgeSol.com/
Modular KBE Strategy Implementation: Specs Definitions (Excel Inputs)
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Brian Prasad http://www.KnowledgeSol.com/
Parameters
TypePart
CATParts
TypePartSpecs
TypePartSizing
TypePartGeometry
CATProduct
OpenLocked
Restricted
Type: Tandem
Modular KBE Strategy Implementation: SmartParts Creation
Parameters
TandemPiston
CATProduct
OpenLocked
Restricted
CATParts
TandemPistonSpecs
TandemPistonSizing
TandemPistonGeometry
Parameters
TandemGland
CATProduct
OpenLocked
Restricted
CATParts
TandemGlandSpecs
TandemGlandSizing
TandemGlandGeometry
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Brian Prasad http://www.KnowledgeSol.com/
Modular KBE Strategy Implementation: Achieving a Product Solution
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Brian Prasad http://www.KnowledgeSol.com/
Modular KBE Strategy Implementation: Inter- & Intrapart communications
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Brian Prasad http://www.KnowledgeSol.com/
Build a Component
Templates
Apply Intra-Part Relations
Apply System Specs
Build Assembly Constraints
Choose a Sub-System
Configuration
Build System
Solution Choose a System
Configuration
Choose a Component
Configuration
Build Intra-Part Rules & Relations
Apply Inter-
Component
Relations
Apply Assembly Constraints
Build System Specs
Build Sub-system
Solution
Build Component
Solution
Build Inter-
Component
Relations
Instantiate Component
Templates
SmartPart Configurator
Aggregation
Product Solution Configurator Product Definition
Configurator
Modular KBE Strategy Implementation: Demo
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Brian Prasad http://www.KnowledgeSol.com/
Demo–Salient points
• Initialize parameters • SmartParts pulled and Rules added • Specs parameters & constraints passed from
“systems” to “subsystems”, to “components,” to “parts” during “decomposition” and vice versa during “aggregation”
• SmartParts were “instantiated” and constraints satisfied
• Solution is reconfigurable for changing spec requirements
Modular KBE Strategy Implementation
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Brian Prasad http://www.KnowledgeSol.com/
Modular KBE Strategy Implementation:
…directly from spec
• Good for early program stages (Quick evaluation of various “alternate designs” scenarios)
• Gets you 80% there and you can finish the rest (20%) in native CATIA mode
Engineered design…
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Brian Prasad http://www.KnowledgeSol.com/
Engineered design…
• Good for early program stages (Quick evaluation of various “alternate designs” scenarios)
• Gets you 80% there and you can finish the rest (20%) in native CATIA mode
…directly from spec
• Unbalanced tandem actuator with 4100 psi supply pressure and 9.49 inch stroke.
Modular KBE Strategy Implementation
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Brian Prasad http://www.KnowledgeSol.com/
Engineered design…
• Balanced simplex actuator with 3050 psi supply pressure and 3.89 inch stroke.
…directly from spec
Modular KBE Strategy Implementation
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Brian Prasad http://www.KnowledgeSol.com/
Key Benefits
• Knowledge resides in one system and reused widely across the enterprise
• Order of magnitude savings (1:10 ~ 1:100)
• Promotes collaboration & knowledge sharing
• Product independent architecture
• Experts now become knowledge-keepers
• Promotes innovations and creativity
• Good for preliminary studies & portfolio mgt
• Knowledge inside, Lean inside, standards inside, analysis inside, best practices inside
Modular KBE Strategy for Lean Product Development (LPD)
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Brian Prasad http://www.KnowledgeSol.com/
Keys to maximizing productivity gains …
• KBE has its own life. Think about integration and interfaces. They are big deal for KBE.
• Holistic view of product development process • Employ a modular, open, and concurrent
strategy for building KBE systems • Think engineering centric versus geometry-
centric; analysis driven, geometry is a by-product
• Follow a knowledge management framework for applying KBE
Modular KBE Strategy for Lean Product Development (LPD)
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Brian Prasad http://www.KnowledgeSol.com/
Questions?
Contact: Biren (Brian) Prasad, Ph.D.
[email protected] [email protected]
Tel: (714) 396 9424
Knowledge Solution A PLM-LPD Service Company
Irvine, CA
Modular KBE Strategy for Lean Product Development (LPD)