new iprod meeting university novi sad 25. – 28.11.2013 teaching...
TRANSCRIPT
1 01.07.2011 KIT – Universität des Landes Baden-Württemberg und nationales Forschungszentrum in der Helmholtz-Gemeinschaft www.kit.edu
IPEK – Institut für Produktentwicklung
IPROD Meeting University Novi Sad 25. – 28.11.2013 Teaching basics in Product Development – SPALTEN Prof. Dr. Ing. Albert Albers / OI Norbert Burkardt, Chief Engineer Education
2 01.07.2011
Karlsruhe Institute of Technology One institution. Two missions.
Staff
350 Professors
23.500 Students
650 Million Euros Budget
8.000
3 01.07.2011
IPEK Institute of Product Engineering
4 01.07.2011
2 professors
7 research groups 5 senior engineers 62 scientists 20 technical staff
education since 1996 50 Ph.D. 14 lectures over 300 student assistants ~3000 coached students
equipment automotive test labs high performance computing test vehicles mech. & elec. workshops
IPEK Institute of Product Engineering Karlsruhe Facts
Prof. Albert Albers – KaLeP: Karlsruher Lehrmodell für Produktentwicklung – Ein Ansatz zur Kompetenzerfassung in der Ingenieurausbildung
5 01.07.2011
IPEK Research Approach Research Fields
Research Designs the Future.
optimization lightweight design condition monitoring design methods and management friction systems NVH / driveability mechatronic systems appliance and power tool design Competence Measurement
in Teaching Programs
KIT – University of the State of Baden-Württemberg and National Research Center of the Helmholtz Association
Dipl.-Ing Burkhardt, Norbert | Karlsruhe, 24th and 25th of November
www.kit.edu
Product Development – Development Management April 2013 www.hectorschool.com
7 01.07.2011
Innovation
Ident-Nr. 110091
8 01.07.2011
Idea for a product – product of an idea
?
9 01.07.2011
WHAT IS A PROBLEM ??
Ident-Nr. 111004
10 01.07.2011
Types of problems
Ident-Nr. 109666
t
target
present
present
E.g. Production rejects IT-problems Customer rejects due to defects
E.g. Develop new product Prototype SOP Increase production output
Emergency situation
Scheduling situation target
11 01.07.2011
Emergency situation Target: Retrival of the initial PRESENT state
Types of problems in product design
Ident-Nr. 109670
t
TARGET
PRESENT
12 01.07.2011
Scheduling situation Target: Definition of a new TARGET state and adapting the PRESENT state
Types of problems in product design
Ident-Nr. 109672
TARGET
PRESENT t
13 01.07.2011
Subjektive perception of the difficulty of the problem Subjektive perception of the PRESENT-TARGET process Subjektive perception of the urgency Difference between PRESENT and TARGET is already existent
Emergency situation Difference between PRESENT and TARGET will only be existend in the future
Scheduling situation: Chances und risks
Complexity of processes and interrelations vary on a wide range
Characteristics of a problem
Ident-Nr. 109673
14 01.07.2011
Functionality of physiological brain structure Short-time memory
Ability to abstract and logical thinking Evolution focuses on problems of medium dimensions and low complexity
Effort/time minimizing as natural principle of evolutionary systems
Human beings tend to simplify and to static perception of problems
Safety ambition Remain in existing schemes
Causes for errors in problem solving
Ident-Nr. 109679
Source: „Integrierte Produktentwicklung“, Klaus Ehrlenspiel, 3. Auflage
15 01.07.2011
Influencing factors on creativity
Problem solving needs creative thinking
Ident-Nr. 109678
Creativity
Fantasy
Knowledge Experience
16 01.07.2011
From neurobiologic point of view the brain is not made for learning by heart of following instructions, but for solving of problems A brain can not be changed by pulling and pushing The brain has to be touched emotionally
Activation of the emotional centres in the midbrain leads to dispersion of neuroplastic transmitters which show effects comparable to brain-fertilizer
People only achieve their full creative potential for problem solving if they get stimulated by enthusiasm
Enthusiasm is an important and effective multiplier for neuronal remodeling processes
Influences on our problem solving potential
Ident-Nr. 110999
source: Prof. Dr. G. Hüther, Neurobiologist
17 01.07.2011
Meta competences are found in the frontal lobe Inner attitudes Convictions
based on which we decide and assess
Those cannot be influenced by instructions and advice, but only by new positive experiences Einstein: „The problems that extist in the world today cannot be solved by the level of thinking that created them.“
Motivation for creative problem solving
source: Prof. Dr. G. Hüther, Neurobiologist Ident-Nr. 111000
18 01.07.2011
Precise Identification of problem: facts / presumptions Enforce a sequence: analysis solution Generate a variety of solutions Choose the best solution Learn for the future
General objectives of problem solving methodology
Ident-Nr. 109683
19 01.07.2011
SPALTEN… describes an universal methodology for dealing with problems bases on experience and research results on problem solving and systems engineering can be applied both on future orientated developing problems and on spontaneous problems can be applied both on technical problems and on non-technical problems
Problem Solving Methodology SPALTEN Basics and range of application
Ident-Nr. 109684
20 01.07.2011
SPALTEN… integrates many tools of problem solving to a holistic method has to be applied with adjusted concretion and abstraction level depending on task. This embeds all sub-processes as well should always be used problem adapted to optimize profit/effort relation
Problem Solving Methodology SPALTEN Basics and range of application
Ident-Nr. 109685
21 01.07.2011
Problem solving methodology SPALTEN:
Methods for problem solving in product development
S – Situation analysis
P – Problem isolation
T – Analysis of consequences
A - Alternative Solutions
L – Solution selection
E – Decision and implementation
N – Review and learning
Prob
lem
ana
lysi
s So
lutio
n se
arch
So
lutio
n im
plem
enta
tion
Situation diagnostics
Problem diagnostics
Variety of solutions
Selection of solution
Chances and risks
Project management
CIP
Continous inform
ation check
Continous check of problem
solving team
Continous Im
provement P
rocess and Ideas Storage
Ident-Nr. 110995
22 01.07.2011
SPALTEN Activity flow and interrelations SA to AL
Ident-Nr. 109736
PL Team (PLT)
SA PE PLT ok. ? AL
Information about the problem
targets
way unclear
way clear
TA
Problem No Problem
Way
~
IC* IC*
solution search Process of the P-analysis
*IC: information check
23 01.07.2011
SPALTEN Activity flow and interrelations SA to AL
Ident-Nr. 109737
Solutions search
AL LA PLT ok? TA EU NL
PLT ok?
PLT ok?
PLT ok?
IC IC IC IC CIS PL
Team Feed- back LV1
LV2
LV3
.....
Solution moti- vation
Risk Scenario
Solution moti- vation
Chances Scenario
Problem?
Problem?
Action plan Result ?
No problem
solution implementation
Solution implementation
Way
~
24 01.07.2011
The first step of a problem solving process is to select a qualified PST Before every SPALTEN-activity, the PST is to be checked with respect to qualification and competence and has to be adapted if necessary In case of very limited HR
Employ persons according to actual demands Compensation of missing types by motivation and moderation
Systematic Problem Solving ProblemSolvingTeam (PST)
Ident-Nr. 109738
25 01.07.2011
Ideas for proceeding and problem solving are generated continuously during the problem solving process by PST
Those ideas are fixed immediately and deposited in the CIS, to be used at any time during the problem solving process (PSP)
The PST appoints a responsible CIS organizer in the first meeting
Systematic Problem Solving Continous Ideas Storage (CIS)
Ident-Nr. 112263
26 01.07.2011
Continous Ideas Storage (CIS) Examples
Ident-Nr. 112264
27 01.07.2011
Information base used effectively? (ist aktueller Wissens-/Informationsstand ausreichend?)
Check ratio profit / effort
Is level of detail of process step adequate to situation?
Information about process status to be processed to affected institutions (e.g. departments, customer, ...)!
Systematic Problem Solving Information Check (IC): Questions and Activities
Ident-Nr. 112265
28 01.07.2011
SPALTEN Integration of SA in activity flow and interrelations
Ident-Nr. 109736
PL Team (PLT)
SA PE PLT ok. ? AL
Information about the problem
targets
way unclear
way clear
TA
Problem No Problem
Way
~
IC* IC*
solution search Process of the P-analysis
*IC: information check
29 01.07.2011
Situation = Information demanding action Situation analysis = situation evaluation Objective:
Identification and cognition of situation Define target course and procedure of PSP Create information base for generation of alternative solutions
S P A L T E N SA
Ident-Nr. 109744
30 01.07.2011 Ident-Nr. 112266
Clarify situation
Determine situation handling
SA 1
SA 2
SA 3
SPALTEN - SA Segmentation in 3 sub-activities
Comprehend and classify situation
31 01.07.2011
SPALTEN – SA 1 and SA 2 comprehend and clarify situation
Ident-Nr. 109746
SITUATION
Causes?
- symptoms - assumptions/ facts - backgrounds
System?
Time? Solutions? intervention possibilities
target direction means
expectations
occurrence
future development?
urgency
intervention → effect
interaction
structure
32 01.07.2011
Which criteria determine priority? Checklist for criterion Explosiveness
Ident-Nr. 109748
no. criteria influence reasonwho ? h m lwe 1 immediate danger
2 deadline3 missed deadline4 interactions5 subcontractor678
customer 1 immediate danger2 deadline3 missed deadline4 interactions5 subcontractor67
competition 1 strategic position improvement2 short-term market volumina3 immediate competition advantage
*h = high, m = medium, l = low
33 01.07.2011
Which criteria determine priority? Checklist for criterion Impact
Ident-Nr. 109749
no. criteria influence reasonwho ? h m lwe 1 corporate mission
2 endangerment potential3 amount4 market position5 sales6 costs7 image - customer relationship8 subcontractor
customer 1 corporate mission2 endangerment potential3 amount4 market position5 turnover6 costs7 image - customer relationship
competition 1 strategic market position2 market volumina3 competition advantage
*h = high, m = medium, l = low
34 01.07.2011
Which movement exists regarding the situation elements? rise, fall, stay
What happens without reaction? short-term, medium-term, long-term
How fast did the changes occur?
How fast can influence be taken?
Which criteria determine priority? Checklist for criterion Movement
Ident-Nr. 109750
35 01.07.2011
SPALTEN Einordnung PE in Ablauf & Wechselwirkungen
Ident-Nr. 107167
PL Team SA PE
PLT i.o. AL
Informationen zum Problem
Ziele
Weg unklar
Weg klar
TA
Problem Kein Problem
Weg
~
IC IC
Lösungssuche Prozess der P-Analyse
36 01.07.2011
Ziel: Identifikation des eigentlichen Problems
Bewusste Klärung des Ist- und des Soll-Zustandes Genaue Ermittlung der Gründe für die Abweichung
Aufstellung und Untersuchung der Kausalkette
SPALTEN Wozu Problemeingrenzung (PE)?
Ident-Nr. 107168
37 01.07.2011
SPALTEN - PE Segmentation in 4 sub-activities
Ident-Nr. 112268
PE 1
PE 2
PE 3
PE 4
locate anomalies
describe and outline anomaly
locate possible causes for anomaly
assess causes by probabilities
38 01.07.2011
SPALTEN – PE Extrusion of window-profile: IS / IS Analysis
Ident-Nr. 112269
IS IS Which object has anomaly?
Which anomaly exactly? Main window profile XY Surface quality under-runs limit
Where did the anomaly occur on the object?
Top side (surface xy, on an area of … mm)
Which similar objects are not affected? Main window profile XX All other profiles of the same category
Which anomaly could have
been occurred, but did not? Other plain surfaces of the profile Other profiles of the same type
39 01.07.2011
SPALTEN – PE Extrusion of window-profile: IS / IS Analysis
Ident-Nr. 112272
IS IS Where exactly was the
object when the anomaly occurred? Not exactly known when and where in the production process
When did the anomaly occur first? When was it observed?
Was first documented at …
Where else could an anomaly occur? Where else could the object be? Surface damages can occur in the following packaging processes
When else could it have occured first?
Max. 2 hours before (because of the testing frequencies
40 01.07.2011
SPALTEN – PE Extrusion of window-profile: IS / IS Analysis
Ident-Nr. 112273
IS IS When and how did it occur
again? Sporadically, periodically, continuously? Started sporadically, 6 hours later it occurred continuously
How will the future development of the anomaly be? Which trend can be recognized?
Surface quality will decrease constantly
When else could it have been identified first?
See above Which other trend could have
been happened? Surface quality could stay on a certain level
41 01.07.2011
SPALTEN Integration of LA in activity flow and interrelations
PL Team SA PE
PLT Okay? AL
Information about the problem
Aims
way not clear
way clear
TA
Problem No problem way
~
IC* IC*
Solution search Process of P-Analysis
*IC: information check Ident-Nr. 110569
42 01.07.2011
Aim: Generation of as many as possible alternative solution propositions to eliminate deviation Conscious solution-variety to increase probability to really find the best solution
SPALTEN What for alternative Solutions (AL)?
Ident-Nr. 109767
43 01.07.2011
SPALTEN Activity flow and interrelations SA to AL
Ident-Nr. 109737
Solutions search
AL LA PLT ok? TA EU NL
PLT ok?
PLT ok?
PLT ok?
IC IC IC IC CIS PL
Team Feed- back LV1
LV2
LV3
.....
Solution moti- vation
Risk Scenario
Solution moti- vation
Chances Scenario
Problem?
Problem?
Action plan Result ?
No problem
solution implementation
Solution implementation
Way
~
44 01.07.2011
Innovation
Ident-Nr. 110091
45 01.07.2011
Innovation – walking on your own roads
„Never you can pass by
somebody if you are
stepping in his
footprints“
Ident-Nr. 106038