Skip to main content
Top
Published in: International Journal on Interactive Design and Manufacturing (IJIDeM) 2/2017

07-06-2016 | Original Paper

Cost engineering for variation management during the product and process development

Authors: Alain Etienne, Shirin Mirdamadi, Mehrdad Mohammadi, Roozbeh Babaeizadeh Malmiry, Jean-François Antoine, Ali Siadat, Jean-Yves Dantan, Reza Tavakkoli, Patrick Martin

Published in: International Journal on Interactive Design and Manufacturing (IJIDeM) | Issue 2/2017

Log in

Activate our intelligent search to find suitable subject content or patents.

search-config
loading …

Abstract

Variation Management during the Product & Process Development can profoundly impact the quality, the cost of the product and the number of scraps in mass production... Designers want tight tolerances to ensure product performance; manufacturers prefer loose tolerances to reduce manufacturing and assembly cost. To analyse compromise solutions, the primary aim is to establish an objective function. This paper presents a model for the key indicators assessment to the relevance of variation management: cost, and investigates which model used in decision analysis is the most appropriate to prioritize and aggregate the predetermined performance measures. The applications of this model are demonstrated through an industrial case study where tolerance allocation, product development, problem is firstly addressed. Once optimized tolerances are attained, inspection planning, process development, problem is approached to ensure the optimized awaited quality level for the least cost.

Dont have a licence yet? Then find out more about our products and how to get one now:

Springer Professional "Wirtschaft+Technik"

Online-Abonnement

Mit Springer Professional "Wirtschaft+Technik" erhalten Sie Zugriff auf:

  • über 102.000 Bücher
  • über 537 Zeitschriften

aus folgenden Fachgebieten:

  • Automobil + Motoren
  • Bauwesen + Immobilien
  • Business IT + Informatik
  • Elektrotechnik + Elektronik
  • Energie + Nachhaltigkeit
  • Finance + Banking
  • Management + Führung
  • Marketing + Vertrieb
  • Maschinenbau + Werkstoffe
  • Versicherung + Risiko

Jetzt Wissensvorsprung sichern!

Springer Professional "Technik"

Online-Abonnement

Mit Springer Professional "Technik" erhalten Sie Zugriff auf:

  • über 67.000 Bücher
  • über 390 Zeitschriften

aus folgenden Fachgebieten:

  • Automobil + Motoren
  • Bauwesen + Immobilien
  • Business IT + Informatik
  • Elektrotechnik + Elektronik
  • Energie + Nachhaltigkeit
  • Maschinenbau + Werkstoffe




 

Jetzt Wissensvorsprung sichern!

Springer Professional "Wirtschaft"

Online-Abonnement

Mit Springer Professional "Wirtschaft" erhalten Sie Zugriff auf:

  • über 67.000 Bücher
  • über 340 Zeitschriften

aus folgenden Fachgebieten:

  • Bauwesen + Immobilien
  • Business IT + Informatik
  • Finance + Banking
  • Management + Führung
  • Marketing + Vertrieb
  • Versicherung + Risiko




Jetzt Wissensvorsprung sichern!

Literature
1.
go back to reference Zhang, C., Wang, H.P.: Simultaneous optimization of design and manufacturing—tolerances with process (machine) selection. CIRP Ann. Manuf. Technol. 41(1), 569–572 (1992)CrossRef Zhang, C., Wang, H.P.: Simultaneous optimization of design and manufacturing—tolerances with process (machine) selection. CIRP Ann. Manuf. Technol. 41(1), 569–572 (1992)CrossRef
2.
go back to reference Lööf, J., Hermansson, T., Söderberg, R.: An efficient solution to the discrete least-cost tolerance allocation problem with general loss functions. In: Models for computer aided tolerancing in design and manufacturing, pp. 115–124. Springer, Netherlands (2007) Lööf, J., Hermansson, T., Söderberg, R.: An efficient solution to the discrete least-cost tolerance allocation problem with general loss functions. In: Models for computer aided tolerancing in design and manufacturing, pp. 115–124. Springer, Netherlands (2007)
3.
go back to reference Schmitt, R., Behrens, C.: A statistical method for analyses of cost-and risk optimal tolerance allocations based on assured input data. In: Proceedings 10th CIRP International Seminar on Computer-Aided Tolerancing (2007) Schmitt, R., Behrens, C.: A statistical method for analyses of cost-and risk optimal tolerance allocations based on assured input data. In: Proceedings 10th CIRP International Seminar on Computer-Aided Tolerancing (2007)
4.
go back to reference Moroni, G., Petrò, S., Tolio, T.: Early cost estimation for tolerance verification. CIRP Ann. Manuf. Technol. 60(1), 195–198 (2011)CrossRef Moroni, G., Petrò, S., Tolio, T.: Early cost estimation for tolerance verification. CIRP Ann. Manuf. Technol. 60(1), 195–198 (2011)CrossRef
5.
go back to reference Savio, E.: A methodology for the quantification of value-adding by manufacturing metrology. CIRP Ann. Manuf. Technol. 61(1), 503–506 (2012)CrossRef Savio, E.: A methodology for the quantification of value-adding by manufacturing metrology. CIRP Ann. Manuf. Technol. 61(1), 503–506 (2012)CrossRef
6.
go back to reference Kunzmann, H., Pfeifer, T., Schmitt, R., Schwenke, H., Weckenmann, A.: Productive metrology-adding value to manufacture. CIRP Ann. Manuf. Technol. 54(2), 691–704 (2005)CrossRef Kunzmann, H., Pfeifer, T., Schmitt, R., Schwenke, H., Weckenmann, A.: Productive metrology-adding value to manufacture. CIRP Ann. Manuf. Technol. 54(2), 691–704 (2005)CrossRef
7.
go back to reference Mirdamadi, S., Etienne, A., Hassan, A., Dantan, J.Y., Siadat, A.: Cost estimation method for variation management. Procedia CIRP 10, 44–53 (2013)CrossRef Mirdamadi, S., Etienne, A., Hassan, A., Dantan, J.Y., Siadat, A.: Cost estimation method for variation management. Procedia CIRP 10, 44–53 (2013)CrossRef
8.
go back to reference Ullman, D.G.: The mechanical design process. McGraw-Hill, New York (2010) Ullman, D.G.: The mechanical design process. McGraw-Hill, New York (2010)
9.
go back to reference Beitz, W., Pahl, G., Wallace, K.: Engineering design: a systematic approach. Springer, New York (2007) Beitz, W., Pahl, G., Wallace, K.: Engineering design: a systematic approach. Springer, New York (2007)
10.
go back to reference Tata, M.M., Thornton, A.C.: Process capability database usage in industry: myth vs. reality (1999) Tata, M.M., Thornton, A.C.: Process capability database usage in industry: myth vs. reality (1999)
11.
go back to reference Srinivasan, V.: An integrated view of geometrical product specification and verification. In: Geometric Product Specification and Verification: Integration of Functionality, pp. 1–11. Springer, Netherlands (2003) Srinivasan, V.: An integrated view of geometrical product specification and verification. In: Geometric Product Specification and Verification: Integration of Functionality, pp. 1–11. Springer, Netherlands (2003)
12.
go back to reference Etienne, A., Dantan, J.Y., Siadat, A., Martin, P.: Cost estimation for tolerance allocation. In: Proc. of the 10th CIRP International Seminar on Computer Aided Tolerancing (2007) Etienne, A., Dantan, J.Y., Siadat, A., Martin, P.: Cost estimation for tolerance allocation. In: Proc. of the 10th CIRP International Seminar on Computer Aided Tolerancing (2007)
13.
go back to reference Speckhart, F.H.: Calculation of tolerance based on a minimum cost approach. J. Eng. Ind. ASME 94, 447–453 (1972) Speckhart, F.H.: Calculation of tolerance based on a minimum cost approach. J. Eng. Ind. ASME 94, 447–453 (1972)
14.
go back to reference Sutherland, G.H., Routh, B.: Mechanism design: accounting for manufacturing tolerances and costs in function generating problems. J. Eng. Ind. 97, 283–286 (1975)CrossRef Sutherland, G.H., Routh, B.: Mechanism design: accounting for manufacturing tolerances and costs in function generating problems. J. Eng. Ind. 97, 283–286 (1975)CrossRef
15.
go back to reference Abel-Maleck, L., Asadathorn, N.: An analytical approach to process planning with rework option. Int. J. Prod. Econ. 46–47, 511–520 (1996)CrossRef Abel-Maleck, L., Asadathorn, N.: An analytical approach to process planning with rework option. Int. J. Prod. Econ. 46–47, 511–520 (1996)CrossRef
16.
go back to reference Duverlie, P., Castelain, M.: Cost estimation during design step: parametric method versus case based reasoning. Int. J. Adv. Manuf. Technol. 15, 895–906 (1999)CrossRef Duverlie, P., Castelain, M.: Cost estimation during design step: parametric method versus case based reasoning. Int. J. Adv. Manuf. Technol. 15, 895–906 (1999)CrossRef
17.
go back to reference Kim, G.H., An, S.H., Kang, K.I.: Comparison of construction cost estimating models based on regression analysis, neural networks, and case-based reasoning”. Build. Environ. 39, 1235–1242 (2004)CrossRef Kim, G.H., An, S.H., Kang, K.I.: Comparison of construction cost estimating models based on regression analysis, neural networks, and case-based reasoning”. Build. Environ. 39, 1235–1242 (2004)CrossRef
18.
go back to reference Feng, C.X., Kusiak, A., Huang, C.C.: Cost evaluation in design with form features. Comput. Aided Design 28(11), 879–885 (1996)CrossRef Feng, C.X., Kusiak, A., Huang, C.C.: Cost evaluation in design with form features. Comput. Aided Design 28(11), 879–885 (1996)CrossRef
19.
go back to reference Johnson, H.T., Kaplan, R.S.: Relevance cost: the rise and fall of management accounting. Harvard Business School Press, Boston (1987) Johnson, H.T., Kaplan, R.S.: Relevance cost: the rise and fall of management accounting. Harvard Business School Press, Boston (1987)
20.
go back to reference Gupta, M., Galloway, K.: Activity based costing and management and its implications on operations management. Technovation 23(3), 131–138 (2003)CrossRef Gupta, M., Galloway, K.: Activity based costing and management and its implications on operations management. Technovation 23(3), 131–138 (2003)CrossRef
21.
go back to reference Bosch Mauchand, M., Siadat, A., Perry, N., Bernard, A.: VCS: value chains simulator, a tool for value analysis of manufacturing enterprise processes (a value-based decision support tool). J. Intell. Manuf. 23/4, 1389–1402 (2012)CrossRef Bosch Mauchand, M., Siadat, A., Perry, N., Bernard, A.: VCS: value chains simulator, a tool for value analysis of manufacturing enterprise processes (a value-based decision support tool). J. Intell. Manuf. 23/4, 1389–1402 (2012)CrossRef
22.
go back to reference Etienne, A., Dantan, J.Y., Qureshi, J., Siadat, A.: Variation management by functional tolerance allocation and manufacturing process selection. Int. J. Interact. Des. Manuf. 2(4), 207–218 (2008) Etienne, A., Dantan, J.Y., Qureshi, J., Siadat, A.: Variation management by functional tolerance allocation and manufacturing process selection. Int. J. Interact. Des. Manuf. 2(4), 207–218 (2008)
23.
go back to reference Pfeifer, T.: Production metrology. Oldenbourg Verlag, München, ISBN 10: 3486258850 (2002) Pfeifer, T.: Production metrology. Oldenbourg Verlag, München, ISBN 10: 3486258850 (2002)
24.
go back to reference Zhao, F., Xu, X., Xie, S.Q.: Computer-aided inspection planning-the State of the Art. Comput. Ind. 60, 453–466 (2009)CrossRef Zhao, F., Xu, X., Xie, S.Q.: Computer-aided inspection planning-the State of the Art. Comput. Ind. 60, 453–466 (2009)CrossRef
25.
go back to reference Mohammadi, M., Siadat, A., Dantan, J.Y., Tavakkoli-Moghaddam, R.: Mathematical modelling of a robust inspection process plan: Taguchi and Monte Carlo methods. Int. J. Prod. Res. 53(7) (2014) Mohammadi, M., Siadat, A., Dantan, J.Y., Tavakkoli-Moghaddam, R.: Mathematical modelling of a robust inspection process plan: Taguchi and Monte Carlo methods. Int. J. Prod. Res. 53(7) (2014)
26.
go back to reference Shah, L.A., Etienne, A., Siadat, A., Vernadat, F.: Decision-making in the manufacturing environment using a value-risk graph. J. Intell. Manuf. 27(3), 617–631 (2014)CrossRef Shah, L.A., Etienne, A., Siadat, A., Vernadat, F.: Decision-making in the manufacturing environment using a value-risk graph. J. Intell. Manuf. 27(3), 617–631 (2014)CrossRef
27.
go back to reference Vernadat, F., Shah, L., Etienne, A., Siadat, A.: VR-PMS: a new approach for performance measurement and management of industrial systems, International Journal of Production Research, pp. 1–19. Taylor & Francis, London (2013) Vernadat, F., Shah, L., Etienne, A., Siadat, A.: VR-PMS: a new approach for performance measurement and management of industrial systems, International Journal of Production Research, pp. 1–19. Taylor & Francis, London (2013)
28.
go back to reference Mousavi, M., Mirdamadi, S., Siadat, A., Dantan, J.-Y., Tavakkoli-Moghaddam, R.: A new intuitionistic fuzzy grey model for selection problems with an application to the inspection planning in manufacturing firms. Eng. Appl. Artif. Intell. 39, 157–167 (2015)CrossRef Mousavi, M., Mirdamadi, S., Siadat, A., Dantan, J.-Y., Tavakkoli-Moghaddam, R.: A new intuitionistic fuzzy grey model for selection problems with an application to the inspection planning in manufacturing firms. Eng. Appl. Artif. Intell. 39, 157–167 (2015)CrossRef
29.
go back to reference Hassan, A., Siadat, A., Dantan, J.Y., Martin, P.: Conceptual process planning an improvement approach using QFD, FMEA, and ABC methods. Robot Comput. Integr. Manuf. 26(4), 392–401 (2010)CrossRef Hassan, A., Siadat, A., Dantan, J.Y., Martin, P.: Conceptual process planning an improvement approach using QFD, FMEA, and ABC methods. Robot Comput. Integr. Manuf. 26(4), 392–401 (2010)CrossRef
30.
go back to reference Hassan, A., Siadat, A., Dantan, J.Y., Martin, P.: A quality/cost-based improvement approach for conceptual process planning. Int. J. Manag. Sci. Eng. Manag. 4(3), 188–197 (2009) Hassan, A., Siadat, A., Dantan, J.Y., Martin, P.: A quality/cost-based improvement approach for conceptual process planning. Int. J. Manag. Sci. Eng. Manag. 4(3), 188–197 (2009)
Metadata
Title
Cost engineering for variation management during the product and process development
Authors
Alain Etienne
Shirin Mirdamadi
Mehrdad Mohammadi
Roozbeh Babaeizadeh Malmiry
Jean-François Antoine
Ali Siadat
Jean-Yves Dantan
Reza Tavakkoli
Patrick Martin
Publication date
07-06-2016
Publisher
Springer Paris
Published in
International Journal on Interactive Design and Manufacturing (IJIDeM) / Issue 2/2017
Print ISSN: 1955-2513
Electronic ISSN: 1955-2505
DOI
https://doi.org/10.1007/s12008-016-0318-3

Other articles of this Issue 2/2017

International Journal on Interactive Design and Manufacturing (IJIDeM) 2/2017 Go to the issue

Premium Partner