- HW#1 due today. - No HW today. - Reading, Kalpakjian, P Monday 2/16, Holiday. - Wednesday 2/18, Yo-Yo case study

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1 2.008 Design & II Spring 2002 Systems Design - HW#1 due today. - No HW today. - Reading, Kalpakjian, P Monday 2/16, Holiday - Tuesday 2/17, Monday s lecture & lab group A - Wednesday 2/18, Yo-Yo case study 1 2 Super bowl 2002 Image removed due to copyright considerations. BIG PICTURE MIT, S. Kim 4 Systems Design Is Pats a good team? Is MIT a good school? Am I a good teacher? A University ( System) High schools Colleges Etc. Suppliers Faculty, staff, academic programs admission F So J Se graduation administration system Fundamental Knowledge Hands-on knowledge Graduate schools Industry Government Society Customers MIT, S. Kim MIT, S. Kim 6 1

2 Good Design lecture room? Boston T? Logan Airport? Honda Civic? Government? Design s What to How, Top to Bottom What Functional Requirements How Design Parameters No impromptu designs!! MIT, S. Kim MIT, S. Kim 8 Case study TMA(thinfilm micromirror array) Light Projection Lens TMA Black 50 µm Mirror Mirror Array on Piezoelectric Actuator Array Light Source No No Tilting Tilting Modulation Stop Max. Max. Tilting Tilting Increase of tilting angle Piezoelectric Actuator Active Matrix Daewoo Electronics Source Stop TMA Mirror White MIT, S. Kim MIT, S. Kim 10 Evolution of TMA Pixels Functional Requirements of TMA Optical Efficiency(%) st 1st 2nd 2nd 3rd 3rd Year Daewoo Electronics 1st Generation = light reflection = mirror tilting = cantilever top surface = PZT sandwich = X X X X MIT, S. Kim MIT, S. Kim 12 2

3 Image by 1 st Gen. TMA Functional Requirements of TMA 2nd Generation = light reflection = mirror tilting = cantilever top surface = PZT sandwich = X O X X MIT, S. Kim MIT, S. Kim 14 Image by the 2nd Gen. TFAMA Functional Requirements of TMA 3rd Generation = light reflection = mirror tilting = cantilever top surface = PZT sandwich = X O O X MIT, S. Kim MIT, S. Kim 16 TMA Image by the 3rd Gen. TMA XGA 1024 X ,432 pixels Human Hair VGA 640 X ,200 pixels 50 µm 150 in. Screen 150 in. Screen MIT, S. Kim MIT, S. Kim 18 3

4 XGA Image, Nov Good Design in small scale products? What to How, Top to Bottom What Functional Requirements How Design Parameters Design Axioms MIT, S. Kim MIT, S. Kim 20 Example: Shower Faucet Functional Requirements -Temperature -Flow rate Independence Axiom Maintain the independence of FRs. Shower faucet example = Temperature = Flow rate = Temperature = Flow rate = Hot water = Cold Water = Horizontal Angle = Vertical Angle = X X X X = X O O X θh θv MIT, S. Kim MIT, S. Kim 22 Information Axiom Minimize the information content of the design Functional Requirements Al Cans 12 FRs System range Design range MIT, S. Kim MIT, S. Kim 24 4

5 Systems View Four Design s Customer Functional Physical Process Isolated domains? High walls MIT, S. Kim MIT, S. Kim 26 Concurrent Engineering Customer Lower walls Functional Physical Process -Car program manager -Project Manager CA systems Maretials Performances Software Business Organization Four domains Attributes desired ROI Customer satisfaction FR Properties Output of programs Business goals Functions DP Microstructure Input variables Business structure Programs offices PV Processes Subroutines Resources People resources MIT, S. Kim MIT, S. Kim 28 Systems Design Customer Satisfaction Concurrent Design Design for, Assembly and X Quality Control, Six Sigma House of Quality, Takuchi method Axiomatic Design Any of these efforts in MEMS/Nano? Principles of Design Axioms Does scale matter? Multi-scale Systems design, 2.76 Culpepper & Kim, Fall 2004 Axiomatic Design, N.P. Suh, Principles of Design, Oxford, N. P. Suh, Axiomatic Design: Advances and Applications, Oxford, N. P. Suh, Complexity: Theory and Applications, Oxford, MIT, S. Kim MIT, S. Kim 30 5

6 Market Research Conceptual Design Design for Manufacture System Marketing Design Factory, Systems & Enterprise Assembly and Joining Welding Bolting Bonding Soldering Unit Processes Machining Injection molding Casting Stamping Chemical vapor deposition Raw materials Factory operations Processing Material handling inspection control Value add process Finished products planning Support system Facilities Factory equipments MIT, S. Kim MIT, S. Kim 32 Transformation of materials and information into goods for the satisfaction of human needs Big Picture? History 1. Greek manu factus : made by hand 2. Early mode: piece by piece by skilled artisan 3. In : Industrial revolution Early machine tool Concept of factory MIT, S. Kim MIT, S. Kim 34 History (cont) s Process specialization Division of labor Eli Whitney, etc., Interchangeable parts 5. Early 1900: Optimization ( systems) F.W. Taylor Economy of scale Cost reduction for high volume production Henry Ford s Model T s: Numerical control (Information technology) Automation Lean manufacturing, JIT 6 sigma, ppm Post-Industrial-Revolution History of Technologies The Industrial Revolution ( ): Introduction of steam power to replace waterpower and animalmuscle 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 MIT, S. Kim MIT, S. Kim B. Benhabib 36 6

7 Automotive 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). Automotive Industry (cont.) Table. Motor vehicle production numbers per year per country (in thous.) U.S.A ,265 8,005 10,206 10,864 13,024 Canada ,353 2,237 3,056 France ,459 3,155 3,032 Germany ,739 3,990 5,687 Italy N/A ,592 1,267 1,701 Japan N/A 32 4,674 11,227 9,905 S. Korea 45 2,050 2,832 U.K ,183 1,569 1,972 World N/A ,800 10,577 29,745 46,856 54, MIT, S. Kim B. Benhabib MIT, S. Kim 38 Industry Gross State Product $4 Trillion, shipments, Economic Census, U.S. Census Bureau Whole Sale $4 T, Retail $2.5 T 459 SIC industries (NAICS) MIT, S. Kim MIT, S. Kim 40 US Gross State Product, 1992 Big Picture Information Technology (digital) Globalization New Technology New Materials MIT, S. Kim MIT, S. Kim 42 7

8 Key Issues Engineering disciplines Materials processes equipment Design for manufacturing (DFM) Management disciplines Work force Societal obligation For-profit organization 2.96 Integration systems MIT, S. Kim 43 Processes of Metal components Plastic components Joining processes Silicon Removal Squeezing Melting Injection molding Thermo forming Welding Soldering/brazing Gluing Deposition Etching Milling, turning, drilling Forging, stamping Casting CVD, PVD Wet, dry MIT, S. Kim 44 Attributes for Decision Making Material removal the oldest Cost Rate Quality Flexibility Expensive $100 - $10,000 Quality: Very high Flexibility: Any shape under the sun Rate: Slow MIT, S. Kim MIT, S. Kim 46 Metal squeezing Cheap, $0.1 - $100 Quality: reasonable Flexibility: Shapes limited constant cross-section Rate: Fast (cycle time in sec), high volume Melting Expensive $100 - $10,000 Quality: Requires post finishing Die casting Flexibility: Very flexible, good for large parts Rate: Very slow 16V engine block Machine tool surface plate, gray iron 14,500 lbs MIT, S. Kim MIT, S. Kim 48 8

9 Plastics processing Expensive mold and die, over $10,000 Quality: Very high Flexibility: Opening for ejection Rate: Very fast Joining Cheap, but expensive labor Quality: Wide range Flexibility: Manual vs automated Rate: Slow in general Very Large Crude Carrier (VLCC) MIT, S. Kim MIT, S. Kim 50 Thinfilm fabrication Typical Cost Breakdown Very expensive $Millions Quality: Very high Flexibility: Any shape in 2-D Rate: Slow 300mm dual stage lithography system capable of 110nm resolution Selling Price Engineering R&D 14% 5% Admin, sales 24% 38% Profit 19% Costs Plant Machinery 12% Indirect labor 26% Direct labor 12% Parts, Material 50% MIT, S. Kim MIT, S. Kim 52 Performance Measures Capital cost Production rate or capacity Cycle time Lead time Machine utilization Work-in-process On-time deliveries MIT, S. Kim 53 9