Controlling Design Variants:

Transcription

1 Controlling Design Variants: Modular Product Platforms By Anna Ericsson and Gunnar Erixon, Ph.D. Society of Manufacturing Engineers Dearborn, Michigan

2 Copyright 1999 by Modular Management AB and Society of Manufacturing Engineers All rights reserved, including those of translation. This book, or parts thereof, may not be reproduced by any means, including photocopying, recording or microfilming, or by any information storage and retrieval system, without permission in writing of the copyright owners. No liability is assumed by the publisher with respect to use of information contained herein. While every precaution has been taken in the preparation of this book, the publisher assumes no responsibility for errors or omissions. Publication of any data in this book does not constitute a recommendation or endorsement of any patent, proprietary right, or product that may be involved. Library of Congress Catalog Card Number: International Standard Book Number: Additional copies may be obtained by contacting: Society of Manufacturing Engineers Customer Service One SME Drive, P.O. Box 930 Dearborn, Michigan SME staff who participated in producing this book: Millicent Treloar, Senior Editor Rosemary Csizmadia, Production Supervisor Frances Kania, Production Assistant Kathye Quirk, Production Assistant/Cover Design Cover photo: Christoph Eshenbach conducting the Houston Symphony, Photographer: Crossley and Pogue Printed in the United States of America iv

3 About the Authors Anna Ericsson and Dr. Gunnar Erixon are consultants in product development with Modular Management AB, Stockholm, Sweden. You may contact them with questions at Anna Ericsson has a MSc degree in mechanical engineering from The Royal Institute of Technology in Stockholm, Sweden. Part of her engineering studies were also performed at Ecole Nationale Supérieure des Mines de Nancy, France. In 1997, she joined Modular Management AB and is today project manager. She has vast experience from working on product development projects within industrial equipment, power transmission, construction equipment, and telecommunications companies. Dr. Erixon is a Senior Lecturer at Dalarna University in Sweden. He completed his Ph.D. in engineering in 1998 at the Royal Institute of Technology, Stockholm, Sweden. Much of the material in this book is drawn from research performed in completion of his doctoral thesis. With more than 20 years experience at different Swedish companies, Dr. Erixon became one of the co-founders of Modular Management AB in In 1994, he received the Alde Nilsson ABB Prize for production engineering research contribution, and in 1999, the Karlebo Prize for the work behind his doctoral thesis. vii

4 Table of Contents Preface... xi 1 Introduction Expanding and Deviating Demands on Product Design...9 Explosion of Variants... 9 Time Design Scope Design and Manufacture Product Modularity...17 What is Product Modularity? Module Drivers How are the Module Drivers Used? Modular Function Deployment...29 Step 1: Define Customer Requirements Step 2: Select Technical Solutions Step 3: Generate Module Concept Step 4: Evaluate Module Concept Step 5: Optimize Modules Illustrative Example: Vacuum Cleaner...43 Step 1: Customer Requirements Step 2: Select Technical Solutions ix

5 Controlling Design Variants Step 3: Generate Module Concept Step 4: Evaluate Module Concept Step 5: Optimize Modules Applying MFD in Practice...57 Volvo Car Corporation Atlas Copco Controls VBG Sepson Modular Product Platform Management...93 The Link between Strategy and Development Take and Keep the Lead Control and Manage Variety Structured Working Methods Building Small Factories within the Factory Appendix A: Evaluation of Module Concepts Lead Time in Development Development Costs Development Capacity Product Costs System Costs Lead Time in Assembly Quality Variant Flexibility Service/Upgrading Recycleability Summary Appendix B: Glossary Abbreviations References Index x

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