Professional Documents
Culture Documents
By
CYNTHIA MATHE
STUDENT NUMBER
N008 1572H
SUPERVISOR
MR N. GWANGWAVA
ACKNOWLEDGEMENTS
I would like to express my gratitude and appreciation to the Mealie brand staff for the support and
constructive criticism they gave when I was sharing ideas with them and for their guidance
throughout my stay there. For the foundation l have on engineering principles l thank the Industrial
and Manufacturing Engineering lecturers for enlightening me. Finally l thank the Almighty God.
ABSTRACT
The project serves to encourage the use of scientifically justifiable means of product
development which are systematic and less rigorous in a Research and development
environment. In this project, the author makes use of a Visual Basic program as well as an
Oracle database to come up with an integrated tool which will aid in product development.
Software modules are to be linked in such a way as to obtain customer requirements, analyse
data by means of an automated Quality Function Deployment (QFD), cluster parts according
to dependencies and give feedback in terms of a summarised report on the different stages of
the analysis. This will be achieved through the use of an internet based application to gather
customers views for example through a questionnaire that can be filled in online and
accessed from the company in-house application system for further analysis. The main thrust
being the incorporation of modular clusterization techniques for example the Modular
Function Deployment and design structure matrices.
TABLE OF CONTENTS
DEDICATION
ACKNOWLEDGEMENTS
ABSTRACT
TABLE OF CONTENTS
CHAPTER 1 : INTRODUCTORY CHAPTER
1.0 INTRODUCTION
1.1 AIM
1.2 OBJECTIVES
1.3 DEFINITION OF CRITICAL TERMS
1.4 SCOPE
1.5 BACKGROUND
1.6 NEED JUSTIFICATION
1.7 METHODOLOGY
1.8 TIME SCALE
1.9 CONCLUSION
1.1 Aim
To design a software program that supports modular product design in a new product research
and development (R&D) environment
1.2 Objectives
Design a database model for a research and development (R&D) enterprise with focus
on modular product design approach.
Implement the physical database model on a database management system (DBMS).
Design the Graphical User Interface (GUI) of the program.
Create a visual basic program featuring the following software modules;
o Internet based customers voice gathering and relationship
o Quality Function Deployment (QFD) and analysis
o Product module clustering using the Design Structure Matrix (DSM)
1.3 Definition of critical terms
Software program - Written procedures or rules and associated documentation pertaining to
the operation of a computer system and that are stored in read or write memory (Pressman,
2001)
Modular products -Refer to products, assemblies and components that fulfil various functions
through the combination of distinct building blocks (Pahl and Beitz, 1988).
Product development - Product Development is a creation of, innovation of, enhancing the
utility of or continuous improvement of earlier characteristics (like design, service, etc.) of an
existing product or developing an entirely new kind of product to satisfy the end-user's
1.4 Scope
The project focuses on database modelling in connection with an application which will be
placed online to interact with customers and then analysed in the in-house system application
of the company. Design of the corresponding Visual Basic program to carry out the in-house
analysis will be done. The Design Structure Matrix will be the only clustering technique used
in coming up with the modularisation tool. The software will be used in the Research and
Development department in liaising with customers, forecasting any new designs, design
changes, revisions or updates.
1.5 Background
Mealie Brand has been the monopoly in the manufacture of animal drawn implements mainly
targeted for subsistence farming. It distributes its products both to the local market and export
market within Southern Africa. Although the needs of the subsistence farmers have always
been the standard plough, cultivator and harrows etc the company decided to introduce a
Research and Development department to obtain new knowledge applicable to the company's
business needs, that eventually will result in new or improved products, processes, systems,
or services that can increase the company's sales and profits. Globally it has been apparent for
at least a century that future economic progress will be driven by the invention and
application of new technologies. R&D is one category of spending that develops and drives
these new technologies hence the need to concentrate on it.
An area that merits consideration is the use of various tools for organisation and planning of
R&D activities. The in-house Research and Development department at Mealie Brand is
fairly new and currently there is no software to analyse new obtained knowledge to aid in the
product development process. There are no highly analytical and prioritisation methods to
map the way forward. Decisions to execute that is transfer results to operations or not are
based on a series of meetings with heads of departments concerned and it takes a long time.
Traditionally, scientific and technological knowledge and skills concerning the product were
the prime source. Nowadays, managerial competencies and the ability to work for and with
clients and suppliers are becoming more important. To become a competitive business
research and development departments should create the competencies that enable them to
create value for their clients.
In this era of globalisation and intense competition the long term health of companies is tied
to their ability to innovate successfully and rapidly with the customer in mind thus it will be
worthwhile to have tools which aid in that. The solutions for local companies lies is in
grasping globalisation and embracing it wholesomely, being innovative not seeking to
optimize the poor yesterdays solution and having the customer in mind call for maintaining
strong customer relations and especially knowing what they want through such tools as QFD.
The software has provisions to store pre designed product modules such that should a
customer require a product consisting of existing modules development consists of simply
refining and assembling what is there thus reducing costs of development and production.
Information can be analysed quickly and shared across departments through the software
furthermore production managers can be able to establish the costs inherent or locked in the
particular design before committing any resources to it.
Mass customization is the new paradigm that replaces mass production, which is no longer
suitable for todays turbulent markets, growing product variety, and opportunities for ecommerce. The emphasis is on fast and easy production to eliminate delays at any point. In
designing products for mass customisation one approach amongst others is that of modular
customisation whereby product modules are literally building blocks that can customise a
product by assembling various combinations of modules. The software program can help in
coming up with the product building blocks.
1.7 Methodology
The research methodology will be as follows
A review of literature from relevant sites, various journals and conference proceedings
will be conducted.
Communication with customers via questionnaires on an internet based application
will be carried out to establish the current requirements on product properties, desired
functions or features.
A review of matrix representations techniques for example Design structure matrix
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1.9 Conclusion
Systematic procedures need to be adhered to in pinpointing possible flaws and opportunities
for improvement hence the need for a close scrutiny in continuous improvement, product
design and product development. This chapter has therefore given a summary of what the
project is set to achieve.
level.
Function sharing means that several functions are allocated to one module. Again,
function sharing increases the level of integration.
Integrated design means that several functions are allocated to several modules.
Functions are distributed and shared, thereby further increasing the level of
integration
All approaches to modularity have to build a model of reality, that captures the aspects of the
product that have implications for the architecture (where the interfaces are required, for
example). Although some of the details differ between different approaches, there are
similarities.
Step One
On the far left, we see an icon that tries to represent the view of reality: this may be a view of
the requirements of the product .Whatever the source of data, team representatives from
Engineering or Marketing functions in the company gather data about the product, its usage,
the customers etc
Step two
Sift through the data to determine what is important in the project. Some data will be
discarded at this point, because it is out of scope or does not fit into the representation of the
product, be it a matrix, a drawing, a flowchart etc. What is left may be a list of customer
requirements, product properties, desired functions or features, cost data for concept
selections.
Step three
Some choice is typically made about the way this data should be represented. One or several
representations may be available, including matrices, flowcharts, product sketches.
Step four
If the objective is to make predictions about the best possible modules, it usually becomes
necessary to select some type of pre-defined representation. The upper is a matrix
representation, which has computer algorithm support for generating modules. The lower is a
function structure diagram (a type of flowchart). When diagrams are used, the work may be
conducted on paper, and module generation may be manual, using a set of pre-defined
heuristic rules for what constitutes good modules. Computer algorithms operating on matrix
representations include such methods as Design Structure Matrix, DSM, and Module
Function Deployment, MFD.
Step five
Depending on the algorithm, the output may be a sorted matrix or a dendrogram, as shown in
the graphic. The computer-generated output is analyzed by the team members, and decisions
are made about modules. Typically, there are many iterations of changing data and resorting
before the output is satisfactory. Once the output is deemed useful, it is documented in some
form, and goes to detailed design,
In this project step four is of paramount importance and thus an analysis of product
modularisation methods is necessary.
The analysis, however, must consider what the core of the modularization method is. The
selected methods will be evaluated in terms of these three different phases:
2. The next step involves documenting the interactions between elements. Pimmler and
Eppinger (1994) distinguish four types of interactions: spatial, energy, information,
and material. These interactions should be scored on a five-point scale (from 2 to +2)
based on the relative need for each interaction. The interaction between two elements
can be seen as a vector of four scores.
3. Clustering the elements into chunks is the final step in the method. The interactions
between the elements are documented in a DSM with each of the elements on each
axis. Then a clustering algorithm is used to reorder the rows and columns in the
matrix to cluster the positive elements closer to the diagonal. This results in a block
matrix in which the blocks on the diagonal correspond to the resulting architectural
clusters. There are several algorithms that can be used for clustering the elements, or
the clustering can be done with regard to the most important interaction in the design.
2.2.2.2 (AD) Axiomatic Design [Suh, 1990]
The axiom that is the basis for the method stipulates that functions in a product should be
independent of each other The AD method is rather simple in its design. The tool in the
method is the design equation
{FR} = [DM]{DP}..................................................................................................2.2.2.2.1
Where
{FR} is a vector representing the functional requirements, which are derived from
decomposition of the products functions.
{DP} is a vector representing the design parameters, which is the physical realization of the
{FR}.
[DM] is the design matrix that contains the product information needed by the designer.
The formation of the equation should be carried out by using the two following axioms
Axiom 1: The independence axiom
In an acceptable design, the DPs and the FRs are related in such a way that a specific DP can
be adjusted to satisfy its corresponding FR without affecting other functional requirements.
Axiom 2: The information axiom
The best design is a functionally uncoupled design that has the minimum information content.
The solution of the equation is the best design
2.2.2.3 (MFD) Modular Function Deployment [Erixon, 1998]
This method contains five steps, and, in the description of these steps, several tools to be used
in the modularization process are given.
1. The first step, clarifying the customers requirements, is realized by the use of Quality
Function Deployment (QFD). However, the QFD matrix has been changed by the
addition of a column for modularity to the design requirement axis. This is done in
order to emphasize the aim to modularize the product. Erixon [1998] further argues
that this first step should be completed in a cross-functional team. The use of QFD
results in the most important product properties, based on customers requirements.
2. The second step in the method is to create sub functions and then find the technical
solutions that fulfil these functions. Further, the best technical solution has to be
chosen; this selection is done by using a selection matrix, e.g., that of Pugh [1981]. In
that matrix all suggested technical solutions of a function are evaluated and rated.
Preferable is to do this by comparing the different technical solutions with the one
3.
fully replacing the detailed development work that has to be done for each of the
modules.
2.2.2.4 ( MPM) Modeling the Product Modularity [Huang and Kusiak, 1998]
The MPM method uses a different approach for creating the modular structure than the other
methods that have been presented so far. In this method, matrix algebra is used for structuring
both the interactions between the parts in the product, and the suitability of the interactions.
Suitability is determined on the basis of module drivers, or strategic reasons for components
to be parts of modules.
1. The first step in the method is to specify the upper number of components in the
module, and then the matrix is created with columns and rows corresponding to
component numbers. An entry1 indicates that there is an interaction between two
components, and a blank indicates no interaction. If a component exists in different
designs, the number of designs is shown instead of the 1.
2. The next step is to use an algorithm for triangularization of the interaction matrix.
Then the suitability matrix should be rearranged so that the sequence of columns and
rows is the same as in the interaction matrix.
3. After that, the suitability matrix should be combined with the interaction matrix.
Using algebra, and the conditions and axioms stated in the method, gives the suitable
modules. The components that should be included in a module are found along the
diagonal in the matrix.
In this modularization method, the evaluation is included in the integration phasethe phase
in which the selection of the modules is made on the basis of the suitability of two
components or modules interaction.
2.2.2.5(MPD) Modular Product Development [Pahl and Beitz, 1996]
This method consists of six steps, and supports the user with guidelines about how each step
should be accomplished. It starts with clarifying the task for the product to be designed, and
ends with preparing production documents for the product.
1. The first step, clarifying the task, focuses on ascertaining what variety of tasks the
product should be able to perform.
2. The second step is an economic optimization of the modules; especially the economic
consequences when adding variety should be highlighted. It is suggested that all
common functions are used as a base part and then the variety is created by functional
add-ons to the base part.
3. Establishing function structures is the next step in the method, namely, dividing the
required overall functions into smaller sub functions. All functions must be
subdivided into a minimum of similar and recurrent sub functions, which should be
logically and physically compatible with each other. All variants should be included in
the sub functions and based on their characteristics, divided into the following groups:
basic, auxiliary, special, adaptive, and customer. The basic sub functions are the ones
that perform the products essential functions.
4. Searching for solution principles and concept variants is the step in the method where
the functional structure should be realized into technical solutions. Pahl and Beitz
[1996] stress that the use of similarity between energetic and physical working
principles is preferable in the function modules. When all sub functions are realized in
solutions, the selecting and evaluating phase starts. If several concept variants have
been found during the previous steps, each must now be evaluated with the help of
technical and economic criteria, to ensure that the most favourable solution concept is
5.
selected.
Once the solution concept has been selected, the individual modules must be
designed in accordance both with their functions and with the production
5. Finally, the fractals are redesigned and optimized by using classical redesign, such as
design for x and FMEA. Also QFD is mentioned.
DSM, the components were reordered in the matrix. The criteria used for regrouping was one
which placed the squares representing high interface dependency as close to the diagonal as
possible. Using this strategy, components that have a high degree of interdependence will
tend to form clusters. Since these DSMs were of moderate size, it was found that it was
acceptable to perform this activity by inspection using a spreadsheet.
To ensure consistency between the design phase and the actual fabrication. QFD can
minimize the problems that usually are detected on the interaction between design and
construction phases (including feasibility problems and reworks).
Optimize the integration of customers perceptions and variables that can affect the
return on investment such as construction cost, speed of sales, schedule and cash flow.
Reduce the time to perform quality features throughout product development
2.4.2 QFD matrices and functions
QFD is a series of interconnecting matrices often called the House of Quality because the
completed matrices resemble a house. An excellent description of how to build such a house
is given in Hauser and Clausing (1988). Each segment of the matrix is important in
assessing:
customer requirements;
the actions over which a business has control; and
the relationship between these two
the highest score will have the greatest impact on the most important customer
2.
Develop the technical requirements for meeting the buyers and users needs.
To reach this objective, a brainstorming section is used with the members of the design team.
Brainstorming helps to determine the improvements level and technical details for the design.
All information developed in this phase is organized in the Technical Requirement Table
HOWS as shown in (Figure 2) below. The design team should consider the movement of
Target Values for improvement or optimization of the features design.
By using QFD the design team could also evaluate some details of the layout and features
during the development of the design. By using the roof of the QFD Matrix (Figure 2), it
is possible to examine the correlation among technical requirements. The roof of the House
of Quality helps identify the interactions among the technical requirements and provide early
recognition of positively and negatively correlated features with technical solutions defined
by the design team. After the project design team has determined the technical solution
directions, and had assigned the relative importance and weight to these solutions.
new layout solutions and new features in the specification and design of the apartment unit.
In the new design for example it was necessary to increase or decrease some of the areas or
shapes of compartments and to eliminate or add new specific solutions.
2.5 Database design
Many details and features are involved during the design of any database.
These details, features and purpose of the database, once gathered are
eventually formatted into a database structure using a predetermined
database model. During the actual design of the database, these details
and features are fashioned artistically and skilfully into a database model.
2.5.1 Database
A database is a mechanism that is used to store information, or data. Information is something
that we all use on a daily basis for a variety of reasons. With a database, users should be able
to store data in an organized manner. Once the data is stored, it should be easy to retrieve
information. Criteria can be used to retrieve information. The way the data is stored in the
database determines how easy it is to search for information based on multiple criteria. Data
should also be easy to add to the database, modify, and remove.(R Stephens and R Plew
2001)
There are many purposes and types of databases. Relational databases are among the most
common. For example, customer relationship management (CRM) databases, which manage
sales leads, customer records, management and billing, are relational databases.
A database is useful in automating as much work as possible to enhance
manual processes.
Some of the most common uses for a database include
or business
Maintaining historic information
Most methodologies used today stem from that of the traditional method. Three of the
primary phases involved in the traditional method are as follows:
Requirements analysis
Data modelling
Normalization
1. Requirements analysis
During the requirement-analysis phase, research is conducted in order to capture all the
business needs as related to the proposed database system. Interviews are conducted by the
development team in order to gather the information that will be used to design the database
system. After all appropriate parties have been interviewed, the development team is
responsible for considering all the issues and requirements brought forward by the customer,
the end user, and perhaps management in order to begin formulating a basic model of the
actual processes involved in the daily operations of the business. The parties interviewed will
help the development team determine the categories of data, business processes, rules, and
other information important to begin modelling the system.
2. Data Modelling
The data modelling phase involves the creation of the logical data model
that will be used to define the physical database structures, or the
physical data model. After the system has been modelled and designed
During the first parts of the data modelling phase, processes and entities that were previously
defined are now defined in more detail. The basic ERD is detailed to include attributes within
each entity. Attributes might be assigned different properties that dictate the specific type of
data to be stored. Process models are used to determine how processes access entities within
the organization. During logical
modelling, relationships that were established between entities are refined if necessary, and
business rules are integrated into the model.
Flat files do not promote a structure in which data can easily be related.
It is difficult to manage data effectively and to ensure accuracy.
It is usually necessary to store redundant data, which causes more work to accurately
maintain the data.
The physical location of the data field within the file must be known.
A program must be developed to manage the data.
the database.
The user has to understand the structure of the database.
The relational database model is the most popular database model used today. Many
improvements have been made to prior database models that simplify data management, data
retrieval, and change propagation management. Data is easier to manage, mainly through the
use of integrity constraints. The retrieval of data is also a refined process, allowing the user to
visualize the database through relational table structures and to ask for specific data without a
detailed knowledge of the database layout. Changes are also easier to propagate, thanks to
features such as integrity constraints and the benefits that normalization (reduction of data
redundancy) provides.
database concerns bulk data loads. OLAP data is used to make intelligent business decisions
based on summarized data, company performance data, and trends. The two main types of
OLAP databases are Decision Support Systems (DSS) and Data Warehouses. Both types of
databases are normally fed from one or more OLTP databases, and are used to make decisions
about the operations of an organization. A data warehouse differs from a DSS in that it
contains massive volumes of data collected from all parts of an organization; hence the name
warehouse. Data warehouses must be specially designed to accommodate the large amounts
of data storage required and enable acceptable performance during data
retrievals. Historic information can be maintained. Historic data is usually related to and
often a part of a transactional database. Historic data may also be a significant part of an
OLAP database. For companies that desire to keep data for years, it is usually not necessary
to store all data online. Doing so will increase the overall amount of data, which means that
more information will have to be read when retrieving and modifying information. Historic
information is typically stored offline, perhaps on a dedicated server, disk drive, or tape
device. For example, in the infrequent event that a user needs to access corporate data from
three years ago, the data can be restored from tape long enough for the appropriate data to be
retrieved and used.
2.5.3.4.2 Relational Database Objects
Various types of objects can be found in a relational database. Some of the most common
objects found in a relational database include
Table - A table is the primary object used to store data in a relational database. When
data is queried and accessed for modification, it is usually found in a table. A table is
defined by columns. One occurrence of all columns in a table is called a row of data.
View- A view is a virtual table, in that it looks like and acts like a table. A view is
defined based on the structure and data of a table. A view can be queried and
sometimes updated.
Constraint - A constraint is an object used to place rules on data. Constraints are used
to control the allowed data in a column. Constraints are created at the column level
and are also used to enforce referential integrity (parent and child table relationships).
Index - An index is an object that is used to speed the process of data retrieval on a
table. For example, an index might be created on a customers name if users tend to
search for customers by name. The customer names would be stored alphabetically in
the index. The rows in the index would point to the corresponding rows in the table,
The first four objects deal with the definition of the database, whereas the last two objects
deal with methods for accessing database objects. Objects in a relational database provide
users with a logical representation of data, such that the physical location of the data is
immaterial to the user.
Drawbacks of the relational database model are as follows:
data.
Users must be familiar with the relationships between tables.
Users must learn SQL.
understand relational database concepts in order for the application to access the data. It can
be confusing for the developer to switch modes of thinking between relational and OO.
Users must learn OO concepts because the OO database does not work with
Data is stored on some hardware device and should persist after being accessed.
Access methods include the creation of new data, modification of existing data, and
user.
Data should be recoverable from a failure. If data is lost, the DBMS should have the
capability to recover the data to any given state.
Note how the savings, checking, and instalment loan programs use a database management
system to share a customer database. Note also that the DBMS allows a user to make a direct,
ad hoc interrogation of the database without using application programs.
2.5.6 Database environments
A database environment is a habitat, if you will, in which the database for a business resides.
Within this database environment, users have means for accessing the data. Users might come
from within the database environment, or might originate from outside the environment.
Users perform all different types of tasks, and their needs vary as they are mining for data,
modifying data, or attempting to create new data. Also within the environment, certain users
might be either physically or logically restrained from accessing the data.
1. Mainframe environment
The traditional environment for earlier database systems was the mainframe environment.
The mainframe environment consisted mainly of a powerful mainframe computer that
allowed multiple user connections. Multiple dumb terminals are networked to the mainframe
computer, allowing the user to communicate with the mainframe. The terminals are basically
extensions of the mainframe, they are not independent computers. The term dumb terminal
implies that these terminals do no thinking of their own. They rely on the mainframe
computer to perform all processing.
2. Client/Server Environment
The client/server environment involves a main computer, called a server, and one or more
personal computers that are networked to the server. The database resides on the server, a
separate entity from the personal computer. Each user who requires access to the database on
the server should have their own PC. Because the PC is a separate computer system, an
application is developed and installed on the PC through which the user can access the
database on the server. The application on the client passes requests for data or transactions
over the network directly to the database on the host server. Information is passed over the
network to the database using open database connectivity (ODBC) or other vendor specific
networking software. One of the problems in the client/server environment is that when a
new version of the application is developed, the application must be reinstalled and
reconfigured on each client machine, which can be quite tedious and very time-consuming.
second largest city. Zimplow has grown from a small manufacturing base into Southern
Africas largest producer of animal drawn traction implements. The company employs more
than 300 people and markets its products throughout the region through experienced and
professional agents.
The following have all contributed to Zimplows growth:
The merging of Bulawayo Steel Products.
The use of Japanese manufacturing procedures and cellular manufacturing.
Its acquisition of C.T Bolts and Tassburg.
A strong continual improvement focus by the management team.
An excellent team which is made up of outstanding performers.
The attainment and maintenance of ISO 9002 Certification in May 1999 and the
subsequent attainment of ISO 9001: 2008 in June 2010.
3.2.2 Vision
To have a local presence in all African countries south of the Sahara by 2020(36 by 2020).
3.4.1Sales/Marketing department
This department is responsible for marketing the companys products through various
strategies of demand planning and demand management. Demand planning is done through
customer awareness programs in the form of field days on targeted areas. On the field days,
the use of different companys products is demonstrated to customers, hence helping them
gain extensive knowledge about the products. On the other hand, demand management is
achieved through promotions, advertisement and special discounts under stated conditions.
The company markets its products both in local and export markets with Zambia being one of
the best customers on the export market.
It is this department that drives the production system in the sense that it makes analysis of
the sales trend and sets demand forecasts that are then used as a guideline in the production
department. This department also issues production with daily sales updates, pending orders
and stock on hand updates for planning purposes. Such information can also be used by the
procurement department as an input to material requirements planning (MRP).