Assignment 4 IE 655 Concurrent Engineering

Process Failure Mode and Effects / Failure Risk Analysis in the CE Context

Full Name: Pavan Patel

Student ID: 31321594
Student e-mail: pp488@njit.edu
eLearning Pack ID: IE655-Fall 2016-33-15
My Company: AquaDrive, Inc.
4 Collaborating Companies: Land Rover
Discovery , BMW Group (Mini), California
Motors, LLC, Cognex Corporation

Statement of Work
Sustainable Green Design for Manufacturing / Assembly / Environment Methods and
Technologies Study
Contents
I.
II.
III.
IV.

V.
VI.
VII.

Introduction
Objectives
Methodologies
Main Body of the Project
a. AquaDrives Sustainable Green Design based on 3D eBook.
b. Collaborative approach using other Green Design, Methods & Tools.
c. Chapter 3 10 Questions & Answers
d. Other Research Sustainable Green Design
e. Collaborative approach using 4 companies
f. Social Networking Content
Summary
Future Work Proposed
References

I.

Introduction

The AquaDrive organization is the future of tomorrow. From land, sea or air, we strive to
move towards a cleaner, safer and efficient world of transportation. By utilizing what we
consider a vast resource, water, we can leave an enormous & effective global footprint for our
generation and generations to come.
At AquaDrive, we manufacture high quality modes of transportation that run on clean
and pure H2O. We also Research and Develop ways to replace or reduce the use of natural gas
to power transportation. Through our persistent and economic approach, weve been able to
build a foundation that upholds and administers the ISO standards: 9001, 14001, 50001
amongst others.
II.

Objectives

The objective of this assignment is for AquaDrive to develop sustainable green designs
and methods and to implement tools so that we may manufacture high quality products. These
objectives also strengthen our assembly line as well improve our environmental impact. Being
that AquaDrive strives to be a sustainable company in a competitive and fast paced economy,
these tools will help our mission towards the path of a high quality company.
III.

Methodologies

The main methodologies utilized in this project are (but not limited to):
Elimination of MUDA, MURA and MURI, and implementing KANRI, KAISEN, POKA-YOKE. There
are also several tools that were used in previous projects that will be taken into account in this
project:
1. PLM
2. TQM
3. Lean & 6 Sigma Manufacturing
4. ISO 9001, 14001, 50001
5. GMP & cGMP
IV.

Main Body of the Project:

a. AquaDrives Sustainable Green Design based on 3D eBook.
There are 4 approaches that AquaDrive will utilize concerning this project:
1. Kaisen: This continuous improvement approach will aide in
AquaDrive eliminating waste in our process. We will implement the
4 step process of Plan, Do, Check and Act. Using Kaisen, our
assembly process will become more efficient through the gradual

modification of our product process & design, as well improving the

process itself.
2. DFM (Design for Manufacturing): By mapping out the process of
manufacturing, we can alter the design of it ensuring all production
problems are taken out before continuing any production.
3. DFQ (Design for Quality): There are several methods inside the area
of Design for Quality that AquaDrive will implement. These include
but are not limited to: Identifying & fixing past quality problems,
utilizing a quality functional deployment scheme, performing
thorough work before proceeding any task, utilizing and
implementing Poka-Yoke strategies and last but not least producing
Right the First Time products.
4. DFA (Sustainable Green Design for Assembling): In this approach,
we will take into account any design flaw or problems associated
with our assembly line of products. For example, if there any issues
when building our cars as far as rigidity and strength go.
b. Collaborative approach using other Green Design, Methods & Tools.
There is a myriad of tools, programs, software, that can be utilized within our
process. For example, we have begun simulating our process using two
programs called Arena & SIMIO. Both programs have enabled us to map out
our process from start to finish, this helps us visualize the concepts behind
our assembly line and enables us to draw out any time wasted modules or
adapt to new ideas. Each program has it owns features, advantages &
disadvantages, however from a management perspective, SIMIO gives a
clearer 3D representation of our model, which helps us make more efficient
decisions.
c. Chapter 3 10 Questions & Answers
1. What are some conflicting management & technical factors that
affect manufacturing & assembling?
A company should take into account: Market & design
strategy, understand all processes involved from market
analysis (amongst others), analyze manufacturing & assembly
functions, apply the most appropriate rather than later
technology, and also take advantage of the product
specification, modeling simulation, carbon footprint, etc.
2. Define Kaisen, MUDA, MURI, MURA.
Kaisen is a Japanese term that means to improve a current
stage in the process and control it in such a way to prevent

3.

4.

5.

6.

7.

errors and defects. Kaisen determines and develops

systematic ways to gradually improve a process by identifying
and fixing problems. It also includes the elimination of waste
by way of the terms MUDA (unbalanced workload, long wait
times), MURA (irregularity or differences caused by men) and
MURI (stress & strain).
What are the steps of control in KANRI?
There are 4 steps in control of quality using KANRI:
a. Plan: Where the criteria of control, variables and
objectives are defined and set.
b. Do: Based on the criteria set, the process or operation
is reviewed to ensure conformance to the
rules/standard.
c. Check: From the word, this step is to check the
output(results) of an operation.
d. Act: Based on the checking of the operation, actions
are taken to either change or improve processes.
How is Poka-Yoke utilized?
Poka-Yoke is a method used to avoid simple human error and
strives to aim for zero defects within a process (including
smaller sub processes). It was developed by the Japanese in an
effort to reduce any type of defect in the process design. For
example, Poka-Yoke emphasizes that a company should
inspect product 100% during the process.
How do Demings Ways affect or influence the Concurrent
Engineering Mission of a company?
Deming established that the objectives or mission of a
company should not be to make profits for the companys
survival. What it should be is to produce the best service or
goods at the lowest cost following his 14 steps.
How can the method of Design for Manufacturing be improved by
single setup machining?
For design and manufacturing engineers, it is vital to try to
reduce the number of steps or machinery a part or assembly
goes through. By doing so, lead times are reduced as well as
tooling and set up costs. These ideas can be implemented
using new developments made in CNC (Computer Numerical
Control).
Besides utilizing single setup machining, what are the benefits in
reducing the number of parts or tools in an assembly?

 Other benefits include low costs in maintenance,

manufacturing & assembly, waste recycling, or goods storage
costs. Lowering these costs helps in budget planning,
overhead management, basically freeing up capital or to
reinvest in the production facility.
8. What are/is the role of Quality Circles?
Quality Circles are a way of dealing with internal or external
customers in the realm of achieving high quality products. It is
a forum for individuals to discuss day to day or longer term
problems that affect quality output. The intent for this group
is to also promote the culture of quality within the process so
that it is embedded in all employees actions.
9. What is Total Quality Excellence?
TQE is the foundation that builds on quality principles in an
effort to improve product quality through a reduction of
defects. Some techniques that are used to accomplish this are:
defining quality by the customer needs, preventing problems
rather than detecting & correcting them, continuous product
& process improvement.
10. What are the overall benefits for design of quality, manufacturing
and assembly?
With a competitive marketplace in this economy, all
companies aim to strive a quality product that will both
benefit them internally and their end customers. To do so, a
company should try to implement different strategies in the
design stages of certain processes. For quality, designs are
made to ensure the quality of a product are up to standard.
For manufacturing & assembly, the benefits are that processes
are maintained and improved in such a way as to cut costs,
waste and processing times.

d. Other Research Sustainable Green Design

In AquaDrives efforts to a sustainable process/environment, several other
Green PLM methods were researched. Some of these topics that were
defined had to deal with Environmental impacts as well as Financial. For
example, our company will strive to implement a process that is green
friendly. That is, prevent waste from occurring that can and will harm the
environment. Another area in our business that we can improve is our supply
chain process. By pairing and collaborating environmental

impacts/considerations with process performance, business activities can

lessen or eliminate the footprint our company will have on the environment.
e. Collaborative CE/PLM approach using 4 companies
Land Rover Discovery: We can work together to research how we can build
machines that can navigate through various terrains yet have little or no
impact on the environment.
BMW Group (Mini): Together with BMW, we can build a luxurious vehicle
that can and will maintain defect free end products. Since design is an
important element in all of our processes, especially in the manufacturing
and assembly stages, we can research ways how our process and their
process can work together to create high quality things.
California Motors: This company is known for their complex and diversified
types of motors. Together, we can build a motor or a series of motor that not
only is sustainable by a green method but also by performance.
Cognex Corporation: Our two companies can collaborate by implementing
single setup machines that require little effort in the inspection process.
Since Cognex develops parts & assembly machines for companies, we can
help each other figure out design flaws and more efficient processes.
f. Social Networking Content:
Link 1: http://www.manufacturing.net/news/2016/08/vws-employee-chieffloats-idea-taking-stakessuppliers?et_cid=5495667&et_rid=576098541&location=top&et_cid=549566
7&et_rid=576098541&linkid=http%3a%2f%2fwww.manufacturing.net%2fne
ws%2f2016%2f08%2fvws-employee-chief-floats-idea-taking-stakessuppliers%3fet_cid%3d5495667%26et_rid%3d%%subscriberid%%%26locatio
n%3dtop
Discussion Link:
http://njit2.mrooms.net/mod/forum/discuss.php?d=175333#p482217
My comments: Supplier validation and verification is essential in the
producing quality product in a demanding market. It would make sense for
the VW's employee chief to consider having a stake in the company's

suppliers. This not only ensures that suppliers meet their quality demands
but also their financial and supply chain demands.
Link 2: http://newatlas.com/drones-airports-elistairtether/45047/?utm_source=Gizmag+Subscribers&utm_campaign=d2f0d282
3f-UA-2235360-4&utm_medium=email&utm_term=0_65b67362bdd2f0d2823f-76679458
Discussion Link:
http://njit2.mrooms.net/mod/forum/discuss.php?d=163635#p482233
My comments: With any use of portable technology, consumers will always
be wary of the advantages but also, if not more than pro, the disadvantages.
Use of surveillance equipment can be unnerving for many citizens, however
with assurance from a different design perspective can possibly alter those
mindsets. There also begs the question, how can we be certain advanced
drone technology does not fall into the wrong hands?
Link 3: http://newatlas.com/lovefone-phone-box-mobile-repair/45039/
Discussion Link:
http://njit2.mrooms.net/mod/forum/discuss.php?d=166689#p482237
My comments: In my opinion, repurposing old technology should be on every
country's docket moving forward. As we start to replace older ideas, we
should begin to think how we can recycle the older ideas by using small,
sometimes inexpensive routes. Being able to use those iconic red phone
boxes, for ironically another avenue of communication, is just another way
we can strive to be sustainable.

V.

Summary
This report will help AquaDrive develop a strong understanding of the impact of
design stages and the design engineers that control quality objectives,
manufacturing and assembly processes, and a lean and sustainable progress.

VI.

Future Work Proposed

As products, processes and people change, so does the various methodologies
we applied today will. Manufacturing and assembly line productivity is always

changing, it is a game that is played constantly as technology changes. For

example, a production speed for our cars may be 25 cars a day but in due time
can be double that amount. Therefore, continuously monitoring and improving
all the ideologies learned to day will help AquaDrive become a sustainable
business.
VII.

References

1. Paul G Ranky Concurrent Engineering 3D eBook

2. http://www.cimwareukandusa.com/All_IE655/IE655Fall2016.html#Anchor26625
3. http://www.design4manufacturability.com/design_for_quality.htm
4. https://en.wikipedia.org/wiki/Design_for_manufacturability
5. https://en.wikipedia.org/wiki/Design_for_assembly