Technology and Manufacturing Process Selection: The Product Life Cycle Perspective PDF
Preview Technology and Manufacturing Process Selection: The Product Life Cycle Perspective
Springer Series in Advanced Manufacturing Elsa Henriques Paulo Peças Arlindo Silva Editors Technology and Manufacturing Process Selection The Product Life Cycle Perspective Springer Series in Advanced Manufacturing Series editor Duc Truong Pham, Cardiff, UK For furthervolumes: http://www.springer.com/series/7113 Elsa Henriques Paulo Peças • Arlindo Silva Editors Technology and Manufacturing Process Selection The Product Life Cycle Perspective 123 Editors ElsaHenriques PauloPeças ArlindoSilva IDMEC,Instituto Superior Técnico Universidade deLisboa Lisbon Portugal ISSN 1860-5168 ISSN 2196-1735 (electronic) ISBN 978-1-4471-5543-0 ISBN 978-1-4471-5544-7 (eBook) DOI 10.1007/978-1-4471-5544-7 SpringerLondonHeidelbergNewYorkDordrecht LibraryofCongressControlNumber:2013953217 (cid:2)Springer-VerlagLondon2014 Thisworkissubjecttocopyright.AllrightsarereservedbythePublisher,whetherthewholeorpartof the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation,broadcasting,reproductiononmicrofilmsorinanyotherphysicalway,andtransmissionor informationstorageandretrieval,electronicadaptation,computersoftware,orbysimilarordissimilar methodology now known or hereafter developed. Exempted from this legal reservation are brief excerpts in connection with reviews or scholarly analysis or material supplied specifically for the purposeofbeingenteredandexecutedonacomputersystem,forexclusiveusebythepurchaserofthe work. Duplication of this publication or parts thereof is permitted only under the provisions of theCopyright Law of the Publisher’s location, in its current version, and permission for use must always be obtained from Springer. Permissions for use may be obtained through RightsLink at the CopyrightClearanceCenter.ViolationsareliabletoprosecutionundertherespectiveCopyrightLaw. The use of general descriptive names, registered names, trademarks, service marks, etc. in this publicationdoesnotimply,evenintheabsenceofaspecificstatement,thatsuchnamesareexempt fromtherelevantprotectivelawsandregulationsandthereforefreeforgeneraluse. While the advice and information in this book are believed to be true and accurate at the date of publication,neithertheauthorsnortheeditorsnorthepublishercanacceptanylegalresponsibilityfor anyerrorsoromissionsthatmaybemade.Thepublishermakesnowarranty,expressorimplied,with respecttothematerialcontainedherein. Printedonacid-freepaper SpringerispartofSpringerScience+BusinessMedia(www.springer.com) Editorial Board Wim Dewulf, Katholieke Universiteit Leuven, Leuven, Belgium Joost Duflou, Katholieke Universiteit Leuven, Leuven, Belgium Paulo Ferrão, Universidade de Lisboa, Lisbon, Portugal Michael Z. Hauschild, Technical University of Denmark, Lyngby, Denmark Elsa Henriques, Universidade de Lisboa, Lisbon, Portugal Paulo Martins, Universidade de Lisboa, Lisbon, Portugal Paulo Peças, Universidade de Lisboa, Lisbon, Portugal Roy Rajkumar, Cranfield University, Bedfordshire, UK Inês Ribeiro, Universidade de Lisboa, Lisbon, Portugal Rich Roth, Massachusetts Institute of Technology, Cambridge, USA Arlindo Silva, Universidade de Lisboa, Lisbon, Portugal v Preface In a global market, competitive advantage lies not only on the mastering of existing processes and methodologies, but most of all on the ability to pursue different avenues,with anincreasedvalue.This can only beachieved with anup- to-date technological knowledge and scientific principles materialized in the design and manufacturing of new products, with the goal of protecting the envi- ronmentandconservingresources,whileencouragingeconomicprogress,keeping in mind the need for sustainability. Design and process engineering problems are frequently of an ill-defined nature, demanding for the analysis and evaluation of complex alternative solutions, in which environmental, economic, and functional performance criteria interact in a complex net of influences, with an emergent behavior. Moreover, even when decisions are made in a well-defined and narrow timeframe, their effects are normally felt over a larger time sphere and scope domain, shaping the future further than anticipated and in eventually unsought ways. Technology and manufacturing process selection is essential in the continuous improvementofexistingproductsandprocessesasakeyfactortocompetitiveness and sustainability. Technology-based innovation relies on the combination of design and manufacturing areas, bringing together a multidisciplinary team with different expertise and perspectives. The complexity of the decision-making pro- cess under such a widespread knowledge framework implies the use of efficient and reliable approaches. The analysis and synthesis mechanisms to support this decision-making process must also be effective in the early design phases and integrate all the aspects related with the life cycle stages of both product and technologies. To deploy a technology evaluation and selection process under a life cycle scope, it is essential to capture all the evolutions and impacts of the selected alternatives,frequentlysupportedonvagueinformationanduncertaindata.Infact, nowadays product developers need to address not only the production costs, but alsoallthecostsincurredthroughouttheentireproductlifecycle(LifeCycleCost -LCC). The estimation of all the costs associated with a product in a ‘‘cradle to grave’’ perspective—or, even in a broader way, from ‘‘cradle to cradle’’—inte- grates the analysis of the impact of design for cost, design for maintainability, design for assembly, design for recycling, etc. With the aim of providing drivers andindicatorsforasustainableengineeringpractice,itisalsoimportanttodesign vii viii Preface and evaluate the technological alternatives on a life cycle environmental basis, namelyinvolvingLifeCycleAssessment(LCA)methods.Accordingly,theuseof methodologies like LCA to estimate the environmental performance supports the disciplines of design for the environment, design for recycling, design for stan- dards, etc. The main reason for including a life cycle perspective in the early stages of product and process development is that decisions taken at the front end of the development largely influence the production of competitive products with high quality standards in regards to functional performance, cost and environmental impact for their entire life. Therefore, to better design for the entire life, Design- for-Xstrategies,supportedbythecorrespondingtools,havebeenincreasinglyand successfully applied. These strategies drive the design team in the creation of products,processes,andservicesthatachieveaspecifictargetorthatmaximizethe performance in a wide range of engineering fields (cost, environment, assembly, etc.). The problem then becomes one of striking a balance between different ‘‘optimizations,’’ as optimizing for recycling will necessarily lead to a different outcomethanoptimizingformanufacturingandassembly,whichfurtherenhances the need to better understand the way in which these dispersed approaches/tools need to be used in a coherent and comprehensive way. Theconsiderationofalllifecyclestagesofaproductintheearlydesignphase allows a more complete perception of the product’s value in the market and in society.ThiswayofdesigninganddevelopingaproductcanbecalledDesignfor the LifeCycle. Todifferentiate it fromthe regular DfX strategies,several authors prefer to denominate it as Life Cycle Engineering, understood as a decision- making methodology that considers functional performance, environmental, and cost dimensions throughout the duration of a product or, in a narrower sense, throughout the time horizon affected by an engineering decision, guiding design engineers toward informed decisions. TheresearchinLifeCycleEngineeringchallengestheacademicworldbecause it endorses a multidisciplinary approach on a problem solving framework. In fact the development of Life Cycle Engineering tools and its implementation in product design and development requires the collaboration of different areas of expertise during several phases of such a project. Therefore, the incorporation of concurrent engineering practices is recommended, if not mandatory. In conclusion, the development of decision-making methodologies based on Life Cycle approaches is extremely important to support informed and reliable assessment and selection of technological solutions. Based only on singular types of performance or integrating several types of performance, these methodologies are under development by several research groups worldwide. This book provides specific topics intending to contribute to an improved knowledge on Technology Evaluation and Selection in a Life Cycle Perspective. Althougheachchapterwillpresentpossibleapproachesandsolutions,thereareno recipes for success.Each reader will find his/her balance in applying the different topicstohis/herownspecificsituation.Casestudiespresentedthroughoutwillhelp in deciding what fits best to each situation, but most of all any ultimate success Preface ix will come out of the interplay between the available solutions and the specific problemoropportunitythereaderisfacedwith.Contributionswereacceptedfrom 47 authors in seven countries from around the world: China, France, Germany, Italy, Portugal, Sweden, and the United States of America. Editingabookembodiesteamworkandrepresentsconsiderableworkfromthe authors, editors, and editorial advisory board. This collaborative teamwork involves keeping track of contacts of authors and their contributions, exchanging information and ideas, managing the review process, feeding back review to the authors, managing conflicting perspectives, and integrating contents into a rea- sonablestructure,withtheultimategoalofdevelopingaproductthataddsvalueto the readers’ body of knowledge. Asteamleaders we,theeditors,havetothankourteammembersfortheeffort involved in this initiative. This book is primarily supported by the team of pro- fessionalsfromSpringer.Wethankthemfortheopportunityandconstantsupport in editing the book, timely suggestions, prompt feedback, and friendly reminders aboutdeadlines.TotheMembersoftheEditorialBoard,ourgratitude forsharing with us their knowledge and experience in the support of the decision-making processes inherent to the project, for assisting in the review process, and for their help in shaping the book. We acknowledge all the authors, without whom there would be no book in the first place! Many contributions were not considered, despitetheirmerit,eitherbecausetheywereoutofthescopeforthisbook,oftime limitations, or other constraints. A special word to our home institution, the In- stituto Superior Técnico of the Technical University of Lisbon, for providing the infrastructure, material resources, and logistics required for our work. We hope the book will enlighten the reader in the same way it enlightened us duringtheeditingprocess,andthatitscontentswillhelpfosternewandinnovative research worldwide. Elsa Henriques Paulo Peças Arlindo Silva Contents Product Architecture Decision Under Lifecycle Uncertainty Consideration: A Case Study in Providing Real-time Support to Automotive Battery System Architecture Design. . . . . . . . . . . . . . . 1 Qi D. Van Eikema Hommes and Matthew J. Renzi Consideration of Legacy Structures Enabling a Double Helix Development of Production Systems and Products . . . . . . . . . . . . . . . 21 Magnus Wiktorsson Six Sigma Life Cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Pedro A. Marques, Pedro M. Saraiva, José G. Requeijo and Francisco Frazão Guerreiro On the Influence of Material Selection Decisions on Second Order Cost Factors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Marco Leite, Arlindo Silva and Elsa Henriques Aircraft Industrialization Process: A Systematic and Holistic Approach to Ensuring Integrated Management of the Engineering Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 José Manuel Lourenço da Saúde and José Miguel Silva Material Flow Cost Accounting: A Tool for Designing Economically and Ecologically Sustainable Production Processes . . . . 105 Ronny Sygulla, Uwe Götze and Annett Bierer Life Cycle Based Evaluation and Interpretation of Technology Chains in Manufacturing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 F. Klocke, B. Döbbeler, M. Binder, R. Schlosser and D. Lung Selecting Manufacturing Process Chains in the Early Stage of the Product Engineering Process with Focus on Energy Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 Martin Swat, Horst Brünnet and Dirk Bähre xi xii Contents Manufacturing with Minimal Energy Consumption: A Product Perspective. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 Alexandra Pehlken, Alexandra Kirchner and Klaus-Dieter Thoben Integrated Framework for Life Cycle-Oriented Evaluation of Product and Process Technologies: Conceptual Design and Case Study. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193 Uwe Götze, Andrea Hertel, Anja Schmidt, Erik Päßler and Jörg Kaufmann Life Cycle Engineering Framework for Technology and Manufacturing Processes Evaluation. . . . . . . . . . . . . . . . . . . . . . 217 Inês Ribeiro, Paulo Peças and Elsa Henriques Proposal for an Architectural Solution for Economic and Environmental Global Eco-Cost Assessment: Model Combination Analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239 Nicolas Perry, Alain Bernard, Magali Bosch-Mauchand, Julien Le Duigou and Yang Xu The Ecodesign of Complex Electromechanical Systems: Prioritizing and Balancing Performance Fields, Contributors and Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257 S. Esteves, M. Oliveira, F. Almeida, A. Reis and J. Pereira Composite Fiber Recovery: Integration into a Design for Recycling Approach. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281 Nicolas Perry, Stéphane Pompidou, Olivier Mantaux and Arnaud Gillet Design for Disassembly Approach to Analyze and Manage End-of-Life Options for Industrial Products in the Early Design Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297 Claudio Favi and Michele Germani Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
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