Application of Lean in Product and Manufacturing Engineering

Abstract: Shortening product development lead time, while reducing the cost and increasing reliability, is a perpetual challenge of engineering. This, coupled with changing consumer needs, doesn’t make product development any easier. While manufacturing function has embraced the lean philosophy with relative ease and enthusiasm, it is a struggle for engineering due to inherent uncertainties.

This whitepaper discusses an approach to continually enhance the effectiveness and efficiency of product development. We believe the first step is always to get the process right, before deploying tools and technologies to run it better. We have also tried to illustrate the power technology tools bring to make product development ‘Lean’.

This paper focuses on engineering pieces of product development with an objective that is defined from the product development context.

Cost Optimization Across the Product Realization Value Chain

Abstract: Manufacturing organizations face a strategic dilemma between increasing revenue and decreasing cost to enhance profitability. In this context, cost optimization is often thought to be a purely cost reduction exercise. However, if carefully balanced, cost optimization can help in increasing both profits as well as revenue. Cost optimization aims at reducing the costs ‘built-in’ the product; this will ultimately help in increasing the profit margin of the product by lowering the price-points, and expand the footprint of the product in virgin markets as also in existing markets.

Most cost optimization initiatives are carried out when products are successfully implemented on the manufacturing product line. Whenever firms undergo a profit-maximization drive, they undertake a cost optimization program focused on post-development functions like production, sales, and other operational overheads. The choice is based on the fact that materials and manufacturing expenses constitute a major part of costs. However, most of the cost structure for the product is locked into place because of the product specifications and decisions made during the development stage. Therefore, it is necessary to focus on cost optimization right from the beginning of the product development lifecycle, i.e. at the conceptualization stage of a new product. Companies can create significant cost optimization through better understanding and evaluation of cost drivers across the entire product realization value chain.

This whitepaper focuses on the need and scope for cost optimization, barriers to effective product cost optimization, mechanisms for early product cost estimation and identifying key elements to product cost optimization.

DFM in Project Industry

Abstract: This paper outlines various aspects related to detailed engineering of a project, while specifically looking at a case of process equipment design and explaining how design issues related to manufacturing can be addressed with DFM rules. These DFM rules can be easily converted into software‐based checks which can help automate the design process. This, in turn, ensures considerable time and cost savings, while ensuring the right quality of design.

Effective Implementation of DFM

Design for Manufacturing (DFM) comprises of a set of tools and associated knowledgebase that help design engineers to evaluate manufacturability of their designs in simple and cost effective steps without compromising on design intent and functionality.

Ensuring Success of Global MES Deployments

Abstract: The importance of Manufacturing Execution Systems (MES), in achieving manufacturing excellence and rapidly scaling up production to meet customer demands for new products is well established. But manufacturers still struggle to replicate the benefits across all sites. As a result, standardization of processes and activities across sites has become one of the top priorities for global manufacturers. A global approach to MES deployment can enable this initiative of standardization. In this article, Geometric presents the best practices of Global MES deployments, abstracted from its experience of deploying global systems. The best practices are presented in a readily usable, global program management framework.

Maturity Assessment of Digital Manufacturing Initiative

Digital Manufacturing has become an integral part of product lifecycle management solution. Process planning definition to finalization by digital validation has become the key function in reducing of product deployment time in the lifecycle and addresses several critical business challenges faced by today’s global manufacturers.

This white paper outlines the framework and methodology that can be used for assessing the maturity of Digital Manufacturing solution implementation.

Nesting – An Essential Aid for Cost Reduction

Abstract: Cost reduction seems to be today’s mantra as competition is increasing on a global level. To sustain in the market, every aspect that accounts to cost has to be studied thoroughly and measures have to be taken to reduce unwanted elements of design to reduce the product cost. Material cost and manufacturing cost are two major elements that influence total product cost. By thoughtful design, both costs can be controlled or limited at the early design stage itself.

In sheet metal manufacturing, nesting is commonly used to fit multiple two-dimensional shapes on a larger sheet for optimizing material utilization. Automatic nesting softwares are generally used in the manufacturing stage for cutting blanks of multiple components from standard sheet sizes.

To ensure that both senior and junior design engineers make their designs cost effective, few companies have started using nesting technology at the design stage itself as an aid for all designers. It gives the designers the ability to understand how parts will be laid out, and what would be the approximate cost. It also helps in price negotiation with suppliers and provide constructive feedback in case they provide lower utilization and hence increased cost than that obtained by the designers.

This whitepaper reveals how by incorporating Design for nesting into the current DFM process, organizations can reap considerable benefits in terms of cost reduction.