Modular KBE Strategy for Lean Product Development
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The document discusses a modular knowledge-based enterprising (KBE) strategy for lean product development. It proposes using a rule-based modular system with smart parts that are parametric and associative. This approach allows knowledge to reside in one system and be reused across projects, providing major savings over traditional methods. The strategy is implemented using CATIA V5, with specifications defined in Excel and smart parts created to achieve reconfigurable product solutions directly from specifications.
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Modular KBE Strategy for Lean Product Development
- 1. Brian Prasad Knowledge-based Enterprising (KBE) Strategy for Lean Product Development (LPD) Biren (Brian) Prasad, Ph.D. President, Knowledge Solution, Irvine, CA http://www.KnowledgeSol.com/ Keynote Talk at The 27th International Conference on CAD/CAM, Robotics and Factories of the Future Conference (CARS & FoOF 2014), 22-24 July 2014, London, UK
- 2. Brian Prasadhttp://www.KnowledgeSol.com/ Mission Our mission is to provide unequaled value through superior quality, performance technical innovation speed and responsiveness, cost savings via lean product development & premier customer service via knowledge-based developments to our customers. Innovation Vision Continuous Improvement Vision Knowledge Solution - Company
- 3. Brian Prasadhttp://www.KnowledgeSol.com/ Product Development Process Functional Requirements Engineered Product Content Time $Cost A Typical Product Development– What it is?
- 4. Brian Prasadhttp://www.KnowledgeSol.com/ A typical Product-development process Value-added activity Type I waste Partial value-added Type II waste Non value-added TRADITIONAL Value-added & Creative efforts Repetitive tasks Re-do’s Reinventing solutions Repeating mistakes CE With KBE KBAD Further reduction in development effort Innovate Automate Value activity Reuse Apply Best practices Apply Analysis Insert New Ideas Creative Efforts Reduction in development effort EliminateContinuous Improvements Minimize With Continuous Improvement Repetitive tasksValue-added activity Minimize Creative Efforts KBE: Knowledge –Based Enterprising or Engineering KBAD: Knowledge-Based Application Development Knowledge–based Enterprising (KBE) Strategy for Lean Product Development – What it is?
- 5. Brian Prasadhttp://www.KnowledgeSol.com/ A typical design scenario Expert Engineers Expert Analysts Expert Designers Product Engineers Product Analysts Product Designers Project Managers Function Managers Knowledge –based Enterprising (KBE) Strategy for LPD – What it is?
- 6. Brian Prasadhttp://www.KnowledgeSol.com/ What’s wrong with this? • Knowledge is fragmented • Subject matter experts (SME) often scarce and busy • Less uniformity and consistency • Time-intensive, manpower dependent • When people retire, information is lost • Often design is done via trial and error— case-based reasoning Knowledge –based Enterprising (KBE) Strategy for LPD – What it is?
- 7. Brian Prasadhttp://www.KnowledgeSol.com/ Expert Engineers Expert Analysts Expert Designers Product Engineers Product Analysts Product Designers Project Managers Function Managers KBE Strategy for Lean Product Development: Knowledge-centric approach
- 8. Brian Prasadhttp://www.KnowledgeSol.com/ Modular Procedural Tightly-coupled open Level of integration concurrent serial Process path KBE Strategy for Lean Product Development: Enrichment of knowledge… is a continuum
- 9. Brian Prasadhttp://www.KnowledgeSol.com/ KBE Strategy for LPD: Let’s consider this situation BalanceTube LVDT SecondaryPiston (SPiston) CenterGland (CG) EndGland (EG) RodEnd (RE) PrimaryPiston (PPiston) RampWasher CEBearing CGRetainer EGRetainer EGNut REBearing Cylinder
- 10. Brian Prasadhttp://www.KnowledgeSol.com/ Procedural Strategy: Serial, tightly-coupled KBE system Tandem SPiston Tandem CenterGland Tandem PPiston Tandem Cylinder Tandem EndGland Tandem EGRetainer Tandem CGRetainer Tandem RodEnd Tandem EGNut Tandem REBearing Tandem CGBearing Tandem RampWasher Tandem BalanceTube Tandem LVDT … Table Design Table Specs Table Material Table Analysis Tools Modular Procedural
- 11. Brian Prasadhttp://www.KnowledgeSol.com/ Drawbacks of procedural KBE Strategy for LPD • Part and product specific • Hard-coded interfaces • Cumbersome to maintain • Incompatible API’s • External parameter linking issues • Very sensitive to interface changes (parameters, rules, features) • Expansions are complex and error prone • Inflexible Modular Procedural Procedural KBE Strategy- Drawbacks?
- 12. Brian Prasadhttp://www.KnowledgeSol.com/ Product Assembly Completed Assembly Detail Parts SmartPart Modular KBE Strategy: Rule-based System Control Structure High Level Requirements Detail Requirements An assembly of parametric parts, where dependence of one part to another is controlled by a “control structure logic”—whose primary function is to link relationships and attributes throughout a product hierarchy resulting in a product assembly that is associative. Modular Procedural
- 13. Brian Prasadhttp://www.KnowledgeSol.com/ Modular KBE Strategy for LPD: System Approach PERFORMANCE SPECIFIED product concept (initial) materials / attributes / features / parameters develop system concept decompose systems into subsystems decompose subsystems into components decompose components into parts design each part design pairs of parts design pair of parts into components design pair of components into subsystems design pair of subsystems into system design system concept product concept (working) PERFORMANCE VERIFIED Level 5 Level 4 Level 3 Level 2 Level 1 Level 0 Modular Procedural
- 14. Brian Prasadhttp://www.KnowledgeSol.com/ Modular KBE Strategy for LPD Product Lifecycle Management (PLM) Implementation
- 15. Brian Prasadhttp://www.KnowledgeSol.com/ Result of Modular KBE Strategy for LPD: Open, Concurrent LPD System Product Definition Configurator Product Solution Configurator SmartPart Configurator Modular Procedural Apply Intra-Part Relations Apply System Specs Build System Solution Apply Inter- Component Relations Apply Assembly Constraints Build Sub-system Solution Build Component Solution Instantiate Chosen Component Templates Build chosen Component Templates Build Assembly Constraints Choose a Sub-System Configuration Choose a System Configuration Choose a Component Configuration Build Intra-Part Rules & Relations Build System Specs Build Inter- Component Relations
- 16. Brian Prasadhttp://www.KnowledgeSol.com/ Merits of modular lean product development • Product-Independent • Architecture • Part-Independent • Concept • Tool-Independent • Method Modular Procedural Product Definition Configurator Product Solution Configurator SmartPart Configurator Modular KBE Strategy for LPD?
- 17. Brian Prasadhttp://www.KnowledgeSol.com/ A CATIA V5 implementation • System Architecture • JustOne system model and common tree structure • Generative Rule Bodies • Rule bodies create more rules dynamically on the tree; asleep until awaken • Retrieve templates; no generative geometry • Internal Linking • Two generalized automation methods to pass/exchange information intrapart and interpart Modular KBE Strategy for LPD?
- 18. Brian Prasadhttp://www.KnowledgeSol.com/ Modular KBE Strategy Implementation: Specs Definitions (Excel Inputs)
- 19. Brian Prasadhttp://www.KnowledgeSol.com/ Parameters TypePart CATParts TypePartSpecs TypePartSizing TypePartGeometry CATProduct Open Locked Restricted Type: Tandem Modular KBE Strategy Implementation: SmartParts Creation Parameters TandemPiston CATProduct Open Locked Restricted CATParts TandemPistonSpecs TandemPistonSizing TandemPistonGeometry Parameters TandemGland CATProduct Open Locked Restricted CATParts TandemGlandSpecs TandemGlandSizing TandemGlandGeometry
- 20. Brian Prasadhttp://www.KnowledgeSol.com/ Modular KBE Strategy Implementation: Achieving a Product Solution
- 21. Brian Prasadhttp://www.KnowledgeSol.com/ Modular KBE Strategy Implementation: Inter- & Intrapart communications
- 22. Brian Prasadhttp://www.KnowledgeSol.com/ Build a Component Templates Apply Intra-Part Relations Apply System Specs Build Assembly Constraints Choose a Sub-System Configuration Build System Solution Choose a System Configuration Choose a Component Configuration Build Intra-Part Rules & Relations Apply Inter- Component Relations Apply Assembly Constraints Build System Specs Build Sub-system Solution Build Component Solution Build Inter- Component Relations Instantiate Component Templates SmartPart Configurator Aggregation Product Solution ConfiguratorProduct Definition Configurator Modular KBE Strategy Implementation: Demo
- 23. Brian Prasadhttp://www.KnowledgeSol.com/ Demo–Salient points • Initialize parameters • SmartParts pulled and Rules added • Specs parameters & constraints passed from “systems” to “subsystems”, to “components,” to “parts” during “decomposition” and vice versa during “aggregation” • SmartParts were “instantiated” and constraints satisfied • Solution is reconfigurable for changing spec requirements Modular KBE Strategy Implementation
- 24. Brian Prasadhttp://www.KnowledgeSol.com/ Modular KBE Strategy Implementation: …directly from spec • Good for early program stages (Quick evaluation of various “alternate designs” scenarios) • Gets you 80% there and you can finish the rest (20%) in native CATIA mode Engineered design…
- 25. Brian Prasadhttp://www.KnowledgeSol.com/ Engineered design… • Good for early program stages (Quick evaluation of various “alternate designs” scenarios) • Gets you 80% there and you can finish the rest (20%) in native CATIA mode …directly from spec • Unbalanced tandem actuator with 4100 psi supply pressure and 9.49 inch stroke. Modular KBE Strategy Implementation
- 26. Brian Prasadhttp://www.KnowledgeSol.com/ Engineered design… • Balanced simplex actuator with 3050 psi supply pressure and 3.89 inch stroke. …directly from spec Modular KBE Strategy Implementation
- 27. Brian Prasadhttp://www.KnowledgeSol.com/ Key Benefits • Knowledge resides in one system and reused widely across the enterprise • Order of magnitude savings (1:10 ~ 1:100) • Promotes collaboration & knowledge sharing • Product independent architecture • Experts now become knowledge-keepers • Promotes innovations and creativity • Good for preliminary studies & portfolio mgt • Knowledge inside, Lean inside, standards inside, analysis inside, best practices inside Modular KBE Strategy for Lean Product Development (LPD)
- 28. Brian Prasadhttp://www.KnowledgeSol.com/ Keys to maximizing productivity gains … • KBE has its own life. Think about integration and interfaces. They are big deal for KBE. • Holistic view of product development process • Employ a modular, open, and concurrent strategy for building KBE systems • Think engineering centric versus geometry- centric; analysis driven, geometry is a by- product • Follow a knowledge management framework for applying KBE Modular KBE Strategy for Lean Product Development (LPD)
- 29. Brian Prasadhttp://www.KnowledgeSol.com/ Questions? Contact: Biren (Brian) Prasad, Ph.D. Prasad@KnowledgeSol.com Prasadbiren@gmail.com Tel: (714) 396 9424 Knowledge Solution A PLM-LPD Service Company Irvine, CA Modular KBE Strategy for Lean Product Development (LPD)