Product Information Systems – Product Lifecycle Management

SCHOOL of MECHANICAL and MANUFACTURING ENGINEERING 15MMP330 Product Information Systems – Product Lifecycle Management Modelling a laptop design scenario

Author:

Zhehao Jiang

Student ID:

B515966

Assessor:

Prof Bob Young

Date:

10/12/2015

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Product Information Systems – Product Lifecycle Management 1. Describe the general structure of a full IDEF0 model and identify the viewpoint from which your model is being composed The glossary of IDEF0 stemmed from 1970s, the US air force programed their Integrated Computer Aided Manufacture project and developed a series of techniques called IDEF for better analysis on design and more mature productivity (NIST, 1993). IDEF0 is used for function modelling, using a set of graphical diagrams to describe the organizations or systems in their decisions, actions, activities, and information flows, as a member of IDEF family which is derived from the functional modelling language Structured Analysis and Design Technique designed by Douglas Ross (Sullivan, 1991). Nowadays, the main function of IDEF0 is used for improving the manufacturing ability. The general structure of IDEF0 model consists of a set of hierarchical linked diagrams associated with the defined text in the diagrams and glossary of terms refer to each other respectively. Two composition types include activities and data or objects inter-relate to those activities by arrows. The figure below illustrates the full structure of IDEF0 model.

Figure 1: the full structure of IDEF0 model (NIST, 1993) The IDEF0 model must have four arrows respectively are input arrows from left represent the needs and data, control arrows from top represent constraints and standards, mechanism

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Product Information Systems – Product Lifecycle Management arrows from below represent equipment and output arrows to right represent achievements of process. Each arrow must be an entity like data, materials, objects and information. The model activities should start from top left to bottom right, and the output entities of previous activity can be used as the input or control entities of the following activity. Each activity has a node number representing its place in the model hierarchy, and top activity is labelled as A0. Each activity can be decomposed into sub-activities, from general to detail. The following IDEF0 model is to simulate the process of manufacturing activity of a laptop design. The aim of this model is to help project manager facilitate laptop design change management, and enhance inter-communication between each department, to make the laptop design process look very clear and easy to understand. To design a laptop, customer needs, market data, manufacturing tooling and vendor orders are required as model input. The modelling process should be controlled by various design constraints, laptop standards and evaluation guidelines which associated in design and manufacturing progress. Design knowledge includes CAD software and QFD/FMEA analysis tool, component catalogs, resource description and time & cost data are as mechanism to aid the laptop design and manufacturing activities. After integrated input, control and mechanism those elements, the product inventory, customer order status, total cost, and end products would be output of IDEF0 laptop design modelling. The laptop design modelling is decomposed into three hierarchies. A0 is the top hierarchy that realizes product, A1 is the second hierarchy that designs laptop, and A13 is the third hierarchy that performs preliminary design. 2. Abbreviation BOM – Bill of Material CAD – Computer Aided Design CAM – Computer Aided Manufacturing QFD – Quality Function Deployment FMEA – Failure Mode and Effect Analysis

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Product Information Systems – Product Lifecycle Management

External Constraints

Design Laptop Standards Constraints

Evaluation Guidelines

Production Requirements

Tolerance Standards

Planning Policies

Manufacturing Calendar

Time & cost constraints Resource available

Customer needs

Design of Laptop A1

Partial BOM

Product model

Market data

Engineer Manufacture of Laptop

Production cost estimates Facility cost estimates Facility impl. plans

Process specifications Mfg features

A2 Engineer Production System Design change requests

Customer order staus

A3

Cost reports

Process change requests Product orders

Produce Laptops

Receiving reports Tooling Labors

A4

Validation run reqmts Laptop Design Knowledge Materials Knowledge

NODE:

4

A0

Laptop component catalogs CAD QDF/ FMEA

TITLE:

Product inventory Facility reports Products

Tooling designs

Validation run results Material stock desc. Machinability data

CAM

Resource Mfg process Process knowledge models desc.

Manufacturing Activity Model for Laptop Design

Time & cost ref. data

NO.:

Realize Products

Product Information Systems – Product Lifecycle Management

External Buying drivers constraints

Laptop standards

Evaluation guidelines

Design constraints

Tolerance constraints

Laptop constraints Time & cost constraints

Laptop Design Planning

Customer needs

A11 Laptop concept Market data

Evaluation criteria

PDS of Laptop Design A12

Detail specs

PDS

Conceptual Design of Laptop

Func model

A13

Prelim. feedback Design change requests

Product model

Detailed Design of Laptop

Partial BOM

A14 Detail feedback

(ERP QDF/FMEA software)

NODE:

5

A1

TITLE:

Laptop design knowledge

Laptop component Material catalogs knowledge

Manufacturing Activity Model for Laptop Design

CAD Mfg process knowledge

NO.:

Design Product

Product Information Systems – Product Lifecycle Management

Laptop product constraints

External constraints

Develop Functional Decompositions

PDS

Design constraints

Laptop standards

Alternative decompositions

Evaluation guidelines

Evaluation criteria

Oomponent constraints

A131

Layout constraints

Evaluate Decomposition A132 Selected decomposition

Market data

Preliminary configuration

Develop Preliminary Configurations A133 Oomponent specs

Detail feedback

Decomposition knowledge Laptop component catalogs Materials knowledge Laptop design knowledge

NODE:

6

A13

TITLE:

Oomponent specs

Consolidate Configurations Evaluate Alternative Designs

A134 Layout

Prelim. feedback

Strengths & weaknesses

A135 Assignment knowledge

Func. model

Select Design

Oonsolidation knowledge

Detail specs

A136 Mfg process knowledge

QFD/FMEA

Manufacturing Activity Model for Laptop Design

CAD

NO.:

Conceptual Design of Laptop

Product Information Systems – Product Lifecycle Management

Vendors

BPMN

Need this laptop

Need ? N

Request the order

Y

Receive the goods

Satis fied?

Test the goods

Y

Pay the bill

N Terminate the action

Designer

Laptop Design Office

Project Manager

Feedback

Approved

Design Planning

Appr ove?

Check the order Receive the order

Rejected

Standards

Track the process

Transaction Cancelled

Conceptual design

Receive the complaint

External Constraints

Detail Design

Prototype test

Qual ified ?

Y

Determine production

PDS

N Design constraints

Manufacturer

Feedback

7

Manufacture prototype

Volume production

Package and Ship to vendors

Manufacturing calendar

invoice

Received the production

Product Information Systems – Product Lifecycle Management 3. Value of IDEF0 and BPMN models in PLM system Product lifecycle management (PLM) is a system to manage the lifecycle of a product from cradle to grave, integrating people, data, processes and systems into a product information backbone for engineering design office (PLM TECHNOLOGY GUIDE, 2008). The IDEF0 function modelling language is used for exhibiting the overall design and manufacturing process of laptop lifecycle, to manage laptop information. Three hierarchies of IDEF0 modelling from general to detail as an input to configure the laptop PLM system, which provided a framework reference in PLM design and manufacture phase. The model figured out the description of laptop started from design planning to end product related status associated with significant inputs, controls, mechanisms and expected outputs. A0 node diagram as preliminary reference for the entire modelling effort, it benefited laptop project managers, laptop designers, and laptop manufacturers to let them understand their responsibility in their scope of duty combined interoperation with each other and the expected output they should contribute in different stages. The top A0 hierarchy called realize product was decomposed into Design of Laptop (A1), Engineer Manufacture of Laptop (A2), Engineer Production System (A3), and Produce Laptops (A4) those four child activities. The second Design of Laptop (A1) hierarchy was refined into more detailed design processing. The third Conceptual Design of Laptop (A13) hierarchy was again decomposed into more descriptive for better decisions. In addition, IDEF0 could make linkage with other PLM software and gave the project managers instinct supervision on the PLM duration, real time regulated the information, and helped the activities focused on the output. To sum up, IDEF0 model made the PLM system more purposive and less error rate. BPMN is a graphical flowchart based business process modelling using specific notations mapping the business procedures and transactions between organizations, and simulating the development processes in the product lifecycle. A flowchart is superior to thousands of words. BPMN modelling of laptop could intuitively express the relationship between vendors and laptop design office, and the interoperation among internal roles like project managers, designers and manufacturers. The business process started from the task whether vendors need this laptop or not, request of laptop made connection with project manager via

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Product Information Systems – Product Lifecycle Management message flow. Once the manager received the order, the laptop design office went through the total design process from design planning to end product delivery by sequence flow, data objects were linked in different tasks through association connectors. The business flow returned to vendors swim lane to the end, vendors paid the bill if they satisfied with the laptop, if not, gave feedback to laptop design office via e-mail. Compared with normal flowchart, BPMN is more detailed which can describe the process in many perspectives such as variables, decisions, roles, scope and timescales. The benefits of BPMN model in configuring a PLM system help project managers accurately assess the business cost, arrange the workforce and locate the process improvements, like mirroring the real laptop design process. 4. The value of other competitive or complementary methods used in configuring a

PLM system PLM system is a software/hardware configuration major focus on data management and process management to improve the efficiency of product development in the format of CAD drawings, images, documents and so forth. Except IDEF0 model and BPMN model introduced above, there are various complementary methods can be used in PLM system to support product development. For instance, UML (Unified Modelling Language), IDEF4, and Behaviour tree are the other competitive modelling languages which aid PLM systems. UML

Figure 2: UML example (uml-diagrams.org, 2015) UML is a development based modelling language which uses graphics and flow connectors to

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Product Information Systems – Product Lifecycle Management visualize the object oriented system design when configuring a PLM system. UML is a standard adopted by Object Management Group (OMG), and can be divided into two types of view, respectively are structural view and behavioural view. Class diagrams and package diagrams are the typical structural view UML and the elements of structural view in system include objects, relationships and attributes. The structure diagrams extensively enhancing the architecture of PLM system. The difference of behavioural view is that the dynamic operation in PLM system is emphasized especially in collaborating among the changes and illustrating the functionality of system. The behaviour view covers activity diagrams, use case diagrams, sequence diagrams and so forth. There are some similarities among UML, IDEF0 and BPMN models, UML activity diagrams take inputs from left hand box and outputs on the right hand side like IDEF0 models, and behavioural view of UML models use specific graphical notations like BPMN models do to express the business flow. The benefits of using UML diagrams in a PLM system are major in providing standards for software development, reducing new design development time, and easily be understood by various departments for effective business management. IDEF4

Figure 3: IDEF4 example (KNOWLEDGE BASED SYSTEMS, INC, 1995) IDEF4 is one of the IDEF memberships, used for support the object-oriented software design in a graphically oriented method. The IDEF4 example in figure 3 exhibits the structure of

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Product Information Systems – Product Lifecycle Management IDEF4, and IDEF4 is usually designed in three intuitive layer partitions. Respectively are system layer partitions, application layer partitions and foundation layer partitions from generic to specific. The design layers provide three dimensional modelling structures to ensure the connectivity between the system interfaces which reduce the complexity of the design. The components in partitions consist of attributes, objects, commercial applications and applications to be designed. The benefits of IDEF4 including easier decision making for designers to catch the pivotal design features and concentrate on them, it greatly relieve the burden on designers in generating innovating concepts during design process. Compared with previous modelling languages, the IDEF4 models are more intuitional and organized, can support engineering design department in creating optimized concepts at the beginning stage of PLM system. Behaviour tree

Figure 4: Behaviour tree example (Dromey, 2008) Behaviour trees are a common used, graphic based modelling language applied in a large scale PLM system. Behaviour trees can deploy hundreds of natural language requirements to express system needs. Behaviour trees can be divided into two forms, respectively are requirement behaviour trees and integrated behaviour trees. The advantages of Behaviour trees include providing an effective method to deploy the initial requirement in a large scale project in the way of natural language, significantly reduce the risk on project defects, employing much simpler notations for analysing the design of a system, and formal semantics can be simulated and compatible with failure mode and effects analysis. However,

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Product Information Systems – Product Lifecycle Management the disadvantages of Behaviour trees are obviously. For instance, the behaviour tree modelling is usually very large which need very good tools to express the full models. What’s more, it costs a large plenty of time to translate natural language and Behaviour tree can’t reveal its specific merits in small level systems. Table 1: comparison among mentioned methods Applications IDEF0

1. Function

Merits

Drawbacks

1. Permit a design in 1. Hierarchy

modelling

high

consistency

and flexibility

model

can’t express the dynamic sequence

2. Effective

of process

engineering design communication method BPMN

1. Graphical flowchart business

1. Intuitively express 1. Too many specific based process

modelling

the

B2B

notations may not be

relationship 2. Accurately assess the business cost

achieved

by

executers in short time 2. Not

suitable

for

structural view UML

1. Object-oriented software design

1. Provide standards 1. Don’t for

software

development 2. Reduce

have

standard

a file

format new 2. Difficult

design

synchronizing code

development time IDEF4

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1. Object-oriented

1. Intuitively

software design

modelling

3D 1. Limited to

capability

analytical

Product Information Systems – Product Lifecycle Management connect

design 2. Lack level

interface 2. Convenient

for

designers capture

of

system design

information

to vital

features Behaviour tree

1. Large scale PLM 1. Reduce system

project 1. Large time costing

risk

2. High

2. Good

tool

requirement

compatibility with simulation tools 3. Simpler notations for design analysis

Reference Dromey, P. R. G., 2008. Integrated Behavior Tree - Larger System. [Online] Available at: https://en.wikipedia.org/wiki/File:Integrated_Behavior_Tree_Larger_System.png [Accessed 09 12 2015]. KNOWLEDGE BASED SYSTEMS, INC, 1995. IDEF4 OBJECT-ORIENTED DESIGN METHOD, OHIO : AIR FORCE SYSTEMS COMMAND WRIGHT-PATTERSON AIR FORCE BASE. NIST, 1993. Announcing the Standard for INTEGRATION DEFINITION FOR FUNCTION MODELING (IDEF0). [Online] Available at: http://vernikov.ru/krisis/item/204-polnye-teksty-standartov-idef-idef0.html [Accessed 08 12 2015]. NIST, 1993. FIPS Publication 183 released of IDEF0. [Online] Available at: http://nvlpubs.nist.gov/ [Accessed 08 12 2015]. PLM TECHNOLOGY GUIDE, 2008. What is PLM. [Online] Available at: www.plmtechnologyguide.com

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Product Information Systems – Product Lifecycle Management [Accessed 08 12 2015]. Sullivan, D. O., 1991. Project management in manufacturing using IDEF0 . In: J. Turner, ed. International Journal of Project Management. Paris: APM, pp. 162-168. uml-diagrams.org, 2015. Sentinel HASP Licensing Domain - UML Class Diagram Example. [Online] Available

at:

http://www.uml-diagrams.org/software-licensing-domain-diagram-example.html?context=cls-ex amples [Accessed 09 12 2015].

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