FLEXIBLE DESIGN METHODOLOGY




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Proceedings of 5th Design for Manufacturing Conference Design Engineering Technical Conferences Baltimore Maryland September 10 13 2000 DETC2000 DFM 14016 FLEXIBLE DESIGN METHODOLOGY Christoph Roser Department of Mech Ind Engineering University of Massachusetts Amherst David Kazmer Department of Mech Ind Engineering University of Massachusetts Amherst Figure 1 shows a predicted feasible design region within which a design is assumed to be feasible From this predicted design region a design is selected according to the objective function The objective function is shown in the graph as the diagonal contour lines However the actual design window and the feasible design window might not coincide due to uncertainties in the system performance If the selected design lies outside of the actual design window a design change is necessary even if the model predicted this design to be optimal This required design change will result in unforeseen development costs and may also alter the performance and cost of the product KEYWORDS Flexible Design Design Uncertainty Robust Design Change Cost Design Variable x2 ABSTRACT A flexible design methodology is developed to minimize the effect of uncontrolled variation by modeling potential design and manufacturing corrections in the product development process Using this flexibility methodology the different defect modes and the likelihood of these defects occurring is evaluated For every defect mode all design change options are investigated including the cost and probability of selection The expected cost of the initial design including design changes is determined thus allowing development of improved more flexible designs The theoretical method is demonstrated using an example The results indicate that small changes in design variables may reduce the likelihood and cost of future design changes yet provide opportunity for downstream cost minimization Prediction INTRODUCTION The goal of robust design methodologies is to reduce the






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