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MIT 2 008 - Design & Manufacturing II

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112.008 Design & Manufacturing IISpring 2002Systems Design2- HW#1 due today. - No HW today. - Reading, Kalpakjian, P177-199- Monday 2/16, Holiday- Tuesday 2/17, Monday’s lecture & lab group A- Wednesday 2/18, Yo-Yo case study2.008 MIT, S. Kim 4Super bowl 2002BIG PICTURE2.008 MIT, S. Kim 5Systems Design Is Pats a good team? Is MIT a good school? Am I a good teacher?2.008 MIT, S. Kim 6A University (Manufacturing System)High schoolsCollegesEtc.Faculty, staff, academic programsGraduate schoolsIndustryGovernmentSocietyadministrationSuppliers CustomersManufacturing systemgraduationadmissionFSo JSeFundamentalKnowledgeHands-onknowledgeImage removed due to copyright considerations.22.008 MIT, S. Kim 7Good Design lecture room ? Boston T ? Honda Civic ? Logan Airport ? Government ?2.008 MIT, S. Kim 8Design Domains“What” to “How”, “Top” to “Bottom”What HowFunctionalRequirementsDesign ParametersNo impromptu designs!!2.008 MIT, S. Kim 9Light50 µmActive MatrixPiezoelectricActuatorMirrorTMA(thinfilm micromirror array)Mirror Array onPiezoelectricActuator ArrayDaewoo ElectronicsCase study2.008 MIT, S. Kim 10TMAProjection LensLight SourceModulation StopTMAMirrorSource StopNo TiltingNo TiltingMax. TiltingMax. TiltingBlackWhiteIncrease of tilting angle2.008 MIT, S. Kim 11Evolution of TMA Pixels00 02 04 06 084812162024Optical Efficiency(%)Year1st1st2nd2nd3rd3rdDaewoo Electronics2.008 MIT, S. Kim 12Functional Requirements of TMA1st GenerationFR1= light reflectionFR2= mirror tiltingDP1= cantilever top surfaceDP2= PZT sandwichFR1FR2DP1DP2=X XX X32.008 MIT, S. Kim 13Image by 1stGen. TMA –96’ 122.008 MIT, S. Kim 14Functional Requirements of TMA2nd GenerationFR1= light reflectionFR2= mirror tiltingDP1= cantilever top surfaceDP2= PZT sandwichFR1FR2DP1DP2=X OX X2.008 MIT, S. Kim 15Image by the 2nd Gen. TFAMA - 1997.072.008 MIT, S. Kim 16Functional Requirements of TMA3rd GenerationFR1= light reflectionFR2= mirror tiltingDP1= cantilever top surfaceDP2= PZT sandwichFR1FR2DP1DP2=X OO X2.008 MIT, S. Kim 17VGA640 X 480307,200 pixels50 µmHuman HairXGA1024 X 768786,432 pixelsTMA2.008 MIT, S. Kim 18Image by the 3rd Gen. TMA -1997.12150 in. Screen150 in. Screen42.008 MIT, S. Kim 19XGA Image, Nov. 19992.008 MIT, S. Kim 20Good Designin small scale products?“What” to “How”, “Top” to “Bottom”What HowFunctionalRequirementsDesign ParametersDesign Axioms2.008 MIT, S. Kim 21Example: Shower FaucetFunctional Requirements-Temperature-Flow rateθhθv2.008 MIT, S. Kim 22Independence Axiom Maintain the independence of FRs. Shower faucet exampleFR1FR2DP1DP2=X XX XFR1= TemperatureFR2= Flow rateDP1= Hot waterDP2= Cold WaterFR1FR2DP1DP2=X OO XFR1= TemperatureFR2= Flow rateDP1= Horizontal AngleDP2= Vertical Angle2.008 MIT, S. Kim 23Information Axiom Minimize the information content of the designDesign rangeSystem range2.008 MIT, S. Kim 24Functional Requirements Al Cans 12 FRs52.008 MIT, S. Kim 25Systems View–Four Design DomainsCustomerDomainFunctionalDomainPhysical DomainProcessDomain?2.008 MIT, S. Kim 26Isolated domainsHigh walls2.008 MIT, S. Kim 27Concurrent EngineeringCustomerDomainFunctionalDomainPhysical DomainProcessDomainLower walls-Car program manager-Project Manager2.008 MIT, S. Kim 28Four domainsPeople resourcesPrograms officesFunctionsCustomer satisfactionOrganizationResourcesBusiness structureBusiness goalsROIBusinessSubroutinesInput variablesOutput of programsAttributesdesiredSoftwareProcessesMicro-structurePropertiesPerformancesMaretialsPVDPFRCAManufacturingsystems2.008 MIT, S. Kim 29Systems Design Customer Satisfaction Concurrent Design Design for Manufacturing, Assembly and “X” Quality Control, Six Sigma House of Quality, Takuchi method Axiomatic Design Any of these efforts in MEMS/Nano?2.008 MIT, S. Kim 30Principles of DesignAxiomsDoes scale matter? Multi-scale Systems design, 2.76 Culpepper & Kim, Fall 2004 Axiomatic Design, 2.8821. N.P. Suh, Principles of Design, Oxford, 19902. N. P. Suh,Axiomatic Design: Advances and Applications,Oxford, 20013. N. P. Suh, Complexity: Theory and Applications, Oxford, 200462.008 MIT, S. Kim 31ManufacturingUnit ManufacturingProcessesAssembly and JoiningDesign forManufactureMarketResearchConceptualDesignFactory, Systems & Enterprise•Welding•Bolting•Bonding•Soldering•Machining•Injection molding•Casting•Stamping•Chemical vapor deposition2.008 MIT, S. Kim 32Manufacturing SystemManufacturingSupportsystemFacilitiesFactoryequipmentsRaw materialsFinished productsFactory operationsProcessingMaterial handlinginspectionDesignManufacturingplanningManufacturing controlMarketingValue add process2.008 MIT, S. Kim 33ManufacturingTransformation of materials and information into goods for the satisfaction of human needsBig Picture ?2.008 MIT, S. Kim 34History1. Greek “manu factus”: made by hand2. Early mode: piece by piece by skilled artisan3. In 1750 - 1800: Industrial revolution  Early machine tool Concept of factory2.008 MIT, S. Kim 35History (cont)4. 1800’s Process specialization Division of labor Eli Whitney, etc., Interchangeable parts5. Early 1900: Optimization (Manufacturing systems) F.W. Taylor Economy of scale Cost reduction for high volume production Henry Ford’s Model T6. 1950’s: Numerical control (Information technology) Automation Lean manufacturing, JIT 6 sigma, ppm2.008 MIT, S. Kim B. Benhabib 36Post-Industrial-Revolution History of Manufacturing Technologies The Industrial Revolution (1770-1830): Introduction of steam power to replace waterpower and animal-muscle power.  Decline in yearly hours worked per person: From 3000 hours to 1500 hours in Europe and to 1600 hours in North America.  Increase in labor productivity. Increase in GDP per worker: 7 fold in U.S.A., 10 fold in Germany, and 20 fold in Japan.72.008 MIT, S. Kim B. Benhabib 37Automotive Manufacturing Industry The Ford Motor Co. has been the most studied and documented car manufacturing enterprise.  The 1909 Model T car was easy to operate and maintain.  By 1920, Ford was building half the cars in the world (more than 500K per year).2.008 MIT, S. Kim 38Automotive Manufacturing Industry (cont.)54,94746,85629,74510,5774,80025655N/AWorld1,9721,5692,1837851761431.6U.K.2,8322,05045S.


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