Concurrent Engineering and Design for Manufacture of Electronics Products

356 Pages·1991·10.452 MB·English

by  Sammy G. Shina (auth.)

Concurrent
Engineering and
Design for
Manufacture of
Electronics Products
SAMMY G. SHINA
University of Lowell
InmiI VAN NOSTRAND REINHOLD
~ _____ New York
Copyright © 1991 by Van Nostrand Reinhold
Softcover reprint of the hardcover 1st edition 1991
Library of Congress Catalog Card Number 90-23616
ISBN-13: 978-1-4684-6520-4
All rights reserved. No part of this work covered by
the copyright hereon may be reproduced or used in any
form by any means-graphic, electronic, or
mechanical, including photocopying, recording, taping,
or information storage and retrieval systems-without
written permission of the publisher.
Van Nostrand Reinhold
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Thomas Nelson Australia
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16 15 14 13 12 11 10 9 8 7 6 5 4 3 2
Library of Congress Cataloging-in-Publication Data
Shina, Sammy G.
Concurrent engineering and design for manufacture of electronics
products / Sammy G. Shina.
p. cm.
Includes index.
ISBN-13: 978-1-4684-6520-4 e-ISBN-13: 978-1-4684-6518-1
DOl: 10.1007/978-1-4684-6518-1
1. Electronic industries. 2. Electronic apparatus and appliances-
- Design and construction. 3. Production engineering. I. Title.
TK7836.S48 1991
621.381-dc20 90-23616
CIP
TO
JACKIE, MIKE, GAIL, NANCY, AND JON
Preface
This book is intended to introduce and familiarize design, production, quality,
and process engineers, and their managers to the importance and recent
developments in concurrent engineering (CE) and design for manufacturing
(DFM) of new products.
CE and DFM are becoming an important element of global competitiveness
in terms of achieving high-quality and low-cost products. The new product
design and development life cycle has become the focus of many manufacturing
companies as a road map to shortening new product introduction cycles,
and to achieving a quick ramp-up of production volumes. Customer
expectations have increased in demanding high-quality, functional, and
user-friendly products. There is little time to waste in solving manufacturing
problems or in redesigning products for ease of manufacture, since product
life cycles have become very short because of technological breakthroughs
or competitive pressures.
Another important reason for the increased attention to DFM is that
global products have developed into very opposing roles: either they are
commodities, with very similar features, capabilities, and specifications; or
they are very focused on a market niche. In the first case, the manufacturers
are competing on cost and quality, and in the second they are in race for
time to market. DFM could be a very important competitive weapon in
either case, for lowering cost and increasing quality; and for increasing
production ramp-up to mature volumes.
Manufacturing companies have long gone past the traditional method of
"throwing new products across the wall to manufacturing." There are many
instances today of bringing manufacturing knowledge into the design cycle,
a concept that is called concurrent engineering. Concurrent engineering is
developed through manufacturing guidelines, manufacturability teams, and
having engineers rotate through manufacturing and design areas similar
to Japanese engineers.
There is a need to go beyond these first steps into a framework
approach to DFM, by integrating the information generated from world-class
manufacturing such as just-in-time (JIT), statistical process control (SPC),
and computer integrated manufacturing (CIM) back into the design cycle.
vii
viii PREFACE
Several tools and methods have become widely used for DFM, and will be
presented and discussed with case studies and exercises. These involve quality
function deployment (QFD) or customer-driven engineering for focusing the
product user's input into the design specifications of new products; rating
products for assembly (both manual and robotic) on the basis of part
geometry or assembly motions; setting the new product specification limits
to match the manufacturing process capability in terms of production average
and variability; the methods of robust design for reducing product and
process variability; estimating tools for low-cost fabrication of parts and
assemblies using sheet metal, plastic or printed circuit boards; and finally
the goals of achieving long product life through the techniques of reliability
engineering.
It has been well documented that the product design cycle is the opportune
time to realize the goals of low-cost, high-quality products. The design
engineers should use the tools of CE and DFM to make the right decisions
in terms of product, process, and material selection.
Acknowledgments
I wish to thank the people who were instrumental in encouraging and
nurturing me during the long period when the book was under development.
First and foremost was my family, who tolerated my mental absence during
the long periods of writing and editing, especially my wife Jackie and our
four children Michael, Gail, Nancy, and Jonathan. I would also like to thank
the contributing authors who made the job easier by writing one-third of
the chapters.
The principles of concurrent engineering discussed in this book were
learned, collected, and practiced through working seventeen years at Hewlett
Packard Company and three years at the faculty of the University of Lowell,
where working as a teacher, researcher, and consultant to different companies
increased my personal knowledge and experience in the field of concurrent
engineering.
Particular thanks goes to Dean Aldo Crugnola of the College of Engineering
at the University of Lowell and Mike Critser of Cahners Exposition Group
who, when asked their opinions at the start of the project, indicated their
confidence and faith in my ability to finish it. In addition, my thanks to
Mr. Steve Chapman of Van Nostrand Reinhold, who first approached me
about the book in Anaheim, California, in February 1990, and guided me
through the difficult first steps of the project; and to Dr. John McWane
of Hewlett Packard, who, as a personal friend and fellow author, was
instrumental in critiquing the original proposal of the project.
My special thanks go to the practitioners of concurrent engineering at major
electronics companies: Mr. Happy Holden of Hewlett Packard, Mr. Anthony
Martinez of IBM, and Mr. A. J. Overton of DEC, who reviewed some of
the early ideas for the project and gave very useful inputs. I am also deeply
grateful to two editors of VNR, Paul Sobel and Robert Marion, who were
very insistent on making sure that every detail was taken care of, and to
Elaine Seigal who helped edit the early rough drafts and instilled some
English language discipline.
Finally, thanks to the many attenders of my seminars on the DFM and
Quality Methods, including the many in-company presentations, who gave
me invaluable feedback on focusing the material and clarifying the case
ix
x ACKNOWLEDGMENTS
studies and presentation of the data through the different figures and
techniques.
ACKNOWLEDGMENT TO CONTRIBUTING AUTHORS
I wish to thank the co-authors who contributed five different chapters in
this book. The six authors and the chapters they penned are as follows.
Mr. Masood Baig, a development engineer with Hewlett Packard Company,
who wrote Chapter 9, "Geometric Dimensioning (GDM) and Tolerance
Analysis," and developed the case studies for that chapter.
Dr. Dave Cinquegrana, a former student and an application consultant
with ICAD, a supplier of CAD /knowledge-based design systems, who wrote
Chapter 13, "Knowledge-Based Design. " He developed the chapter diagrams
and the software shown in the chapter.
Mr. Bill Neill, a manufacturing specialist with Hewlett Packard Company,
who wrote Chapter 12, "Computer-Integrated Manufacturing (CIM); Impact
on Concurrent Engineering," and coordinated the different aspects, examples,
and roles of information technology in concurrent engineering.
Dr. Tim Rodgers, a development engineer with the Printed Circuit Division
of Hewlett Packard Company, who wrote Chapter 10, "Design for Printed
Circuit Manufacture," and collected the data and special case study for the
chapter.
Dr. John Moran and Stan Marsh ofGOAL/QPC, a nonprofit organization
helping companies to continuously improve their quality, productivity, and
competitiveness, who co-wrote Chapter 7, "Customer Driven Engineering,"
and developed the case study, charts, and figures from the data supplied.
Contents
Preface v
Acknowledgments vii
INTRODUCTION: DFM CONCEPTS 1
1.1 Why concurrent engineering? 4
1.2 Concurrent engineering as a competitive weapon 7
1.3 Using structure charts to describe the process of
concurrent engineering 8
1.4 Concurrent engineering strategy and expected benefits
to new product introduction 18
1.5 Concurrent engineering results in the introduction of a
new electronic product 19
1.6 Conclusion 22
Suggested reading 23
2 NEW PRODUCT DESIGN AND DEVELOPMENT
PROCESS 24
2.1 The overall product life cycle model 25
2.2 The role of technology in product development and
obsolescence 27
2.3 The total product development process 32
2.4 The design project phases: milestones and checkpoints 39
2.5 Project tracking and control 42
2.6 Conclusion 46
Suggested reading 47
3 PRINCIPLES OF DESIGN FOR MANUFACTURING 48
3.1 The axiomatic theory of design 49
3.2 The design guidelines 50
3.3 A DFM example: The IBM Pro printer 62
3.4 Setting and measuring the design process goals 65
3.5 Conclusion 66
References and suggested reading 67
xi
xii CONTENTS
4 PRODUCT SPECIFICATIONS AND MANUFACTURING
PROCESS TOLERANCES 68
4.1 The definition of tolerance limits and process capability 68
4.2 The relationship between manufacturing variability and
product specifications for new products 70
4.3 Manufacturing variability measurement and control 79
4.4 Setting the process capability index 98
4.5 Conclusion 100
Suggested reading 100
5 ORGANIZING, MANAGING, AND MEASURING
CONCURRENT ENGINEERING 103
5.1 Functional roles in concurrent engineering: Design,
manufacturing, marketing, quality, and sales 104
5.2 Design guidelines 107
5.3 Organizing for concurrent engineering 109
5.4 Measuring concurrent engineering 115
5.5 Conclusion 118
Suggested reading 118
6 ROBUST DESIGNS AND VARIABILITY REDUCTION 120
6.1 On-line and off-line quality engineering 120
6.2 Robust design techniques 122
6.3 Robust design tool set 128
6.4 Use of robust methods in engineering design projects 142
6.5 Conclusion 145
Suggested reading 145
7 CUSTOMER-DRIVEN ENGINEERING. QUALITY
FUNCTION DEPLOYMENT 147
7.1 Introduction 147
7.2 Quality function deployment 147
7.3 QFD and design systems 150
7.4 The four phases of QFD 151
7.5 Quality function deployment case study 156
7.6 Conclusion 184
7.7 Glossary of QFD terms 185
Suggested reading 186
8 THE MANUFACTURING PROCESS AND DESIGN
RATINGS 188
8.1 The manufacturing process for electronic products 189
8.2 Design ratings for manual assembly 194
CONTENTS xiii
8.3 Design for automation and robotics 196
8.4 Examples of design for manufacture efficiency 204
8.5 Conclusion 206
Suggested reading 206
9 GEOMETRIC DIMENSIONING AND TOLERANCE
ANALYSIS 208
9.1 GDT elements and definitions 209
9.2 Cylindrical tolerance zones 211
9.3 Datums 213
9.4 MMC, LMC, and RFS 216
9.5 Controls 217
9.6 Feature control frame 219
9.7 Tolerance analysis 220
9.8 Tolerance analysis case study 228
9.9 Conclusion 233
Suggested reading 234
10 DESIGN FOR MANUFACTURE OF PRINTED CIRCUIT
BOARDS 235
10.1 Printed circuit design 237
10.2 DFM program requirements 242
10.3 Performance measures 253
10.4 Overall process 254
10.5 Conclusion 255
Suggested reading 257
11 RELIABILITY ENHANCEMENT MEASURES FOR
DESIGN AND MANUFACTURING 258
11.1 Product reliability systems 259
11.2 Design tools and techniques for enhancing reliability 264
11.3 Product testing for enhancing reliability in design and
manufacturing 269
11.4 Defect tracking in the field 273
11.5 Summary 274
Suggested reading 275
12 TOOLS FOR DFM: THE ROLE OF INFORMATION
TECHNOLOGY IN DFM 276
12.1 Information technology's role in DFM 277
12.2 Information technology requirements for DFM 283
12.3 Planning the implementation of technology to support
DFM 296