1 KIT – Universität des Landes Baden-Württemberg und nationales Forschungszentrum in der Helmholtz-Gemeinschaft www.kit.edu
IPEK – Institut für Produktentwicklung
IPROD Meeting University Novi Sad 25. – 28.11.2013 Teaching process models: „ Integrated Product Engineering Model – iPeM“ Prof. Dr. Ing. Albert Albers / OI Norbert Burkardt, Chief Engineer Education
2
Complexity of Product Engineering Processes
Andreas Braun – Integrated Modelling of Information to Support Product Engineering Processes
objectives and constraints
people processes and activitites
methods and procedure models resources
objects
3
Objects of product development are regularly models
Models in product development
Ident-Nr. 110030
θ1
θ7
θ6
θ4
θ2
θ11
θ9
θ10
θ8
θ5
θ3
θ12
θ13
θ14θ1
θ7
θ6
θ4
θ2
θ11
θ9
θ10
θ8
θ5
θ3
θ12
θ13
θ14
4
Example modeling: FEM-Simulation robot component
Ident-Nr. 110031
Illustration: Exact name of the component? Date/ version? Where assembled? Material? …
Reduction: Simplified geometry? Load conditions? Load application? Boundary condition? Material model? Tolerances? ...
Pragmatism: Purpose of simulation? Strength analysis? Weight reduction? ...
Modeling: Who built the model? When? Origin of the loads? Which preprocessor / Solver / postprocessor?
5
Effective working with models requests knowledge of: What does the model represent? (illustration) Which original characteristics does the model copy and which one not? What is the intention of the model? (pragmatism) How was the model developed? (modeling) Advantages: Common objectiveness / understanding Easy reutilization of knowledge
Compare Stachowiak: „Allgemeine Modelltheorie“,1973
Models
Ident-Nr. 110032
6
Models are necessary to reduce and concretize the complexity of reality
Decisive categories to evaluate reality are not truth and objectivity but consense, usability & practicability. Glasersfeld: Konstruktion der Wirklichkeit und des Begriffs der Objektivität, 1992, S. 30.
Importance of models
Ident-Nr. 110033
Explicit model Original Mental model
7
Models are necessary to reduce and concretize the complexity of reality
Decisive categories to evaluate reality are not truth and objectivity but consense, usability & practicability. von Glasersfeld: Konstruktion der Wirklichkeit und des Begriffs der Objektivität, 1992, S. 30.
Importance of models
Ident-Nr. 110034
Explicit model Original Mental model
Theory of cognition: 3-worlds-model of Popper
World 1 reality
World 2 subjectivity
World 3 objectivity cognition
8
General Model Theory: „All cognition in models or by models and any world encounter needs the medium ‘Model‘.“ Stachowiak: Allgemeine Modelltheorie, 1973, S. 56.
Modeling requires common models:
Models must be well-defined Modeling is ambiguous and partly undefined
The model of modeling is a metamodel e.g. language In a syntax – the grammar – is described how the elements – the vocabulary – have to be used.
Models in product development
Ident-Nr. 110035
9
Communication theory: Linguistically established intersubjectivity precedes any common object and target directed cognition. Habermas: Theorie des kommunikativen Handelns, Band II, 1988, S. 198-202.
Not understanding the system or model is as if blind persons argue about colors. Ropohl: Eine Systemtheorie der Technik, 1979. S. 85.
Requirements on product development: Intersubjective metamodels are needed for targets, operations and objects in product development!
Folgerung Intersubjektivität
Ident-Nr. 110037
10
Goal of product development: Transformation of a vague System of Objectives into a concrete System of Objects with the help of an Operation System
System-technological model of product development
System of Objectives
System of Objects
Operation System
11
The System of Objectives characterizes a quantity of targets and interactions between these targets. Objectives characterize aimed at (intended) target attributes of the object system. The character of objectives can be technical, economical, aesthetical, societal... The specification of the objectives is dynamically growing with the degree of realization of the object system.
System of Objectives
12
System of Objectives: Provision of bakery products that
taste good are healthy are cheap are always fresh are always tasty stay fresh for a long time …
System of Objectives example: bakery
13
The Operation System characterizes elements and their links, with which an system of objects is created, that accomplishes the specified system of objectives. Elements of the Operation System are man, organization, resources, processes, methods and tools.
Operation System
14
Operation System bakery staff ingredients recipes backing machines store, delivery service sales promotion / marketing purchase administration …
Operation System example: bakery
15
Operation System: Employees, engineers, workers R&D activites Design Methods Marketing Sales channels
Operation System other examples
16
The System of Objects represents the realization of the specified system of objectives. Between System of Objectives, Operation system and System of Objects strong interactions exist!
System of Objects
17
System of Objects Various bakery goods
System of Objects example: bakery
18
Mercedes A-class Development costs: approx. 1 billion Euro Overhaul costs after „Elchtest“: approx. 150 million Euro Industrial facilities: approx. 1,5 billion Euro Work places manufactoring: approx. 5000 High responsibility and risks! Development processes need to be planned, designed and supervised/controlled
Why are models of operating systems necessary?
Ident-Nr. 110027
19
Management: Planning and controlling Development: support, planning and design of product development processes Common language: uniform and comprehensive comprehensible description of elements and procedures in product development Intersubjectives understanding Transparency, transfer of knowledge out of past development processes in current or future
Motivation models for operating systems
Ident-Nr. 110028
20
There are two fundamental different views on product development processes!
2 fundamental approaches of PDP modeling
What is the fundamental challenge in developing processes?
Ident-Nr. 110039
Management
Planning Controlling
Developer
Support
PEP
21
What is the fundamental challenge in product development processes?
Ident-Nr. 110044
PDP
Structure Repetition, Rules, Automation, skill profile
Process work
Dynamic part Surprise, principle, person, decision, responsibility
Knowledge work
Management
Planning Controlling
Developer
Support
Both views are important for a good PDP. How can they be improved?
22
Process work
Application of knowledge Good to formalize Good to plan concerning resources and the result Precise approach defineable Performers intelligence only influences the result Demands exact rules
Allows synoptic planning
Process work vs. knowledge work
Ident-Nr. 110043
SOLL- Zustand
Synoptic planning
Planning
Implementation
prog
ress
Current state
Time
Knowledge work
Production of knowledge Limited to formalize Limited to plan concerning resources and the result Only targets defineable Performers intelligence essentially influences the „way“ to the result/process Demands clearance
Demands incremental planning
SOLL- Zustand
Incremental planning P
rogr
ess
Planning
Implementation Planning
Implementation Planning
Implementation
Current state
Time
23
Product development processes should be able to: manage the development project. support the developer within the development process. minimize the risks of product development processes. use experiences in context with learning processes.
and all this without reducing innovative performance.
Conclusion for iPeM
Ident-Nr. 110045
24
various aspects at different levels of abstraction various purposes; no integration has been realized yet integrated overview only „in the head“ of experienced designer/manager need to explicate implicit knowledge
Product Engineering Processes
Philosophies
Approaches Languages
Tools
State of the Art
Andreas Braun – Integrated Modelling of Information to Support Product Engineering Processes
Hubka and Eder Suh Andreasen Haberfellner …
Pahl and Beitz VDI guidlines MIL standards, DODAF …
IDEF BPMN SysML …
MS Visio DOORS artisan studio …
25
Background: Approaches to Process Modelling
Andreas Braun – Integrated Modelling of Information to Support Product Engineering Processes
Systems Engineering
socio-economy
industry
business
project
product
26
Background: Approaches to Process Modelling
Andreas Braun – Integrated Modelling of Information to Support Product Engineering Processes
Systems Engineering VDI guidelines
Anforderungsliste
Klären und Präzisieren der Aufgabenstellung 1
Arbeits-ergebnisse Phasen
Ermitteln von Funktionen und deren Strukturen 2
Suchen nach Lösungsprinzipien und deren Strukturen 3
Gliedern in realisierbare Module 4
Gestalten der maßgebenden Module 5
Gestalten des gesamten Produkts 6
Ausarbeiten der Ausführungs- und Nutzungsangaben 7 Ite
rativ
es V
or- u
nd R
ückw
ärts
sprin
gen
zu A
rbei
tssc
hritt
en
Erfü
llen
und
Anp
asse
n de
r Anf
orde
rung
en
Aufgabe
Weitere Realisierung
Aus
-ar
beite
n E
ntw
erfe
n K
onzi
pier
en
Auf
gabe
kl
ären
Funktions-strukturen
Prinzipielle Lösungen
Modulare Strukturen
Vorentwürfe
Gesamtentwurf
Produkt-dokumentation
27
Background: Approaches to Process Modelling
Andreas Braun – Integrated Modelling of Information to Support Product Engineering Processes
Problemanalyse
Problemformulierung
Systemsynthese
Systemanalyse
Beurteilung
Entscheidung
System-vorstudie
System-entwicklungen
System-herstellung
System-einführung
System-betrieb
System-wechsel
Lebensphasen des Systems
Systems Engineering VDI guidelines Problem Solving Cycles
28
Background: Approaches to Process Modelling
Andreas Braun – Integrated Modelling of Information to Support Product Engineering Processes
Stage
1
Stage
2
Stage
3
Stage
4
Stage
5
Stage
1
Stage
2
Stage
3
Stage
4
Stage
5 Produkt
Produkt
Produkt
Strategie,
Projektplan
Anforderungs-
ermittlung Entwicklung Test &
Prototypenbau
Produktion,
Markteinführung
Strategie,
Projektplan
Anforderungs-
ermittlung Entwicklung Test &
Prototypenbau
Produktion,
Markteinführung
Strategie,
Projektplan
Anforderungs-
ermittlung Entwicklung Test &
Prototypenbau
Produktion,
Markteinführung
Idee
Idee
Idee
Gate
2
Gate
3
Gate
4
Gate
5
Gate
5
Stage 1 Stage 2 Stage 3 Stage 4 Stage 5
Gate 2 Gate 3 Gate 4 Gate 1
1. Generation „Supplier to Costumer“
Stage-Gate-Ansatz der 2. Generation
Stage-Gate-Ansatz der 3. Generation
Gate
1
Systems Engineering VDI guidelines Problem Solving Cycles Project Management
note: multiple perspectives i.e. purposes and levels of abstraction • system life cycle • anthropocentric
problem solving
29
objectives
resources
objects
General, balanced structure to provide an overview on
interrelations
Integrated Product Engineering Model (iPeM) Requirements on Engineering Process Models
Maintain constant feedback and communication between designers and management Sequential process models cannot fulfil these requirements
Know-How, tools and methods to support designers in daily problem solving practice
activities
objectives
activities resources
objects
30
activities resources
objects
Activities of Problem Solving
Designers view > Methods and tools
Activities of Product
Engineering
Management view > Structure of active operations
objectives
Integrated Product Engineering Model (iPeM) Integrated view on Engineering Processes
31
Objec-tives Objects
Integrated Product Engineering Model (iPeM)
Operation System System
of Objects
System of
Objectives
Objectives Solutions S P A L T E N
Albers, A.; Braun, A.: A (2011) Generalized Framework to Compass and to Support Complex Product Engineering Processes. International Journal of Product Development, 15(1/2/3), Inderscience, Genèva Albers, A., Braun, A., Muschik, S., (2010), Uniqueness and the Multiple Fractal Character of Product Engineering Processes. 1st International Conference on Modelling and Management of Engineering Processes, Springer, London.
Andreas Braun – Integrated Modelling of Information to Support Product Engineering Processes
32
Objec-tives
Integrated Product Engineering Model (iPeM)
Objectives
Solution Selection L
Assessment & selection of solutions
Albers, A.; Braun, A.: A (2011) Generalized Framework to Compass and to Support Complex Product Engineering Processes. International Journal of Product Development, 15(1/2/3), Inderscience, Genèva Albers, A., Braun, A., Muschik, S., (2010), Uniqueness and the Multiple Fractal Character of Product Engineering Processes. 1st International Conference on Modelling and Management of Engineering Processes, Springer, London.
Andreas Braun – Integrated Modelling of Information to Support Product Engineering Processes
33
Integrated Product Engineering Model (iPeM) S
yste
m o
f Obj
ectiv
es
Sys
tem
of O
bjec
ts
Activities of Product Engineering
Project Planning and Controlling
Profile Detection
Idea Detection
Modelling of principle solution and embodiment
Validation
Production System Engineering
Production
Market Launch
Analysis of Utilization
Analyses of Decommission
Activities of Problem Solving S P A L T E N
Phase Model
Time
Today
Operation System
Albers, A.; Braun, A.: A (2011) Generalized Framework to Compass and to Support Complex Product Engineering Processes. International Journal of Product Development, 15(1/2/3), Inderscience, Genèva Albers, A., Braun, A., Muschik, S., (2010), Uniqueness and the Multiple Fractal Character of Product Engineering Processes. 1st International Conference on Modelling and Management of Engineering Processes, Springer, London.
note: systemic approach • structure • hierarchy • function integration of engineering and process work
Andreas Braun – Integrated Modelling of Information to Support Product Engineering Processes
Sys
tem
of R
esou
rces
34
holistic/comprehensive consideration (iPeM) shared mental model hierarchies, relations* semantic context objectives activities
of product engineering of problem solving
resources objects
* ordering relations (e.g. predecessors), flow relations (e.g. deliverables)
Summary
Andreas Braun – Integrated Modelling of Information to Support Product Engineering Processes
35
Résumé
Andreas Braun – Integrated Modelling of Information to Support Product Engineering Processes
Product engineering processes are complex. Integrated modelling of information can help establishing transparency in the system of product engineering. The iPeM makes it possible to explicate implicit knowledge in the respective overall context. Purposive views (reduction of total information) allow supporting product engineering processes.