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Document 2
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Procedia CIRP 00 (2019) 000–000
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Procedia CIRP 00 (2019) 000–000
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*Abstract
Corresponding author. Tel.: +33 3 87 37 54 30; E-mail address: paul.stief@ensam.eu
Abstract
Introduction of new gas turbine machines on market is a complex project that requires optimization of different performance parameters such as
Introduction of newmaintenance
power, efficiency, gas turbine plan, machines
producton market
cost andis life.
a complex project
The ability that requires
to control optimization
cost and impact onof different performance
performances parameters
and life strongly such as
decreases
power, efficiency, maintenance
from conceptual to detailed design phase. plan, product cost and life. The ability to control cost and impact on performances and life strongly decreases
Abstract
from conceptual
Actually, 80 % oftoproduct’s
detailed design
cost and phase.
performances are committed based on decisions made in conceptual design.
Actually,
This Paper % of product’s
80describes a cost and
systematic performances
procedure are committed
to estimate based on decisions made in conceptual design. design phase, comparing
InThis
today’s
Paperbusiness
describes environment,
a systematic the trend towards
procedure morethe
to estimate the
cost ofvariety
product multiple
cost of multiple anddesign
design
alternatives
customization
alternatives
during conceptual
is unbroken. Due to this
during conceptual development,
design the need of
phase, comparing
different
agile cross sections
and reconfigurable for gas
production turbine solutions.
systems emerged to cope with various products and product families. To design and optimize production
different cross sections for gas turbine solutions.
Examples of parametric costing tool for part family will be described, to show the approach that allows to estimate costs in conceptual design
systems
Examplesas of
well as to choose
parametric costing the optimal product
familymatches, product analysis methods are needed. Indeed, most of the known methods aim to
phase, when detailed design has tool for part
not been developed will
and be described,
lack to show
of information is the approach
a daily topic. that allows to estimate costs in conceptual design
analyze
phase, a product
when or one product family on the physical level. Different product families, however, may differ largely in terms of the number and
The idea is todetailed
be able design
to readhas not been
design developed
information and part
of each lack from
of information
an enhanced is across
dailysection
topic. and enter parametric costing tool to have a
nature
The of
idea components.
is to be able toThis
read fact impedes
design
preliminary cost estimation in conceptual phase. an
information efficient
of comparison
each part from and
an choice
enhanced of appropriate
cross section product
and family combinations
enter parametric costing toolfor to the
haveproduction
a
system. A new
preliminary
Doing that cost
for methodology
estimation
each inis conceptual
part or module proposed
present,tophase.
analyze
it will beexisting
possibleproducts in view
to estimate totalof their
cost of functional
the product. and physical architecture. The aim is to cluster
these
Doingproducts
that isfortoin
The scope newpart
each
create assembly
anorinternal
module oriented product
present,
database it will
where families
be whole
the forknow-how
possiblethetooptimization
estimate and ofcost
total
best existing
of theassembly
practices product.
are lines
stored. and
This the creation
database can be ofexamined
future reconfigurable
in early
The scopesystems.
assembly
program is to create
stages, toBased an on
reduce internal
Datum
time to database
Flow and
market where
Chain,avoid thepursuing
the whole know-how
physical structure that
solutions andthe
of best practices
products
would not be are stored.
is viable
analyzed. This database
Functional
or convenient, can be
subassemblies
in a sort examined
are twin
of digital inapproach.
early and
identified,
aprogram
Another stages,
functional toaspect
analysis
positive reduce time toand
is performed.
pursued market and avoid
Moreover,
presented, pursuing
aishybrid
the solutions
functional
positive impact andonthat wouldarchitecture
physical
engineering notproductivity,
be viable or convenient,
graph directlyinreflects
(HyFPAG)
that isa the
sortoutput
of
on digital twindepicts
which
program approach.
the
Another
similarity positive
developmentbetweencost.aspect
productpursued
families and bypresented,
providing is the positive
design impact
support to on
both,engineering
production productivity, that directly
system planners reflectsdesigners.
and product on program An illustrative
development
example cost.
of a nail-clipper is used to explain the proposed methodology. An industrial case study on two product families of steering columns of
thyssenkrupp Presta France
© 2019 The Authors. is then
Published bycarried
Elsevier outB.V.
to give a first industrial evaluation of the proposed approach.
© 2019
© 2019 The
The Authors.
Authors. Published
Publishedby by
by Elsevier B.V.
Elsevier B.V.
©Peer-review
2017 The Authors.
under
Peer-review under Published
responsibility
under responsibility
responsibility of ofElsevier
the
of the B.V.
scientific
scientific committee
the scientific committee of of the
the CIRP
CIRP Design
Design Conference
Conference 2019 2019.
Peer-review
Peer-review under responsibility of the committee
scientific committee of
of the
the CIRP
28th Design
CIRP Conference
Design Conference2019 2018.
Keywords: new product introduction, gas turbine, target cost, conceptual costing, parametric cost estimation
Keywords:Assembly;
Keywords: new product introduction,
Design method; gas turbine,
Family target cost, conceptual costing, parametric cost estimation
identification
1. Introduction and State of Art higher, up to 60 % [3]. Proceeding in design development, cost
1.1.Introduction
Introduction and State of Art higher,
of
of the up increases
to 60range
product
change % [3]. Proceeding
asand in [4].in design
characteristics
stated development,
manufactured cost
and/or
New Product Introduction is quite a complex procedure assembled of change
Should inincreases
cost as
thisatsystem. stated
conceptual in
In this [4].
context,
design is slowthe and
mainunreliable
challengedue in
whileNew
Due Product
to
dealing withIntroduction
the fast
gas turbine is quite in
development
product. a complex
the domain procedure of to aShould
modelling
lack of cost
and at conceptual
a analysis
specific is now
tool, design
andnotthisis slow
only to and
limits the unreliable
cope due
with single
evaluation of
while dealing
communication
A lot with
andgasanturbine
of performance ongoing
targetsproduct.
trendbe of
shall met,digitization
from powerand to a lackalternatives.
to products,
design aoflimited
a specific tool,range
product and or
Development thisexisting
limits the evaluation
product
and validation of ofa
families,
A lot offrom
digitalization,
efficiency, performance
manufacturing targets
manufacturability shall
enterprises beare met,
to maintenance. from
facing power
important
Each to but
single design
also toalternatives.
configurationbe able Development
to analyze
at conceptual and torequires
stage andmonths,
compare validation
products of thea
to define
limiting
efficiency,
challenges from manufacturability
in today’s
choice is a trade-off studymarket
between to maintenance.
environments:
different scenarios, Each
a continuing single
to select newconfiguration
product of
exploration at conceptual
families. stage requires months, limiting
It can be observed that classical existing
design alternatives. the
choice
tendency is a trade-off
optimizedtowards
solution study
reduction between
of product
for a specific different scenarios,
development
application. Cost astimes to select
well and exploration
can product
Timefamiliesof design
constraints alternatives.
are regrouped
prevent in functioncost
effective of clients or features.
optimization in
optimized
shortened
be considered solution
product for a specific
anlifecycles.
internal In
target application.
addition, there Cost
to match, an as
isand itswell
increasing can However,
related Time constraints
conceptual assembly
design orientedprevent
phase, effective
asproduct
stated costand
families
in [5] optimization
are hardly to find.
[6], since in
no
be
demandconsidered
businessofcase an internal
customization,
for a specificbeing target to match, and
at the same time in a global
NPI project. its related conceptual design
On the product
automation phase,
familyfor
is available as stated
level, in
costproducts [5] and [6], since
differ mainly checks.
versus performance in twono
business
competition casewith
As explained forin
acompetitors
specific NPIall
[1] and [2], project.
over80the
about % world.
of cost This trend,
is locked-in automation
main is available
Valuecharacteristics:
estimation for
(i) the
is used becost
to number versus performance
of components
a qualitative procedure checks.
andbased
(ii) the
on
which As explained
is inducing
at conceptual in [1]
design the and [2], about
development
stage, when 80
project % ofmacro
from
teams cost is to
freeze locked-in
themicro Value
cross type of estimation
components
intuition of an expertis (e.g.
used toonbeanalogies
a qualitative
ormechanical, procedure
electrical, based on
electronical).
of similar products, as
at conceptual
markets,
section the design
ofresults new stage, when
in machine
diminished evenlotproject
sizesteams
though freeze
dueknowledge
the to thegap
augmenting cross
is intuition
Classical
described of an expert
[7]. or onconsidering
bymethodologies
Niazi analogies mainly
of similar products,
single products as
section of the new machine even though the
product varieties (high-volume to low-volume production) [1]. knowledge gap is described by Niazi [7].
or solitary, already existing product families analyze the
To cope with this augmenting variety as well as to be able to product structure on a physical level (components level) which
identify
2212-8271 possible
© 2019 The optimization
Authors. Publishedpotentials in the existing
by Elsevier B.V. causes difficulties regarding an efficient definition and
2212-8271
Peer-review©under
production 2019responsibility
system,The it
Authors. Published
is important
of tobyhave
Elsevier
the scientific B.V.of the
a precise
committee knowledge comparison
CIRP Design Conference 2019 of different product families. Addressing this
Peer-review under responsibility of the scientific committee of the CIRP Design Conference 2019
2212-8271©©2017
2212-8271 2019The
The Authors.
Authors. Published
Published by Elsevier
by Elsevier B.V. B.V.
Peer-review
Peer-review under
under responsibility
responsibility of scientific
of the the scientific committee
committee of the of theCIRP
28th CIRP Design
Design Conference
Conference 2019.
2018.
10.1016/j.procir.2019.04.311
Irene Martinelli et al. / Procedia CIRP 84 (2019) 650–655 651
2 Author name / Procedia CIRP 00 (2019) 000–000
Ability to reduce cost decreases while cost accuracy Results on this specific case of study will be discussed and
increases with ongoing time in design process as described in extended to other items to complete the parametric cost
Figure 1. mapping of all the possible items. The aim is to be able to
evaluate at least all the scale and mix of scenarios already
produced in factory.
Nomenclature
3. Case Study
of disk. That means that the very first cost driver is the material Internal bore present yes=1/no=0 Groove int diameter [mm]
selected. Afterwards, for forged parts is it possible to find a Internal bore diameter [mm] Groove depth [mm]
very good correlation between part weight and item cost. Many
Number of tire rod [#] Number of blades [#]
curves have been defined, one for each material available in our
database selection, and entering the proper material curve, with Tie rod bore diameter [mm] Width of blades base [mm]
the expected part weight, it is possible to have a raw material Overstock material [mm] Depth of blades base [mm]
cost estimation.
Groove features yes=1/no=0 Grinding surface height [mm]
In figure 4, parametric costing curves are shown for three
different materials A, B and C. Parametric equations for two based operation are described
As shown by R2 values, some time is it possible to find a below: drilling and grinding.
good correlation, some other correlation is lower. For drilling and grinding phases we have the following
A lower correlation can have different root causes. inputs:
One of that is the presence of outlier points (due for example
to higher cost payed in case of urgency in procurement or lower Table 2. Drilling Phase Technological and Geometrical Inputs - © 2019
Baker Hughes, a GE company, LLC - All rights reserved.
cost payed in case of bundle buy volumes). In case an outlier
point is identified it will be removed from the data point group. Technological Input Description Unit
Another possible explanation is the presence of other tdrilling Drilling time [s]
important cost drivers not addressed yet. In that case a deep treversal Reversal time [s]
dive into cost model generation and definition is needed to
guarantee more accurate prediction. Only in case of real tload/unload Load/Unload time [s]
business urgency also costing curves with lower fitting can be Nreversal Number of reversal [#]
used, adding a proper contingency value to consider variability Nload/unload Number of load/unload [#]
of the prediction.
tsetup Set up time [s]
T Thickness [mm]
O Overstock [mm]
For the entire grinding time of the component, the equation effort is the positive impact on engineering productivity, that
is as follows: directly reflects on program development cost.
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