Computational simulation applied in choosing the best solution in a product development using design for manufacturing and assembly approach

Abstract

Highlights: The product development methodology aims to assist the planning and design of the product throughout its life cycle. Using selection criteria it is possible to choose a solution will be followed until the end of the development process and this process is known as optimization of product solutions. Design for Manufacturing and Assembly (DFMA) is an approach that allows selecting a product solution with better manufacturing and assembly performance. Computational modeling allows representing systems in virtual environment in order to reproduce its characteristics and to compare scenarios through simulation.
 Goal: The objective of this work was to apply the computer simulation to compare the productive performance, according to production times, productivity and resource utilization rate, of three solutions proposed for a raincoat for pets with thermal protection.
 Methodology: Initially, conceptual models representing the production systems for the three product solutions were generated. The systems were modeled in discrete event simulation software, enabling different scenarios testing, resulting in production performance indicators for each product solution.
 Results: The analysis of the performance indicators allow identifying that the third solution proposed for the product obtained the best productive performance in all proposed scenarios; therefore, it was chosen as the best solution for the product according to the DFMA approach.
 Limitations of the investigation: The application of the methodology indicated in this work was limited to the study of a single productive system of a specific product.
 Practical implications: This work presents a practical application of computer simulation tools applied to product development.
 Originality / Value: The original contribution of this work is the application of computational simulation of production systems in product development following the DFMA approach.

Design for mass customisation, design for manufacturing, and design for supply chain: A review of the literature

“…By comparing the results with the existing products, it was found that the new products designed using the DFM approach had an impressive performance in terms of reduced CO 2 emissions, improved resource efficiency, production assembly time and product complexity. However, like Pinheiro et al [44], this study fails to consider product family design and fails to include product production costs while considering sustainability.…”

“…Therefore, the author concludes that applying DFMA methodologies in the early phase of product design can reduce parts count so as to reduce the total costs. Pinheiro et al [44] take the pet warm raincoat production as an example and use the DFM as a framework to select the optimal production solution according to different scenarios using the discrete-event system simulation model. The simulation results show that the selected production solution has an outstanding performance in production time, resource utilisation, and production cost through computer simulation and considering the DFM approach.…”

“…Parts count reduction [41][42][43][44][45][46][47][48]50] Modular and standard product design [42, 48-50, 52, 53] Function and parts integration [41,42,50,51,53] HOU ET AL.…”

“…However, like Pinheiro et al. [44], this study fails to consider product family design and fails to include product production costs while considering sustainability.…”

DfMA for a Better Industrialised Building System

“…BIM's ability to model and create simulations is highly beneficial in decision making [64]. Modelling and simulation would enable designers and stakeholders to evaluate the methods used in construction activities by representing the actual construction and simulating the cause and effect of a system before the actual construction is undertaken [4,65]. This could lead to producing a digital twin for a project.…”