Kundanpassning är ett ökande problem för tillverkare och det gäller även för Zetterbergs därproblemet nu är att konstruera lastbilsprodukter som ska passa till alla kunder vars lastbils-fabrikat varierar. Syftet med studien var att utveckla CAD-modeller för en ljusanordning medbred kundanpassning, lågt komponentantal och mindre skador vid tillämpning.För att utföra arbetet användes teori inom DFM (Design For Manufacturing), regelverk ochde tillverkningsmetoder som fanns till godo hos företaget. Datainsamlingen bestod av inter-vjuer, litteraturstudier och observationer. Arbetet följde en generell produktutvecklingspro-cess som började med konceptgenerering. Valet av vinnande koncept för vidareutvecklingbestämdes med Pughs matris. Vidareutvecklingen utfördes i Solidworks där även FEM-ana-lyser och topologioptimerings-analyser utfördes i syfte att förbättra konstruktionerna utanatt förlora hållfasthet och vibrationskänslighet.Resultatet blev två CAD-ritade ljusanordningar vars vikt var lägre än den nuvarande anord-ningen. Distansen mellan skadepunkter och lastbilens ände ökade jämfört med originalet. Enav konstruktionerna hade färre komponenter än originalet. De resulterande ljusanordning-arna visade goda egenskaper, men det finns rum för korrigeringar, som delvis missades imån av tidsbrist. Vidare var de utförda FEM-analyser och topologioptimeringar förenklingarav verkligheten och därför är det svårt att bedöma om dessa adekvat representerar praktiskanvändbarhet utan verkliga tester. Det är därför av framtida intresse att tillverka ljusanord-ningarna i resultatet och testa prestandan i verkliga scenarion, men också för att identifieraeventuella tillverkning och monteringsproblem som omedvetet har negligerats. / Product-customization is a growing problem for manufacturers which is also true for Zetterbergs where the problem currently is to construct lorry products that fit the customers varying lorry-types. The purpose of the study is to develop CAD-models for a back light ordinance with broad customer adaptability, lower assembly component quantity and less damage occurrence during use of the product. To complete the task, design theory including DFM (Design For Manufacturing), manufacturing methods available at the company and regulatory limitations were researched. The data collection consisted of interviews, literature studies and observations. The work followed a general product development process that began with concept generation. Choosing the winning concepts for further development was done through Pugh’s decision matrix. Further development was conducted in SolidWorks where FEM analyses and topology optimizations also were conducted with the purpose of improving the constructions without losing strength and vibratory properties. The result of the study were two light ordinances with their respective construction drawings. The weight of the two ordinances were lower than the original. The distance between damage-points and the endpoint of the lorries both increased. One construction had lower component quantity than the original. Both constructions showed good characteristics. There is room for improvement however as some aspects may have been missed due to time restrictions. Furthermore, the FEM and topology analyses were simplifications of reality. It would be valuable to create real prototypes from the result and conduct tests in more realistic scenarios and simultaneously identify subconsciously neglected manufacturing and assembly issues.

With a more global market, manufacturing companies have to increase their focus on cost management to stay competitive. With new technologies available, new methods of evaluating concepts and ideas arise. Among these are simulation tools. Thus, the purpose of this study is to investigate how simulation tools can be integrated into the product development process to improve target costing. To achieve this purpose, a case study was conducted at a large manufacturing company, where a simulation tool was used. It was found that cost and manufacturing simulation tools can be used for target costing, negotiation with suppliers, as well as a helpful tool for design methods such as design for manufacturing and design to cost. Furthermore, cross-functional teams and good collaboration are a postulate for successful implementation and utilization of simulation tools in the product development process. The proposition is therefore that large manufacturing companies with advantage should implement cost and manufacturing simulation tools into their product development process to improve target costing. / Med en mer global marknad måste tillverkningsföretag öka sitt fokus på kostnadshantering för att förbli konkurrenskraftiga. Med ny teknik tillgänglig uppstår nya metoder för att utvärdera koncept och idéer. Bland dessa finns simuleringsverktyg. Syftet med denna studie är därför att undersöka hur simuleringsverktyg kan integreras i produktutvecklingsprocessen för att förbättra arbetet med målkostnader. För att uppnå detta syfte genomfördes en fallstudie på ett stort tillverkningsföretag där ett simuleringsverktyg användes. Det upptäcktes att kostnads- och tillverkningssimuleringsverktyg kan användas för målkostnadsberäkning, förhandlingar med leverantörer, samt att det kan vara ett användbart verktyg för designmetoder såsom design for manufacturing och design to cost. Vidare är tvärfunktionella team och gott samarbete en förutsättning för en framgångsrik implementering och användning av simuleringsverktyg i produktutvecklingsprocessen. Därför bör stora tillverkningsföretag med fördel implementera kostnads- och tillverkningssimuleringsverktyg i sin produktutvecklingsprocess för att förbättraarbetet med målkostnader.

With continuous and aggressive scaling in semiconductor technology, there is an increasing gap between design expectation and manufactured silicon data. Research on DFM (Design for manufacturability), MFD (Manufacturing for Design) and statistical analysis have been investigated in recent years to bridge design and manufacturing. Fundamentally, layout is the final output from the design side and the input to the manufacturing side. It is also the last chance to dramatically modify the design efficiently and economically. In this dissertation, I present the modeling and optimization work on bridging the gap between design expectation and reality, improving performance and enhancing manufacturing yield. I investigate several stages of semiconductor design development including manufacturing process, device, interconnect, and circuit level. In the manufacturing process stage, a novel inverse lithography technology (ILT) is proposed for sub-wavelength lithography resolution enhancement. New intuitive transformations enable the method to gradually converge to the optimal solution. A highly efficient method for gradient calculation is derived based on partially coherent optical models. Dose variation is considered within the ILO process with the min-max optimization method and the computation overhead on dose process variation could be omitted. The methods are implemented in state-of-the-art industrial 32nm lithography environment. After the work in the lithography process stage provides both mask optimization and post-layout silicon image simulation, my work on the first non-rectangular device modeling card extends the post-layout lithography to post-litho electrical calibration. Based on the lithography simulation results, the non-rectangular gate shapes are extracted and their effect is investigated by the proposed non-rectangular device modeling card and post-litho circuit simulation flow. This work is not only the first non-rectangular device modeling card but also compatible with industry standard device models and the parameter extraction flow. Interconnect plays a more critical role in the nanometer scale IC design especially because of its impact on delay. The scattering effect that occurs in nanoscale wires is modeled and different methods of wire sizing/shaping are discussed. Based on closed-form resistivity model for nanometer scale Cu interconnect, new interconnect delay model and wire sizing/shaping strategies are developed. Based on the advanced modeling of process, device and interconnect, circuit level investigation is focused on statistical timing analysis with a new latch delay model. For the first time, both combinational logic and clock distribution circuits are integrated together through statistical timing of latch outputs. This dissertation studies the new phenomena of nanometer scale IC design and manufacture. Starting from the designed layout, through modeling, optimization and simulation, the work moves ahead to the mask pattern and silicon image, calibrates electrical properties of devices as well as circuits. Through above process, we can better connect layout with silicon data to reach design and manufacturing closure. / text

A indústria aeronáutica mundial tem se desenvolvido de modo acelerado em termos tecnológicos e de processos de fabricação aplicados. Com isso, tem se buscado melhores soluções durante o desenvolvimento do projeto e fabricação de aeronaves, visando uma melhor qualidade final dos produtos, redução dos ciclos e custos de fabricação, repetibilidade do processo (padronização), problemas com formação e reposição de mão de obra, além da garantia da competitividade da empresa no mercado global. Uma forma para se inovar tecnologicamente e tornar o negócio mais moderno, atrativo e competitivo, é sempre que possível, automatizar a produção e tornar a montagem mais barata, com mais qualidade, inovadora e da forma mais flexível possível. Sendo assim, este trabalho visa o desenvolvimento de um modelo de análise de processo que utiliza os requisitos e conceitos do DFX e Produção Enxuta, voltado para aplicação específica no desenvolvimento de projetos aeronáuticos com foco em automação da produção. O objetivo da ferramenta é auxiliar os engenheiros que atuam no desenvolvimento de projetos de aeronaves, para que os benefícios da automação na produção possam ser alcançados com a utilização do modelo de análise proposto. O trabalho inicia-se com a apresentação do ambiente da indústria aeronáutica mundial, com foco nos processos e novidades tecnológicas aplicadas nos novos produtos. Em seguida são apresentados os princípios da metodologia DFX, a revisão teórica dos conceitos de Produção Enxuta e também aplicações de Automação nos diferentes setores da indústria. Na sequencia é apresentado o modelo de análise desenvolvido em forma de fluxogramas, elaborado com as regras e plano de ações a ser executado durante o desenvolvimento, visando a automação na produção. Dois estudos de caso são apresentados para demonstrar e validar o modelo desenvolvido. Por fim, os resultados são discutidos e a conclusão estabelecida. / Worldwide Aeronautical Industry has been developed faster and faster in terms of technology and its manufacturing processes applied. Thus, it has been planning to reach better results during the aircraft development and manufacturing phases, aiming to get products with high quality, to decrease cycles times and manufacturing costs, to provide a repeatability of processes (standardization), problems with learn ship and reposition of man power and also to assure the company competitiveness in the global market. One way to innovate technologically and to become the business more modern, attractive and competitive, as always as possible is to automate the production to make it cheaper, with a high quality, innovation and with the most flexible condition. Therefore, this thesis aims to develop a model of process analysis using the requirements and concepts of DFX and Lean Manufacturing for specific application on aeronautical projects development with a focus on production automation. The main goal of the guideline is to drive the engineers who work on aircraft development phases, about the automation benefits that can be achieved when using the proposed analytical model. This study starts with the presentation of worldwide aeronautical industry environment, focusing on processes and technologies innovation applied on new products. Next, is presented the principles of DFX methodology, a theoretical review and concepts of Lean Manufacturing and also applications of Automation on new products. Subsequently, it has shown the principles of DFX methodology, theoretical review of Lean Manufacturing concepts and also applications of Automation in different industry sectors. Following is presented the model of analysis developed in form of flowcharts, drawn up the rules and actions plan to be taken during development, aiming automation in production. Two case studies are presented to demonstrate and validate the model developed. Finally, the results are discussed and the conclusion drawn.

Um sistema composto por orientações de projeto e de processo, por um software CAD, mais especificamente, pelo PRO-ENGINEER (PRO-E) e um sistema de auxílio voltado para a manufatura (SEMF) foi desenvolvido como forma de auxílio ao engenheiro projetista no desenvolvimento do projeto de peças fundidas em areia. Este sistema integrado é capaz de analisar um desenho feito em sistema CAD (PRO-E), de um modelo de uma peça a ser fundida e fornecer um diagnóstico sobre possíveis violações quanto à sua manufatura. Isto é feito através de uma base de conhecimento que reúne informações de como minimizar possíveis defeitos com relação à geometria da peça a o processo de fundição. O desenho deve seguir um procedimento adequado para que as features criadas no PRO-E possam ser reconhecidas pelo sistema, para um possível diagnóstico de problemas existentes na geometria da peça e/ou no processo de fundição. / A computer system based on design and process guidelines and a CAD system has been developed in order to aid an engineer designer to develop cast parts free from defects. The proposed system can analyze and detect, automatically, problems that may happen during the casting process of a part. This is done through a built-in Knowledge Base that gather information on how to avoid defects related to part geometry and casting process. The parts must be designed using the CAD system, PRO-E, and the drawing of the part, must be done following a certain procedure, otherwise the system will not be able to check the part.

A indústria aeronáutica mundial tem se desenvolvido de modo acelerado em termos tecnológicos e de processos de fabricação aplicados. Com isso, tem se buscado melhores soluções durante o desenvolvimento do projeto e fabricação de aeronaves, visando uma melhor qualidade final dos produtos, redução dos ciclos e custos de fabricação, repetibilidade do processo (padronização), problemas com formação e reposição de mão de obra, além da garantia da competitividade da empresa no mercado global. Uma forma para se inovar tecnologicamente e tornar o negócio mais moderno, atrativo e competitivo, é sempre que possível, automatizar a produção e tornar a montagem mais barata, com mais qualidade, inovadora e da forma mais flexível possível. Sendo assim, este trabalho visa o desenvolvimento de um modelo de análise de processo que utiliza os requisitos e conceitos do DFX e Produção Enxuta, voltado para aplicação específica no desenvolvimento de projetos aeronáuticos com foco em automação da produção. O objetivo da ferramenta é auxiliar os engenheiros que atuam no desenvolvimento de projetos de aeronaves, para que os benefícios da automação na produção possam ser alcançados com a utilização do modelo de análise proposto. O trabalho inicia-se com a apresentação do ambiente da indústria aeronáutica mundial, com foco nos processos e novidades tecnológicas aplicadas nos novos produtos. Em seguida são apresentados os princípios da metodologia DFX, a revisão teórica dos conceitos de Produção Enxuta e também aplicações de Automação nos diferentes setores da indústria. Na sequencia é apresentado o modelo de análise desenvolvido em forma de fluxogramas, elaborado com as regras e plano de ações a ser executado durante o desenvolvimento, visando a automação na produção. Dois estudos de caso são apresentados para demonstrar e validar o modelo desenvolvido. Por fim, os resultados são discutidos e a conclusão estabelecida. / Worldwide Aeronautical Industry has been developed faster and faster in terms of technology and its manufacturing processes applied. Thus, it has been planning to reach better results during the aircraft development and manufacturing phases, aiming to get products with high quality, to decrease cycles times and manufacturing costs, to provide a repeatability of processes (standardization), problems with learn ship and reposition of man power and also to assure the company competitiveness in the global market. One way to innovate technologically and to become the business more modern, attractive and competitive, as always as possible is to automate the production to make it cheaper, with a high quality, innovation and with the most flexible condition. Therefore, this thesis aims to develop a model of process analysis using the requirements and concepts of DFX and Lean Manufacturing for specific application on aeronautical projects development with a focus on production automation. The main goal of the guideline is to drive the engineers who work on aircraft development phases, about the automation benefits that can be achieved when using the proposed analytical model. This study starts with the presentation of worldwide aeronautical industry environment, focusing on processes and technologies innovation applied on new products. Next, is presented the principles of DFX methodology, a theoretical review and concepts of Lean Manufacturing and also applications of Automation on new products. Subsequently, it has shown the principles of DFX methodology, theoretical review of Lean Manufacturing concepts and also applications of Automation in different industry sectors. Following is presented the model of analysis developed in form of flowcharts, drawn up the rules and actions plan to be taken during development, aiming automation in production. Two case studies are presented to demonstrate and validate the model developed. Finally, the results are discussed and the conclusion drawn.

After opening of China‟s borders to foreign trade and investment, over the last decades, a growing number of foreign company‟s attention has been drawn to China due to the immense market potential, and a huge source of cheap labor. Swedish industry, however, is not an exception from this tremendous trend in the world, as their recent acquisitions have given access to production facilities in China. This transfer of product/production from Sweden to China has emerged two major concerns including Design and Manufacturing (DM) interaction between geographically distant settings, in conjunction with inter-cultural considerations. Lately, the concept of interaction between DM has been growing in the scholar thoughts. Typically, different challenges such as different personalities and cultural differences exist towards having an enhanced collaboration during the development process. This study uses a framework for integration mechanisms which comprises number of approaches such as DfX, CE, cross-functional teams, and modern quality management. Second, this study by carrying out 6 interviews within the Chinese plants in four Swedish-Chinese based companies identifies the main challenges of interaction of design in Sweden and manufacturing in China (2 pilot companies and 2 target companies). The most frequent challenges are spotted as cultural clashes, ineffective collaboration, frustrating verification process, inadequate management system, and lack of technical knowledge. By including cultural attributes, a literature based classification is adopted to classify the determined challenges. Eventually, this study comes up with suggestions for managing challenges associated with geographical distance. More face-to-face interactions instead of electronic communications in order to have a better insight to the cultural differences (such as trust, lose face, and direct/indirect confrontation), cross-functional integrations, localizing the verification process, facilitating the early involvement of suppliers, rotation of the expertise across projects, use of DfA index, and function-wise motivation system, are stated in our recommendations to cope with these challenges. Besides, the influence of reward system on challenges of dispersed settings, is proposed to be investigated for further studies.

Um sistema composto por orientações de projeto e de processo, por um software CAD, mais especificamente, pelo PRO-ENGINEER (PRO-E) e um sistema de auxílio voltado para a manufatura (SEMF) foi desenvolvido como forma de auxílio ao engenheiro projetista no desenvolvimento do projeto de peças fundidas em areia. Este sistema integrado é capaz de analisar um desenho feito em sistema CAD (PRO-E), de um modelo de uma peça a ser fundida e fornecer um diagnóstico sobre possíveis violações quanto à sua manufatura. Isto é feito através de uma base de conhecimento que reúne informações de como minimizar possíveis defeitos com relação à geometria da peça a o processo de fundição. O desenho deve seguir um procedimento adequado para que as features criadas no PRO-E possam ser reconhecidas pelo sistema, para um possível diagnóstico de problemas existentes na geometria da peça e/ou no processo de fundição. / A computer system based on design and process guidelines and a CAD system has been developed in order to aid an engineer designer to develop cast parts free from defects. The proposed system can analyze and detect, automatically, problems that may happen during the casting process of a part. This is done through a built-in Knowledge Base that gather information on how to avoid defects related to part geometry and casting process. The parts must be designed using the CAD system, PRO-E, and the drawing of the part, must be done following a certain procedure, otherwise the system will not be able to check the part.

Computer aided design and manufacturing (CAD/CAM) has been a focal research area for the manufacturing industry. Genuine CAD/CAM integration is necessary to make products of higher quality with lower cost and shorter lead times. Although CAD and CAM have been extensively used in industry, effective CAD/CAM integration has not been implemented. The major obstacles of CAD/CAM integration are the representation of design and process knowledge and the adaptive ability of computer aided process planning (CAPP). This research is aimed to develop a feature-based CAD/CAM integration methodology. Artificial intelligent techniques such as neural networks, heuristic algorithms, genetic algorithms and fuzzy logics are used to tackle problems. The activities considered include: 1) Component design based on a number of standard feature classes with validity check. A feature classification for machining application is defined adopting ISO 10303-STEP AP224 from a multi-viewpoint of design and manufacture. 2) Search of interacting features and identification of features relationships. A heuristic algorithm has been proposed in order to resolve interacting features. The algorithm analyses the interacting entity between each feature pair, making the process simpler and more efficient. 3) Recognition of new features formed by interacting features. A novel neural network-based technique for feature recognition has been designed, which solves the problems of ambiguity and overlaps. 4) Production of a feature based model for the component. 5) Generation of a suitable process plan covering selection of machining operations, grouping of machining operations and process sequencing. A hybrid feature-based CAPP has been developed using neural network, genetic algorithm and fuzzy evaluating techniques.

‘Holistic Order’ is a new term used in this study. In literature, its synonyms such as beauty, order, visual order, and aesthetic order have been in usage for a long time. Historical studies on arts & crafts from philosophical and aesthetic perspectives reveal that the term ‘beauty’ no longer holds the same meaning as it used to for centuries. ‘Holistic Order’ is the new term being proposed in place of ‘beauty’ in product design. It is argued that this term is more appropriate in present day context. Beauty has been a study of interest to philosophers, aestheticians, poets, artists, scientists, and the common man alike for time immemorial. Though the field of industrial design has been in existence since the industrial revolution in the early 20th century, the roots of this field originates from the time of Plato and Aristotle, more than 2400 years ago. In spite of this long history, there has not been a reliable tool / framework available to product designers, which they can rely on in their pursuit to designing products that are holistic i.e. able to please not only to the physical senses but also to the emotional and mental faculties. Studies in the history of arts & crafts and fundamentals of aesthetics from a new perspective have revealed a perceptible gap in the most widely used design approach. This research work is an attempt to fulfil that gap. Using semiotic and communication theory, existence of dichotomy in product design has been established. Based on this and the widely used elements and principles approach in product design, a new integrated conceptual framework for holistic order in product design has been proposed. It is argued that this framework is more suited to designing holistically than any of the available ones. The objective of this framework is to enable better understanding of the different aspects involved in the aesthetics of product design, their relationships, and the resulting attainments. Knowledge of this framework is useful to designers for designing products in a holistic manner. In the process, more attractive, appealing, and meaningful designs are enabled. Also, it is useful to design critics for identifying factors that are responsible for aesthetic qualities and values in product design. All the interdependent nature of relationships among various parts of the framework of holistic order have been explained. ‘Holistic Order Index’ is proposed as a new measure of design qualities in product design. The Framework of Holistic Order and Holistic Order Index have been validated through qualitative and quantitative methods in two studies, one involving 30 designers and another involving 108 subjects representing the society at large. In another study involving 32 subjects, reliability of the methodology has been established. Results of these studies have been discussed in the thesis and the contributions summarized.