Product Realizations

Product Realization

 

“New product realization” is a term that includes the conceptualization, design, testing, production, deployment, and support INNOVATION  as well as major modifications or enhancements to existing products. “Product realization,” as defined by the TIME program, is the conversion of customer requirements into delivered products (Burleson 1999b). Currently, as practiced by the Army, this process is lengthy and sequential (Burleson 1999b; Osiecki 1999), resulting in extremely lengthy design-to-production cycles, often exceeding 10 years (McWilliams 1999).

For years manufacturers have dreamed of a computerized, integrated product realization process extending from initial concepts through mechanical design, process planning, costing, production, and beyond. This fully integrated process is beginning to become a reality in commercial industry. Examples include Boeing’s development of the 777 and Chrysler’s new Jeep Grand Cherokee, which entered production in 2001 and was completed entirely in a digital realm including design, engineering, and factory layout (Banks 1999).

Product Realization Vision

 


The TIME program plans to implement a product realization strategy based, in part, on that envisioned by the DoE Advanced Design and Production Technologies (ADAPT) Initiative. This integrated product and process development vision includes the following (ADAPT 1999):

  • A science-based design capability in which first-principle models and advanced-simulation capabilities form a foundation for the use of advanced tools to support design and optimization. Computer-aided design (CAD) functions are linked with model-based analysis and simulation capabilities to provide the advanced tools needed to understand and optimize product designs and, with computer-aided manufacturing (CAM), enable the production of hardware directly from CAD drawings. This permits the automated design and fabrication of  parts, tooling, fixtures, and gauges with a minimum of unit processing steps. 

Product Realization Approach

 


  • Model-based manufacturing approaches, from design validation through full integration and control of the factory floor, that provide the flexibility to respond to changes in product type and demand and to rapidly provide products with zero production defects.
  • Selection, validation, and deployment of the tools and technologies needed to support and use advanced computer-aided and automated design and manufacturing systems.
  • The ability to readily implement product and process improvements with a minimum of disruption.
  • Product qualification and acceptance capabilities that enable on-machine and in-process inspection to eliminate defects in final products.
  • Exploitation of the ongoing revolution in information, design, and manufacturing technologies to achieve product realization goals.

The TIME enterprise architecture (Raytheon 2000), described in Chapter 3, captures the vision of the product realization process for the entire enterprise. The architecture facilitates the use of emerging and existing tools to improve product and process integration and to provide a technically sound basis for timely development of robust products, their life-cycle management, and integration with other enterprise systems.

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TIME plans to procure commercial off-the-shelf (COTS) technologies, develop those that are not available, and validate and deploy them to create an information-driven, agile manufacturing base. Figure 4–1 illustrates the breadth of tools required to support the product realization process. Integration technologies will be used to facilitate the seamless operation and interaction of these tools to create a virtual distributed enterprise. TIME plans to accomplish many of its goals through a phased set of technology integration, validation, demonstration, and development activities that includes efforts to accomplish the following (Burleson 1999b):

  • Generate the initial product realization document with emphasis on mechanical piece parts;
  • Update the initial product realization document to include electrical piece parts;
  • Evaluate, procure, and integrate initial collaboration tools, including
  • The Web Integration Manager (WIM),
  • Work flow tools,
  • Product and process models,
  • Resource management, and
  • The design cockpit (see “Conceptual Design Cockpit” later in this chapter); and
  • Develop a product realization training program.

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