柔性产品平台设计理论及其应用
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摘要
大规模的定制模式以客户为核心,通过为客户提供个性化产品来满足顾客的不同要求,客户需求的变化对企业的经营生产起决定性作用。由于日趋激烈的全球化竞争和快速的技术发展,客户驱动的市场变得更加国际化、动态化,不确定性成为大规模定制生产模式下技术和商业环境的一种基本特征。科技水平的发展越来越快,导致预测市场的未来发展变化以及产品核心技术的发展的难度越来越大,对于产品更新换代的速度越来越快,企业的产品平台很难适应不同时代产品的要求,企业的外部环境不确定性越来越复杂。与此同时,由于产品功能-结构的复杂性不断提高,产品功能结构之间的相互影响,导致产品变型设计中出现了大量的零部件的重复设计,降低了设计效率,增加了制造成本以及企业生产过程的复杂性,企业的内部运营不确定性也不断增加。
本课题通过分析大规模定制模式下企业面临的越来越复杂的不确定性因素,将柔性产品开发战略和产品平台设计相结合,从产品平台的创新和变型两个方向进行产品平台的柔性设计,在保证产品平台通用性的基础上,提高产品平台适应多变市场的灵活性。本课题的研究内容分为四个部分的内容,柔性产品平台的市场分析与技术创新规划、柔性功能平台设计、柔性结构平台设计和带式输送机的柔性产品平台开发,具体研究内容如下:
(1)柔性产品平台的市场分析与创新规划:从现有相似产品的产品平台市场分析入手,通过分析市场和客户对产品功能、性能等方面的要求,以及产品技术发展的趋势;应用需求进化定律和功能进化定律确定产品的未来市场变化以及变化对产品功能产生的影响,从市场拉动的角度进行产品平台的市场定位;应用TRIZ的技术成熟度预测和技术进化路线从技术驱动的方向对产品平台的技术发展进行规划,确定出未来产品平台的技术发展方向。
(2)柔性功能平台的设计:根据产品平台市场定位和技术创新规划,应用公理设计的功能独立性公理对产品平台进行功能-技术分解;通过分析子功能之间的相互关联建立功能结构,根据功能结构中各个子功能之间的输入\输出关系,应用三流原则划分功能模块;根据客户需求和功能模块之间的关联确定产品平台的基本功能平台和柔性功能组合,在基本功能平台的基础上通过柔性功能组合来提高其功能定制的柔性,并添加或删除不同的功能模块,以满足不同市场对产品平台功能要求的变化。
(3)柔性结构平台设计:根据客户需求变化确定出产品平台在变型设计时的设计变量,建立设计变量的取值变化与客户需求变化之间的关联,通过设计参数矩阵并分析各个参数之间的影响程度,确定出具有共性的通用平台参数;应用优化设计方法对产品平台参数进行规划,以满足多样化客户需求为约束,提高产品平台设计变量共性为优化目标,确定出适应不同市场网格的平台参数的变量变化范围;在柔性产品功能平台的范围内,建立产品平台结构与设计参数的关联,为后续的变型设计选型提供标准参考。
(4)带式输送机柔性平台设计:带式输送机经历300多年的发展已经非常完善,技术相对比较稳定,其现有核心技术基本定型,市场对产品的要求变化主要是产品的应用工况不同而对产品性能有不同的要求,本课题从技术驱动的角度进行带式输送机的柔性平台规划,对带式输送机的关键技术进行技术预测并确定其产品平台技术的发展趋势;由于应用于煤矿等特殊使用环境,带式输送机设计约束因素很多,受地形结构、输送量和输送倾角影响而要进行产品的变型设计,使产品设计和生产都具有很大不确定性。但是每种新的变型大都是在某些已有机型上进行的变型设计,从功能-技术两个层次进行产品平台的柔性设计,提高带式输送机响应市场多变的能力。
The customer satisfication is the goal of compays’management and production and in mass customization mode companys have to provide individual product for the customer to content different personal requirments. So the customer needs are the crucial fators for a company’s success. Due to the drastic global competition and rapid technology development, market driven by customer becomes more international and dynamic and the uncertaincy is the basic character of both technical and commercial circumstance in mass customization. The speed of science and technology development becomes more and more quickly, so the difficulty of forecasting the future development about market and product core technology is improved, as well as the renewal speed of different generation product is faster than before. Accord to the new challenge in the mass customization, the product platforms of a company is hardly to keep up with the demand of tomorrow customer. In this condition, the uncertaincy which is related to the company outside circumstance is more complex. At the same time, the product function and structure are all complicated, there are lots of redesign which decreasing the design effcency, increasing the manufacture cost and process complexity during the variety design for the interaction between function and structure. So the uncertaincy which is related to the company inside management is more complex too.
Focus on the more complicated uncertaincy of company in the mass customization, this thesis combines the flexible product develop stratagem and product platform deisgn, carry out the flexibl platform design by the innovation and variety two dirctions. The flexible product platform design improves the ability of accommodating variable market on the basis of commoanlity of product platform. This thesis includes four part of contents, first is the market analysis and technology innovation plan of product platform, second is the flexible function platform design, third is the flexible structure platform design, and the last is the case study of belet conveyor whose flexible product platform is design by this method. The detailed contents are as following:
(1) Market analysis and technology innovation plan of product platform: Analizing the similar products’product platform, then generalizing the customer requirement about products’function and performance as well as the trend of the product platform’s technology. The needs and function evolution law are introduced to market orientation of product platform by forecasting the future market variety and their influences to the product platform functions. The technology maturity measuring and technology evolution routes of TRIZ are applied to identify the technical developing direction of future prdocut platform by the forcecastin of product paltform technology.
(2) Flexible function platform design: According to market orientation and technology innovation plan of the product platform, the baic function of product platform is decomposed into levels function and technology subsystem by the function independence axiom of axiomatic design. The function structure is constructed by interrelations of sub functions, and the function modules are partitioned according to three flow rule by analyzing the sub function’s input and output. The basic function platform and flexible function assembly are iedentified by the relations that the function modules realizing some cusotemr needs. The flexibility of customizing function is carried out by the combination of basic function platform and flexible function, and the flexible function platform is also adde or removed some different function modules to satisfy different market niches requirements.
(3) Flexible structure platform design: The design parameters of variety design are clustered according to the different customer needs and are related with change of customer needs. The design parameter matrix is applied to analzing the weight of every design paramenter and the common design parameters are identified as the current platform parameters. The platformn parameters is optimized to layout the parameter values. The optimizing goal is improving the commoality of variable product platform design parameters, the optimizing constraint is the satisifying different customer needs. The quantitative change range of platform parameter values contented to different market gridding are confirmed and then the relationship between platform parameters and product constructures are also built to help the disgner to make decision of selecting product platform during the variety design.
(4) Flexible product platform design of belt conveyor: Belt conveyor has about 300 years history and its technology is very mature, its customer needs are basicly stabile. The main differents requirmet of customer are the different working environments which demands some additional demands about belt conveyor properties. This thesis focus on the technology driven product platform of belt conveyor, forecasts the evolution of belt conveyor key technology and confirms the key technology of next generation belt conveyor. For the belt conveyor is subjected by its working condition such as landform, feeding ability and feeding obliquity which demands every blet conveyor must be redesign so the belt conveyor design has a lot uncertaincy during the development. All variety design of belt conveyor is modified by the old design, so the flexible product platform of belt conveyor is constructed to carry out the funtinal and technical flexibility which improve the belt conveyor’s ability of response to the variety of market.
本课题通过分析大规模定制模式下企业面临的越来越复杂的不确定性因素,将柔性产品开发战略和产品平台设计相结合,从产品平台的创新和变型两个方向进行产品平台的柔性设计,在保证产品平台通用性的基础上,提高产品平台适应多变市场的灵活性。本课题的研究内容分为四个部分的内容,柔性产品平台的市场分析与技术创新规划、柔性功能平台设计、柔性结构平台设计和带式输送机的柔性产品平台开发,具体研究内容如下:
(1)柔性产品平台的市场分析与创新规划:从现有相似产品的产品平台市场分析入手,通过分析市场和客户对产品功能、性能等方面的要求,以及产品技术发展的趋势;应用需求进化定律和功能进化定律确定产品的未来市场变化以及变化对产品功能产生的影响,从市场拉动的角度进行产品平台的市场定位;应用TRIZ的技术成熟度预测和技术进化路线从技术驱动的方向对产品平台的技术发展进行规划,确定出未来产品平台的技术发展方向。
(2)柔性功能平台的设计:根据产品平台市场定位和技术创新规划,应用公理设计的功能独立性公理对产品平台进行功能-技术分解;通过分析子功能之间的相互关联建立功能结构,根据功能结构中各个子功能之间的输入\输出关系,应用三流原则划分功能模块;根据客户需求和功能模块之间的关联确定产品平台的基本功能平台和柔性功能组合,在基本功能平台的基础上通过柔性功能组合来提高其功能定制的柔性,并添加或删除不同的功能模块,以满足不同市场对产品平台功能要求的变化。
(3)柔性结构平台设计:根据客户需求变化确定出产品平台在变型设计时的设计变量,建立设计变量的取值变化与客户需求变化之间的关联,通过设计参数矩阵并分析各个参数之间的影响程度,确定出具有共性的通用平台参数;应用优化设计方法对产品平台参数进行规划,以满足多样化客户需求为约束,提高产品平台设计变量共性为优化目标,确定出适应不同市场网格的平台参数的变量变化范围;在柔性产品功能平台的范围内,建立产品平台结构与设计参数的关联,为后续的变型设计选型提供标准参考。
(4)带式输送机柔性平台设计:带式输送机经历300多年的发展已经非常完善,技术相对比较稳定,其现有核心技术基本定型,市场对产品的要求变化主要是产品的应用工况不同而对产品性能有不同的要求,本课题从技术驱动的角度进行带式输送机的柔性平台规划,对带式输送机的关键技术进行技术预测并确定其产品平台技术的发展趋势;由于应用于煤矿等特殊使用环境,带式输送机设计约束因素很多,受地形结构、输送量和输送倾角影响而要进行产品的变型设计,使产品设计和生产都具有很大不确定性。但是每种新的变型大都是在某些已有机型上进行的变型设计,从功能-技术两个层次进行产品平台的柔性设计,提高带式输送机响应市场多变的能力。
The customer satisfication is the goal of compays’management and production and in mass customization mode companys have to provide individual product for the customer to content different personal requirments. So the customer needs are the crucial fators for a company’s success. Due to the drastic global competition and rapid technology development, market driven by customer becomes more international and dynamic and the uncertaincy is the basic character of both technical and commercial circumstance in mass customization. The speed of science and technology development becomes more and more quickly, so the difficulty of forecasting the future development about market and product core technology is improved, as well as the renewal speed of different generation product is faster than before. Accord to the new challenge in the mass customization, the product platforms of a company is hardly to keep up with the demand of tomorrow customer. In this condition, the uncertaincy which is related to the company outside circumstance is more complex. At the same time, the product function and structure are all complicated, there are lots of redesign which decreasing the design effcency, increasing the manufacture cost and process complexity during the variety design for the interaction between function and structure. So the uncertaincy which is related to the company inside management is more complex too.
Focus on the more complicated uncertaincy of company in the mass customization, this thesis combines the flexible product develop stratagem and product platform deisgn, carry out the flexibl platform design by the innovation and variety two dirctions. The flexible product platform design improves the ability of accommodating variable market on the basis of commoanlity of product platform. This thesis includes four part of contents, first is the market analysis and technology innovation plan of product platform, second is the flexible function platform design, third is the flexible structure platform design, and the last is the case study of belet conveyor whose flexible product platform is design by this method. The detailed contents are as following:
(1) Market analysis and technology innovation plan of product platform: Analizing the similar products’product platform, then generalizing the customer requirement about products’function and performance as well as the trend of the product platform’s technology. The needs and function evolution law are introduced to market orientation of product platform by forecasting the future market variety and their influences to the product platform functions. The technology maturity measuring and technology evolution routes of TRIZ are applied to identify the technical developing direction of future prdocut platform by the forcecastin of product paltform technology.
(2) Flexible function platform design: According to market orientation and technology innovation plan of the product platform, the baic function of product platform is decomposed into levels function and technology subsystem by the function independence axiom of axiomatic design. The function structure is constructed by interrelations of sub functions, and the function modules are partitioned according to three flow rule by analyzing the sub function’s input and output. The basic function platform and flexible function assembly are iedentified by the relations that the function modules realizing some cusotemr needs. The flexibility of customizing function is carried out by the combination of basic function platform and flexible function, and the flexible function platform is also adde or removed some different function modules to satisfy different market niches requirements.
(3) Flexible structure platform design: The design parameters of variety design are clustered according to the different customer needs and are related with change of customer needs. The design parameter matrix is applied to analzing the weight of every design paramenter and the common design parameters are identified as the current platform parameters. The platformn parameters is optimized to layout the parameter values. The optimizing goal is improving the commoality of variable product platform design parameters, the optimizing constraint is the satisifying different customer needs. The quantitative change range of platform parameter values contented to different market gridding are confirmed and then the relationship between platform parameters and product constructures are also built to help the disgner to make decision of selecting product platform during the variety design.
(4) Flexible product platform design of belt conveyor: Belt conveyor has about 300 years history and its technology is very mature, its customer needs are basicly stabile. The main differents requirmet of customer are the different working environments which demands some additional demands about belt conveyor properties. This thesis focus on the technology driven product platform of belt conveyor, forecasts the evolution of belt conveyor key technology and confirms the key technology of next generation belt conveyor. For the belt conveyor is subjected by its working condition such as landform, feeding ability and feeding obliquity which demands every blet conveyor must be redesign so the belt conveyor design has a lot uncertaincy during the development. All variety design of belt conveyor is modified by the old design, so the flexible product platform of belt conveyor is constructed to carry out the funtinal and technical flexibility which improve the belt conveyor’s ability of response to the variety of market.
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