Design for manufacturing meets advanced process control: A survey

Nanometer IC designs are increasingly challenged to achieve manufacturing closure, i.e., being fabricated with high product yield due to feature miniaturizations and process variations. Realizing the critical importance of addressing manufacturability/yield during design (which is loosely termed as DFM, design for manufacturing), there has been a surge of research activities recently from both academia and industry under the “DFM” umbrella. While the primary goal of DFM is to enlarge the manufacturing process yield window, DFM needs to work together with advanced process control (APC) to meet such window, which may be shrinking and changing from design to design. The paper will survey the key DFM activities and discuss related advanced process control issues (i.e., the counterpart of manufacturing for design) to provide a holistic perspective on the design and process integration.     

A knowledge-based approach to design for manufacturability

In the light of growing global competition, organizations around the world today are constantly under pressure to produce high-quality products at an economical price. The integration of design and manufacturing activities into one common engineering effort has been recognized as a key strategy for survival and growth. Design for manufacturability (DFM) is an approach to design that fosters the simultaneous involvement of product design and process design. The implementation of the DFM approach requires the collaboration of both the design and manufacturing functions within an organization. Many reasons can be cited for the inability to implement the DFM approach effectively, including: lack of interdisciplinary expertise of designers; inflexibility in organizational structure, which hinders interaction between design and manufacturing functions; lack of manufacturing cost information at the design phase; and absence of integrated engineering effort intended to maximize functional and manufacturability objectives. The purpose of this research is to show how expert systems methodology could be used to provide manufacturability expertise during the design phase of a product. An object- and rule-based expert system has been developed that has the capability: (1) to make process selection decisions based on a set of design and production parameters to achieve cost-effective manufacture; and (2) to estimate manufacturing cost based on the identified processes. The expertise for primary process selection is developed for casting and forging processes. The specialized processes considered are die casting, investment casting, sand casting, precision forging, open die forging and conventional die forging. The processes considered for secondary process selection are end milling and drilling. The cost estimation expertise is developed for the die casting process, the milling and drilling operations, and the manual assembly operations. The results obtained from the application of the expert system suggest that the use of expert systems methodology is a feasible method for implementing the DFM approach.     

并行工程下基于特征的零件可制造性及其评价方法研究*

结合并行工程的思想,对零件可制造性进行较详细的分析,提出并行工程环境下基于特征的可制造性分析方法,研究建立基于特征的可制造性零件定义模型及评价体系。阐述了基于特征的可制造性的评价方法,认为可制造性评价是一个多层次的决策问题,建立了基于制造约束规则的加工可行性定性评价和基于模糊综合评判的加工可行性定量评价两种评价方法,并给出了解法。利用上述研究方法,全面合理地对零件的可制造性进行评价和反馈,从而指导产品设计。最后以涡轮叶片榫头特征的可制造性分析为应用实例,说明了该方法的有效性和实用性。     

Automating manufacturability evaluation in CAD systems through expert systems approaches

Design for Manufacturability (DFM) represents a new awareness of the importance of product design as an integral part of manufacturing activities. Good design guidelines exist in industry for frequently used manufacturing processes. These guidelines are systematic statements of good design practices, empirically derived over years of design and manufacturing experience. Ensuring that the given product design conforms to each of the guidelines specific to the selected process results in better manufacturability. To meet the objectives of the DFM approach, design and manufacturing planning activities have to be combined into a single engineering effort and applied througout the life cycle of a product. Computer-aided design (CAD) systems offer powerful features such as the ability to develop complex solid models and perform engineering analyses, including stress analysis, interobject interference, collision detection, and inertial analysis. However, a prominent limitation faced by designers in CAD systems is the lack of “intelligence.” Though designs could be developed, analyzed, and perfected from a functional viewpoint in CAD systems, manufacturability consideration may get little or no attention at all. As a result, product designs that are functionally sound may be developed at a high manufacturing cost. Thus, intelligence should be incorporated in CAD systems, whereby product designs could not only be developed and analyzed but also evaluated for cost and manufacturability. This study attempts to perform this task automatically in a CAD system using a knowledge-based approach: the manufacturability criteria are considered for milling and drilling operations performed on a computerized numerically controlled (CNC) milling machine. The results obtained from the application of the expert system suggest that the expert systems methodology is a feasible method for implementing manufacturability evaluation capability in CAD systems.     

A glance of technology efforts for design-for-manufacturing in nano-scale CMOS processes

This paper overviews design for manufacturing （DFM） for IC design in nano-CMOS technologies. Process/device issues relevant to the manufacturability of ICs in advanced CMOS technologies will be presented first before an exploration on process/device modeling for DFM is done. The discussion also covers a brief introduction of DFM-aware of design flow and EDA efforts to better handle the design-manufacturing interface in very large scale IC design environment.     

基于特征的压铸件结构工艺性评价系统

针对压铸件设计特点，提出一种基于特征造型和特征识别相结合的压铸件面向制造的设计系统框架．借助于UGII／UFUNC开发工具进行二次开发，具体构建了压铸件结构工艺性咨询评价系统．建立了产品可制造性评价知识库，并用框架与规则混合方式表达结构工艺性评价知识，及时提供设计修改反馈信息，指导设计人员在压铸工艺和制造资源的约束下进行压铸件合理设计．     

Object-oriented design for manufacture

Economically effective and timely product manufacture requires that appropriate decisions are taken during the design of the product. Recent years have seen very considerable growth in the study and communication of knowledge in the area of design for manufacture (DFM). At the same time there have appeared many additional pressures on the design process: rapid changes in market requirements, evolution and revolution in product and process technologies, legislated strictures and liabilities, and quality and cost issues which must increasingly be addressed earlier in the course of product design. As a consequence there is a strongly perceived need to enhance design methods in order to address the many disparate aspects of design in an efficient manner. In this paper the DFM problem is addressed within this larger context. The approach described in the paper begins with the hypothesis that the concept of manufacturability can be established as one of a number of required attributes of a part which is to be designed and manufactured. An information model is then proposed which provides the potential to allow determination of manufactur-ability to be made in an ongoing fashion in parallel with other design activities. The nature of the information model is shown to be in harmony with object-oriented programming environments. Finally, the information model is used to illustrate the potential to embody the large body of DFM knowledge which is already in existence but which has yet to be systematically encoded.     

Manufacturing evaluation using resource-based, template-free features

This paper addresses the theory and tools that promote rapid product and process development of machined products. A foundation of this approach is the application of a new definition of manufacturing features called resource-based free-form features. Using free-form features we demonstrate how cost, time and quality predictions, based on available equipment, are computed. We also introduce the concept of intelligently clustering alternative features to achieve better process alternatives. The approach presented herein is appropriate throughout the product design life-cycle as an aid to faster product realization by evaluating the parochial manufacturability of a completed design. In particular, this approach will provide the design team with cost, time and quality predictions, based on available equipment, that can be used to guide the design process. It also provides the manufacturing team with an approach to evaluating producibility and generating a production plan for a product model using available equipment in terms of cost, time and quality.     

Multiple platforms design and product family process planning for combined additive and subtractive manufacturing

Industry 4.0 promotes the utilization of new exponential technologies such as additive manufacturing in responding to different manufacturing challenges. Among these, the integration of additive and subtractive manufacturing technologies can play an important role and be a game changer in manufacturing products. In addition, using product platforms improves the efficiency and responsiveness of manufacturing systems and is considered an enabler of mass customization. In this paper, a model to design multiple platforms that can be customized using additive and subtractive manufacturing to manufacture a product family cost-effectively is proposed. The developed model is used to determine the optimal number of product platforms, each platform design (i.e. its features set), the assignment of each platform to various product variants, and the macro process plans for customizing the platforms while minimizing the overall product family manufacturing cost.The multiple additive/subtractive platforms and their process plans are determined by considering not only the commonality between the product variants but also their various manufacturing cost elements and the customer demand of each variant. The design of multiple product family platforms and their process plans is NP-hard problem. A genetic algorithm-based model is developed to reduce the computational complexity and find optimal or near optimal solution. Two case studies are used to illustrate the developed multiple platform model. The model results were compared with a single platform model in literature and the results demonstrate the multiple platform model superiority in manufacturing product families in lower cost. The use of the developed model enables manufacturing product families cost efficiently and allows manufacturers to manage diversity in products and market demands.     

Methodology for capturing and formalizing DFM Knowledge

Design for manufacturing (DFM) practices lead to more competitive products from the point of view of cost, development time and quality. However, the success of considering manufacturing issues during design process would be higher if manufacturing information was more readily available and designers needed less experience to select information relevant to DFM.     

Structural optimization with manufacturing considerations

Product design has traditionally been done in a sequential fashion. This often requires extensive iteration between product and manufacturing engineers to insure manufacturability long after the initial product design. Simultaneous engineering attempts to reduce design time by considering both the product and process from the earliest design stage. Toward this goal, we have extended a structural optimization program by incorporating manufacturability requirements for thin-wall beam type members formed by stamping. This was implemented using a new two-piece beam design element which accounts for thinning of the sidewalls during combined stretch and draw forming. Multiple material types and stamping processes are considered. Simple formulae for forming strain and elastic springback after stamping allow us to evaluate the formability of each beam member. The new capability was tested using both simple beam structures and a complete automotive frame structure. Minimum mass designs were then produced while considering both structural and formability requirements. In general, the mass of the optimal designs was near the mass of the same structures designed without manufacturing considerations. This was possible because of the additional design freedom offered by including the sidewall thinning effects.     

物理设计可制造性优化的研究

为了研究物理设计可制造性的优化途径,总结可制造性的基本问题,分析了目前工业界使用的可制造性技术的原理及其各自的优缺点。不同于目前业界通行的“工艺技术改进法”,这里认为可制造性首先是一个设计问题。基于此,讨论传统可制造性设计的不足,引入了基于“模型”的可制造性设计概念,对各种可制造性设计模型进行了详细分析,并给出了基于模型的设计流程优化。     

Conceptual process planning – an improvement approach using QFD,FMEA, and ABC methods

Conceptual process planning (CPP) is an important technique for assessing the manufacturability and estimating the cost of conceptual design in the early product design stage. This paper presents an approach to develop a quality/cost-based conceptual process planning (QCCPP). This approach aims to determine key process resources with estimation of manufacturing cost, taking into account the risk cost associated to the process plan. It can serve as a useful methodology to support the decision making during the initial planning stage of the product development cycle. Quality function deployment (QFD) method is used to select the process alternatives by incorporating a capability function for process elements called a composite process capability index (CCP). The quality characteristics and the process elements in QFD method have been taken as input to complete process failure mode and effects analysis (FMEA) table. To estimate manufacturing cost, the proposed approach deploys activity-based costing (ABC) method. Then, an extended technique of classical FMEA method is employed to estimate the cost of risks associated to the studied process plan, this technique is called cost-based FMEA. For each resource combination, the output data is gathered in a selection table that helps for detailed process planning in order to improve product quality/cost ratio. A case study is presented to illustrate this approach.     

An efficient approach to human motion modeling for the verification of human-centric product design and manufacturing in virtual environments

The efficient and reliable human-integrated design of products and processes is a major goal of the manufacturing industry. Thus, numerous human-related product functionality and manufacturability aspects need to be verified, using simulation, in the context of the product development procedures. The natural representation of human motions in virtual environments is crucial for the reliability of the simulation results. In this context, the paper presents an efficient approach to human motion analysis and modeling with respect to the anthropometric parameters, based on real motion data. Statistical methods employed for the analysis of the data and additive motion models are derived. The models are capable of predicting human motion and driving digital humans in product and worker simulation environments. A specific test case is presented to demonstrate the application of the suggested methodology on a real industrial problem.     

A decision-making framework model for design and manufacturing of mechanical transmission system development

Knowledge-based systems are proving to be a powerful tool with great potential for developing intelligent design support environments to improve quality of products and reduce product development costs by eliminating or minimizing many of the trial-and-error iterations involved in product development. This article describes an approach towards the development of intelligent design support environments for mechanical transmission systems, along with implementation details of a distributed knowledge-based gearing design and manufacturing system that is deployed over the Internet. The system embodies the various tasks of the design process, with modules that address: performance evaluation, process optimization, manufacturability analysis, and provides reasoning and decision-making capabilities for reducing the time between gear tooth creation, detailed design and final production. This methodology is highly desirable in that it is able to simulate real working conditions, evaluate and optimize the design effectively, prevent designers from time-consuming iterations and reduce long and expensive test phases.     

Domain independent shell for DfM and its application to sheet metal forming and injection molding

The objective for this research is to streamline design for manufacturing (DfM) analysis across all manufacturing domains and to provide transparency for DfM measures and evaluation process used. Generic steps are identified for performing manufacturability analysis and the design of a customizable manufacturability evaluation shell is presented. The shell covers several stages of manufacturability analysis (technical, economic) and can perform analyses at different levels of abstraction (qualitative, quantitative). The shell provides feedback to the designer at each level during the design process. By separating domain-specific knowledge from domain independent knowledge and creating an open architecture, the shell can be customized and expanded by the knowledge engineer and the user. The architecture of the shell is presented and its applications to manufacturability analysis for two domains, sheet metal and injection molding, are illustrated.     

A virtual prototyping approach to product disassembly reasoning

An important aspect of Design for the Life Cycle is assessing the disassemblability of products. After an artifact has completed its useful life, it must be disassembled then recycled, remanufactured or scrapped. Disassemblability of a product can be evaluated by performing disassembly activities on prototypes. Virtual prototyping (VP) is an alternative to hardware prototyping in which analysis of designs can be done without manufacturing physical samples. In recent years, disassembly processes have been generated either by using interactive or automated approaches, but these approaches have limitations. Interactive approaches require extensive user input usually in the form of answering questions, whereas automated approaches can only be used to generate disassembly processes for products with simple component configuration and geometry. In this paper automated and interactive techniques are combined, using VP, to generate complete disassembly processes of a product design. To support generation of disassembly processes of a product, a virtual environment and VP method were developed that will support disassembly activities performed by a designer. The product model of the virtual prototype is generated from the CAD model. The disassembly process model for the prototype is generated using automated reasoning techniques and is completed by interactively disassembling the product in the virtual environment. Extensions to automatic reasoning techniques to compute ranges of feasible directions of component removal were developed to facilitate the generation of the disassembly process. A scheme to represent the disassembly process for disassemblability evaluation was developed and implemented. In this paper a Chrysler LHS center console has been used to illustrate our approach of generating disassembly processes via VP.     

Simultaneous engineering for self-directed work teams implementation: A case study in the electronics industry

Simultaneous engineering is based on the interaction between different disciplines and parallel consideration of design with production. This is usually taken as embracing product design and the manufacturing process (for instance in design for manufacturability), or product, manufacturing process and maintenance strategies (in design for maintainability) etc. A simultaneous engineering approach can also be of great value, however, for work organisation change, and vice versa. This paper describes a case study where problems with the product design and manufacturing process meant that these were redesigned in parallel with the implementation of self-directed work teams. In fact, the involvement of the first pilot team in this redesign enabled them to gain much of the confidence, skills and knowledge they required to operate successfully, and early decisions on the form and management of the team structure were supported.

Relevance to industry

Team work is an increasingly common choice of manufacturing and other companies to organise their production and assembly activities. The case study in this paper illustrates lessons in implementation of self-directed work teams. Moreover, it is emphasised that such implementation can be a fundamental part of simultaneous engineering, and also that teams themselves can contribute to concurrent product and process development.     

面向制造基于特征的零件定义模型的研究及其应用

零件信息的描述是建立适用ＣＥ／ＤＦＭ设计系统必须解决的问题,用于ＤＦＭ的 同于常规的ＣＡＤ／ＣＡＰＰ系统的零件模型。