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An innovative cost modelling system to support lean product and process development

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Abstract

This paper presents a cost modelling system for lean product and process development to support proactive decision making and mistake elimination at the design stage. The foundations of the system are based upon three lean product and process development enablers, namely: Set-based concurrent engineering, knowledge-based engineering, and mistake proofing (Poka-yoke). The development commenced with an industrial field study of eleven leading European industries from the aerospace, automotive, telecommunication, medical and domestic appliance sectors. Based on the requirements of industrial collaborators, the developed system comprises six modules: value identification, manufacturing process/machines selection, material selection, geometric features specification, geometric features and manufacturability assessment, and manufacturing time and cost estimation. The work involved the development of a feature-based cost estimation method for the resistance spot welding process. The developed system was finally validated using an industrial case study. The developed system has the capability to provide estimates related to product cost and associated values concurrently, facilitate decision making, eliminate mistakes during the design stage, and incorporate ‘customer voice’ during a critical decision making stage.

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Authors and Affiliations

  1. Product and Service Innovation Centre, Manufacturing and Materials Department, Cranfield University, Cranfield, Bedford, MK43 0AL, UK

    Ahmad Wasim, Essam Shehab, Ahmed Al-Ashaab & Rahman Alam

  2. School of Architecture, Computing and Engineering, University of East London, London, UK

    Hassan Abdalla

  3. SITECH Sp. So. o., Polkowice, Poland

    Robert Sulowski

Authors
  1. Ahmad Wasim
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  2. Essam Shehab
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  3. Hassan Abdalla
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  4. Ahmed Al-Ashaab
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  5. Robert Sulowski
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  6. Rahman Alam
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Correspondence to Essam Shehab.

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Wasim, A., Shehab, E., Abdalla, H. et al. An innovative cost modelling system to support lean product and process development. Int J Adv Manuf Technol 65, 165–181 (2013). https://doi.org/10.1007/s00170-012-4158-4

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  • DOI: https://doi.org/10.1007/s00170-012-4158-4

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