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This paper discusses the pilot applications of new quality methods and processes, which have appeared in the engineering literature in the last few years. The main impetus of this initiative is to ensure that focus is placed on value-added primary processes that have demonstrated high application potential. The methods discussed emanate from industry, professional societies and engineering institutions. These methods include AHP, PDQ, DFQ/E and probabilistic design, Analytical Hierarchy Process (AHP) deals with many complex and integrated design development strategic decisions and selections. Existing concept selection procedures (e.g. Pugh, Ardayfio) are approximate systems with reduced efficiency in complex systems.

A five level process for improved design for manufacturing and assembly has been in use in several vehicle programs. The method developed over a decade ago internally has proven to be very useful as a quality tool in automotive systems with over a dozen archival papers available in the knowledge base professional literature for reference.. Recent expansions of the process has led to the Proactive Design for Quality system in which the emphasis is placed on the timing and intensity of the integrated quality tools and processes to achieve the maximum benefits. This paper is a continuation of this extensive work in automotive development and focuses on the proactive utilization of computer simulation processes to support product creation and manufacturing. Computer simulation to support product creation can take several forms including dimensional tolerance simulation, impact analysis, design for manufacturing and design for assembly..

In this paper the emphasis is on the applications of DFMA in automotive electrical and electronic systems. This sector seems to have been neglected as a fertile area for DFMA applications. In these systems DFMA goes further into the optimization of processes for the manufacture, assembly and installation of electrical components and units. This paper provides a new approach to the DFMA process by demonstrating its applicability to electrical and electronic systems in the automotive industry. The case studies reported in this paper include the improvement of the assembly plant installation process and sequencing of the a. Airbag Electronic Control Module (AECM), b. Power Distribution Center with minimum impact on tooling schedule, c. Instrument Panel Wiring Harness and d. Electrical Distribution Wiring (EDW). The other case studies that focus on electromechanical systems include the e. Transmission System Selection Indicator ( PRNDL) and f. Overhead Console.

The design for manufacturability process has been recognized as a very effective method for improving the overall quality in mechanical product design. The first part of the paper deals with an extended DFM which encompasses all the various Quality issues in product development. The importance of the three major elements quality, cost and timing are highlighted in the mathematical model for Design for Quality (DFQ). The second part of the paper describes the application of DFQ in the design and development of minivan body and interior systems. The best value of the DFQ is recognized when the process is used proactively during the early stages of the development cycle. Such is the case of the applications discussed in this paper which covers the following systems: hood assembly, seamless door system, sliding door system, instrument panel and message center installation, and fuel filler door-and-housing system.

This paper deals with the applications of the Design for Manufacturing and Assembly (DFMA) process to the development of a new front suspension system in the PL Small Car Platform at Chrysler Corporation. At the very early stages of the program timing schedule, it was found necessary to introduce a structured DFMA program to bring together a cross-disciplinary team from within Chrysler as well as from the supplier companies. The major objective of this simultaneous engineering activity was to optimize all the design, manufacturing and assembly factors of the front suspension system. The Qualitative spreadsheet was created as one of the efficient tools in the DFMA program to perform the analysis and continuously track the DFMA issues. The specific examples in the paper demonstrate how the process optimizes the relationship between design, manufacturing and assembly factors in the development of a product.

This paper describes the application of the Design for Manufacture and Assembly (DFMA) method at Chrysler. Attention is focused on the development of the clutch and brake pedal and bracketry system of the PL project in the Small Car Platform. The Chrysler DFMA procedure including competitive evaluation and value engineering was utilized during the initial design phase involving product concept development from the original functional and manufacturing requirements. After the first laboratory tests, a number of key design and manufacturing concerns surfaced and led to a second cycle of DFMA analysis. The procedure permits major design functions and manufacturing and assembly process issues and criteria to be incorporated in the initial design stages.

This paper is concerned with the development of expert systems for mechanical design and manufacturing automation. The first section provides an overview of expert systems technology and its application in the various phases of manufacturing from design to final product. The second section deals with prototype expert systems in the engineering design domain for the selection of gear drive design factors and for the design of bearing supports in power transmission systems. The next section deals with three prototype expert systems in the diagnostics and troubleshooting domain. In automobile maintenance and repair, an expert human mechanic with several man-years of training and experience has to trace diverse causes of mechanical malfunctioning of vehicles. An expert system has been developed to assist a novice in this type of mechanical diagnosis. The other diagnostic expert systems deals with the maintenance and diagnostics of process pumps used in the chemical industries.