A decision support tool based on QFD and FMEA for the selection of manufacturing automation technologies

With the advent of the new challenge to design a more lean and responsive computer-integrated manufacturing system, firms have been striving to achieve a coherent interaction between technology, organisation, and people to meet this challenge. This paper describes an integrated approach developed for supporting management in addressing technology, organisation, and people at the earliest stages of manufacturing automation decision-making. The approach uses both the quality function deployment (QFD) technique and the failure mode and effects analysis (FMEA) technique. The principal concepts of both applications are merged together to form a decision tool; QFD in its ability to identify the most suitable manufacturing automation alternative and FMEA in its ability to identify the associated risk with that option to be addressed in the manufacturing system design and implementation phases. In addition, this paper presents the results of a practical evaluation conducted in industry.     

Axiomatic design principles in analysing the ergonomics design parameter of a virtual environment

One of the negative side effects experienced by users when interacting with virtual environment is visual symptoms. This paper explores the ergonomics design parameters of the virtual environment to minimize such negative side effect by applying axiomatic design principles. Axiomatic design is a method to provide a systematic way for designing products and large systems. The independence axiom is used to map customer domain (CAs) to functional domain (FRs) and physical domain (DPs). A paper based survey was conducted to identify and define customers' preference in the virtual environment. A virtual robot manufacturing system was developed as a case study to explore ergonomic design parameters that satisfy the independence of FRs and CAs. Results of this study shows that the ergonomic design parameters of virtual environment identified (DP₁₆₁-DP₁₆₂-DP₁₂₁-DP₁₁₁-DP₁₃₁-DP₁₄₁-DP₁₅₁-DP₁₅₂) have satisfied the independence functional requirement and desired visual comfort for users. By uncoupling the design it provides an efficient and effective sequence of design activities FR₁₆₁-FR₁₆₂-FR₁₂₁-FR₁₁₁-FR₁₃₁-FR₁₄₁-FR₁₅₁-FR₁₅₂.     

Participatory ergonomics in design processes: the role of boundary objects

The aim of this paper is to introduce the concept of boundary objects in order to better understand the role of objects in participatory ergonomics (PE) design processes. The research question is: What characterizes boundary objects in PE processes? Based on two case studies, we identify eight characteristics of boundary objects and their use, which make them particularly useful in PE design processes. These characteristics go beyond the object itself and extend into the context of their use. We argue that the selection of boundary objects in PE processes is of great importance, since different objects enable workers’ participation and collaborative design in different ways. The framework developed may serve to provide criteria to guide practitioners and intervention researchers in the selection of objects to facilitate a PE process. The paper concludes with a list of recommendations for ergonomic practitioners that are based on the framework.     

Work-related musculoskeletal complaints: some ergonomics challenges upon the start of a new century

Three themes likely to be important within health-related ergonomics in the coming years are discussed. The first two themes concern methods for risk analysis of low-level biomechanical and psychosocial exposures. The third theme is approaches to successful implementation of ergonomics interventions. Evidence on the assessment of low-level biomechanical and psychosocial exposures by instrumented measurements is discussed. It is concluded that, despite recent advances in our understanding of exposure-effect associations under these exposure conditions, we must at present rely on more subjective methods, employed in a collaboration between expert and worker. This approach to risk analysis identifies in most cases critical exposures in a work situation. The focus should then be on the successful implementation of measures against those exposures, as identification alone does not solve problems. The aim of improved health for the workers further requires that the full complement of risk factors be considered, including work, leisure time and person-based risk factors. Finally, the need to put ergonomics intervention initiatives in an organisational context is emphasised, and examples of approaches used by Norwegian companies are presented.     

Developing human factors/ergonomics as a design discipline

This paper deals with internal challenges that the human factors/ergonomics (HFE) research faces when wishing to strengthen its contribution to development of work systems. Three established characteristics of high-quality HFE, i.e., HFE takes a systems approach, HFE is design-driven, and HFE focuses on two closely related outcomes, performance and well-being, are taken as a starting point of a methodological discussion, in which conceptual innovations, e.g. adopting the technology-in-use perspective, are proposed to support development of HFE towards the high-quality aims. The feasibility of the proposed conceptual choices is demonstrated by introducing a naturalistic HFE analysis approach including four HFE functions. The gained experience of the use of this approach in a number of complex work domains allows the conclusion that becoming design-driven appears as that most difficult quality target for HFE to reach. Creating an own design discipline identity in a multi-voiced collaboration is the key internal challenge for human factors/ergonomics.     

Participatory decision-support model in the context of building structural design embedding BIM with QFD

The design and optimisation of building structures is a complex undertaking that requires the effective collaboration of various stakeholders and involves technical and non-technical expertise. The paper investigated an integrated decision-support framework using Quality Function Deployment (QFD) in structural design optimisation. The aim of the study was to develop and test a systematic participatory model that utilises Building Information Modelling (BIM)-enabled technologies for data collection and group decision-making theory. The uncertainties associated with the decision-makers’ preferences were computed using Evidential Reasoning (ER) algorithms in the QFD house of quality. An actual decision scenario was used to test the proposed framework and investigate its capabilities in the context of reinforced concrete buildings. The study demonstrated how the proposed QFD model could effectively enhance decision-making by managing the diversity of stakeholders’ preferences via design integration, enhanced communication and shared domain knowledge.     

A new hesitant fuzzy QFD approach: An application to computer workstation selection

Computer workstation selection is a multiple criteria decision making problem that is generally based on vague linguistic assessments, which represent human judgments and their hesitancy. In this paper, a new fuzzy quality function deployment (QFD) approach is used to effectively determine the design requirements (DRs) of a computer workstation. Hesitant fuzzy linguistic term sets (HFLTS) are innovatively employed to capture the hesitancy of the experts in this approach. More precisely, the proposed new QFD approach is the first study that determines the importance of customer requirements (CRs), the relations between CRs and DRs and the correlations among DRs via HFLTS. Additionally, HFLTS based Analytic Hierarchy Process (AHP) and Technique for Order Performance by Similarity to Ideal Solution (TOPSIS) methods are utilized in the computational steps to select the best computer workstation. A real industrial application is carried out to validate the implementation of the proposed approach.     

Design parameterization and tool integration for CAD-based mechanism optimization

This paper presents an open and integrated tool environment that enables engineers to effectively search, in a CAD solid model form, for a mechanism design with optimal kinematic and dynamic performance. In order to demonstrate the feasibility of such an environment, design parameterization that supports capturing design intents in product solid models must be available, and advanced modeling, simulation, and optimization technologies implemented in engineering software tools must be incorporated. In this paper, the design parameterization capabilities developed previously have been applied to support design optimization of engineering products, including a High Mobility Multi-purpose Wheeled Vehicle (HMMWV). In the proposed environment, Pro/ENGINEER and SolidWorks are supported for product model representation, DADS (Dynamic Analysis and Design System) is employed for dynamic simulation of mechanical systems including ground vehicles, and DOT (Design Optimization Tool) is included for a batch mode design optimization. In addition to the commercial tools, a number of software modules have been implemented to support the integration; e.g., interface modules for data retrieval, and model update modules for updating CAD and simulation models in accordance with design changes. Note that in this research, the overall finite difference method has been adopted to support design sensitivity analysis.     

Video analysis in cognitive ergonomics: a methodological perspective

The object of this paper is to discuss the methodological issues associated with using video analysis in the evaluation of Human-Computer Interaction. It is proposed that the mapping between low-level observed events and the high-level goals of the usability evaluation ultimately determines the success of this research technique. The paper firstly addresses the advantages of using video as a data-capture medium in the context of usability evaluations, and secondly, evaluates the use of alternative data capture devices. The process of conducting video analysis is then described. The methodological issues that arise in employing this technique are presented in a format consistent with the execution of any empirical investigation: research design, scoring, data analysis and interpretation of results. The reader is alerted to certain methodological problems associated with the use of video analysis as a means of data collection. The conclusion is drawn that video analysis provides a very powerful data source for the study of human performance in cognitive ergonomics and usability evaluations provided that human factors practitioners attend to the methodological requirements imposed by this technique.     

Design patterns for open tool integration

Design tool integration is a highly relevant area of software engineering that can greatly improve the efficiency of development processes. Design patterns have been widely recognized as important contributors to the success of software systems. This paper describes and compares two large-grain, architectural design patterns that solve specific design tool integration problems. Both patterns have been implemented and used in real-life engineering processes.     

A virtual studio environment for design integration

In this paper the authors attempt to stress the social dimension of design and the role of explicit support for human-level interaction during design systems integration. A human-centred approach is proposed by taking design integration as the collaborative use of design artefacts, and a virtual studio environment (VSE) framework is presented as an integration vehicle to link the social and technical dimensions. A VSE consists of two subsystems: the VSE base system and the domain resources. While common generic facilities for human–human interaction are embedded within the VSE base system, the domain-specific resources are loosely coupled into VSE via resource agents. A VSE prototype for the domain of building design is described, and a demonstration of the use of the VSE prototype is presented. This is then followed by some discussion on related research and further work. © 1998 Published by Elsevier Science Ltd. All rights reserved.     

Generative methods and the design process: A design tool for conceptual settlement planning

This paper implores the possible intervention of computers in the generative (concept) stage of settlement planning. The objective was to capture the complexity and character of naturally grown fishing settlements through simple rules and incorporate them in the process of design. A design tool was developed for this purpose. This design tool used a generative evolutionary design technique, which is based on multidisciplinary methods. Facets of designing addressed in this research are:

• •allocation of each design element's space and geometry,
• •defining the rules, constraints and relationships governing the elements of design,
• •the purposeful search for better alternative solutions,
• •quantitative evaluation of the solution based on spatial, comfort, complexity criterions to ensure the needed complexity, usability in the solutions.

Generative design methods such as geometric optimization, shape grammars and genetic algorithms have been combined for achieving the above purposes.The allocation of space has been achieved by geometric optimization techniques, which allocate spaces by proliferation of a simple shape unit. This research conducts an analysis of various naturally grown fishing settlements and identifies the features that would be essential to recreate such an environment. Features such as the essential elements, their relationships, hierarchy, and order in the settlement pattern, which resulted due to the occupational and cultural demands of the fisher folk, are analysed. The random but ordered growth of the settlement is captured as rules and relations. These rules propel and guide the whole process of design generation.These rules and certain constraints, restrictions control the random arrangement of the shape units. This research limits itself to conducting exhaustive search in the prescribed solution search space defined a priori by the rules and relationships. This search within a bounded space can be compared to the purposeful, constrained decision making process involved in designing.The generated solutions use the evolutionary concept of genetic algorithms to deduce solutions within the predefined design solution search space. Simple evolutionary concepts such as reproduction, crossover and mutation aid this search process. These concepts transform by swapping/interchanging the genetic properties (the constituent data/material making up the solution) of two generated solutions to produce alternate solutions. Thus the genetic algorithm finds a series of new solutions. With such a tool in hand various possibilities of design solutions could be analysed and compared. A thorough search of possible solutions ensures a deeper probe essential for a good design.The spatial quality, comfort quality of the solutions are compared and graded (fitness value) against the standard stipulations. These parameters look at the solution in the context of the whole and not as parts and most of these parameters could be improved only at the expense of another. The tool is able to produce multiple equally good solutions to the same problem, possibly with one candidate solution optimizing one parameter and another candidate optimizing a different one. The final choice of the suitable solution is made based on the user's preferences and objectives.The tool is tested for an existing fishing settlement. This was done to check for its credibility and to see if better alternatives evolved. The existing settlement is analysed based on the evaluation parameters used in the tool and compared with the generated solutions. The results of the tool has proved that simple rules when applied recursively within constraints would provide solutions that are unpredictable and also would resonate the qualities of the knowledge from which the rules were distilled from. The complex whole generated has often exhibited emergent properties and thus opens up new avenues of thinking.     

Use of formal ontologies as a foundation for inventive design studies

The paradigm change that rules our industry (currently evolving under the quality paradigm) requires an enterprise to organize innovation in a pragmatic way. Beyond theoretical discourses around the necessity for innovation, methods and tools, based on theories should now be translated into engineering practices to be efficiently applied. One of the consequences of this necessary evolution is that R&D departments (and especially project teams), familiar with methods and tools inherited from quality area, are pushed toward changes in their practices sometimes far from their respective cultures. Software tools for accompanying this evolution are needed. This article proposes the use of ontologies as a base to the development of those software tools. Formalization of the main concepts concerning inventive design is provided by the use of formal ontologies. The tools already developed assist the expert in the conduction of an inventive design study, from problem formulation to the proposal of solution concepts.     

MC Sandbox: Devising a tool for method-user-centered method configuration

Context

Method engineering approaches are often based on the assumption that method users are able to explicitly express their situational method requirements. Similar to systems requirements, method requirements are often vague and hard to explicate. In this paper we address the issue of involving method users early in method configuration. This is done through borrowing ideas from user-centered design and prototyping, and implementing them on the method engineering layer.

Objective

We design a computerized tool, MC Sandbox, to capture method requirements through the use of method-user-centered method configuration, hence bridging the gap between systems developers’ and method engineers’ understanding of and expectations on a situational method.

Method

The research method adopted can be characterized as multi-grounded action research. Our implementation of multi-grounded action research follows the traditional ‘canonical’ action research method, which has cycles of diagnosing, action planning, action taking, evaluating, and specifying learning. The research project comprised three such action research cycles where 10 action cases were performed.

Results

MC Sandbox has proven useful in eliciting and negotiating method requirements in a continuously ongoing dialog between the method users and the method engineers during configuration workshops. The results also show that the method engineer role rotated among the systems developers and that they were indeed committed to the negotiated methods during the systems development projects.

Conclusion

It is possible for method users to actively participate and construct suitable situational methods if they are provided with appropriate high-level modelling concepts, such as method components, configuration packages and configuration templates. This way, the project members’ understanding of the current development practice develops incrementally, both in terms of understanding the needs and available method support. In addition, both method requirements and commitments are made explicit, which are important aspects when working with method configuration from a collaboration point of view.     

Digital twins to enhance the integration of ergonomics in the workplace design

Recently, human-centered design has become one of the most promising approaches for improving the entire production process design. During the design phase, among the main important aspects to investigate, ergonomic performance of the workplace (WP) plays a key role. It is well known that design errors can lead to significant delays in the design and engineering of a production process, especially when it is related to a complex system such as the assembly line of an automotive industry. Prediction of the ergonomic performance, which is often coarsely considered during the design phase, can represent a fundamental step in preventing ergonomic issues since the early design phase of a production process, avoiding also negative consequences on line balancing. Based on a concurrent engineering (CE) approach, the aim of this paper is to present a framework that uses digital twins of stations in order to minimise the time necessary to develop and design a new assembly line. The application of this procedure will allow avoiding the possibility of realising a line that reveals ergonomic problems and correcting design errors during the design phase and not just during the production phase. In this way, it is possible to achieve great advantages in terms of cost avoidance for the correction of the design errors and in terms of time to market, which will be significantly reduced. A digital twin of a real station of a Fiat Chrysler Automobiles (FCA) assembly line is presented to validate the numerical procedure and the design approach proposed in this paper. Finally, numerical results, regarding the evaluation of an ergonomic index, were compared with experimental ones achieved by analysing data collected during an experimental session.     

Consilience for universal design: the emergence of a third culture

Consilience offers a powerful mechanism for borrowing from other disciplines, thereby extending the scope of what can be known. This paper looks at the foundations of the activity of design as a means of providing IT systems that cater for diverse needs. Developing systems that are expected to satisfy needs continuously (i.e., systems that are expected to evolve) calls for a dynamic activity of design that is responsive to changes in the environment. The contrast with the scientific assumption of ordered development invokes a new classification, supported by insights from other disciplines that place the range of approaches in context. Design is neither orderly nor linear; it implies a continuous and active search to resolve trade-offs and satisfy changing constraints. The paper concludes by making a case for design as an alternative culture that borrows from, and supports, both the scientific and the literary cultures. Acceptance of the role of practice as an interface alongside the more traditional cultures enables researchers and practitioners to access and adopt a larger variety of methods and general approaches underpinning an even larger corpus of insights. Consilience can occur at different levels and offer a variety of benefits. Balancing scientific enquiry with artistic flair and creativity through careful sensemaking that supports sharing across cultures provides the greatest benefit from learning to look across rather than blindly focusing inwards.     

Design as integration of axiomatic design and design structure matrix

Axiomatic design and design structure matrix (DSM) are two popular design methods at the moment, while most related researches only apply the basic ideas of axiomatic design or DSM to some use cases. This paper analyses the disadvantages of both axiomatic design and DSM. The axiomatic design method guides the designer finding suitable design parameters to meet the needs of function requirements. But axiomatic design cannot support the designer to know the interactions amongst the design parameters, including geometry, spatial layout, interfaces (e.g. logical and physical connectivity), which will decide the quality of the design. DSM has the advantages at recording and analysing the interaction relationship between existing product elements. However, at the conceptual design stage or for a new product that has never been designed before, it is difficult to make the DSM. After deep investigations, it has been found that there are strong complementarities between axiomatic design and DSM, and integration of both sides is advocated for better-quality design. The main outcome of this work is the formal interpretation of the integration logic between axiomatic design and DSM. Under such integration context, the conceptual design process can be seen as a recursive interaction of axiomatic design's design matrix (DM) and corresponding DSM. In this way, axiomatic design and DSM can benefit from each other. A computer-aided conceptual design system has been developed to realize the proposed integration model of axiomatic design and DSM.     

BCE: a tool for software integration

The integration of software into special-purpose systems (e.g. for gene sequence analysis) can be a difficult task. We describe a general-purpose software integration tool, the BCE program, that facilitates assembly of VAX-based software into application systems and provides an easy-to-use, intuitive user interface. We describe the use of BCE to integrate a heterogeneous collection of sequence analysis tools. Many BCE design features are generally applicable and can be implemented in other language or hardware environments.     

Design aids for designers: an effective role for ergonomics

The paper describes, with examples taken from the mining industry, the role of ergonomics in providing design aids for designers. The examples cover: (a) The provision of ergonomics design guidelines for families of machines; (b) The use of subjective assessment by expert panels to evaluate alternative solutions to development proposals; (c) The development of a computer-based simulation which produces multiple activity charts for the evaluation of the performance potential of new coal face designs. It is suggested that ergonomics specifically directed to the provision of design aids for designers may be one of the most fruitful approaches available to ensure a wider implementation of ergonomics knowledge and practice.