Using Flexible Criteria to Improve Manufacturing Validation During Product Development

Abstract

In order to improve engineering product designs and reduce the number of problems that occur during a new product launch, firms have focused on integrating downstream product development processes into the design phases. Unfortunately, this resource inte gration to solve problems has been less common in the back-end of product development, particularly for complex products involving many components such as an automotive body. Here, manufacturing firms use sequential validation procedures first to approve compo nents, then subassemblies, and finally the end product. One trend has been to tighten component tolerances in efforts to avoid or mini mize downstream assembly problems. These stricter component requirements, however, often result in timing delays and cost overruns due to unnecessary rework of components. For complex-assemblies, the use of "flexible criteria" and an approach called "functional build" can significantly reduce validation time and costs yet still meet end product quality objectives. This paper examines this functional build approach to manufacturing validation and demonstrates its effectiveness with an automotive case example.