1、Confidential&Proprietary information of Ingersoll Rand.Do not print,save or distribute this slide or discuss its contents without prior executive approval.全球化背景下的新产品精益研发Operation Excellence of New Product Development in Global Environment2017-9-24Agenda 主题Global Environment of New Product Developmen

2、t新产品研发的全球背景Product and Lean Product Development of Ingersoll Rand英格索兰产品与新产品精益研发Knowledge Reuse and Modular Design知识的再利用与模块化设计Modeling and Simulation数值仿真与模拟Summary 总结加速推向市场的紧迫性加速推向市场的紧迫性93%项目经理感受到新产品加速推向市场的压力n=94 PMO OrganizationsSource:CEB 2015 PMO Peer Perspectives Poll新产品研发的全球背景新产品研发的全球背景法规要求法规要求客

3、户期望客户期望商业机会商业机会全球化特性：创新全球化特性：创新,变化变化,快速快速How do different leaders see the problem?新产品研发的全球背景新产品研发的全球背景项目管理者与商业领导对项目速度的不同视角项目管理者与商业领导对项目速度的不同视角商业领导需求:从商业建议到价值体现Measure of Speed=Fast(er);“Before Competitors;“time to market”项目团队实现Measure of Speed=On-Timeperformance英格索兰英格索兰公司公司 Ingersoll Rand A$14 billi

4、on diversified industrial company，140亿美金工业公司 About 100 manufacturing facilities worldwide100多个全球化生产基地 Strategic brands are#1 or#2 in their marketsNo1 或品牌战略和市场定位 Products and services for commercial,industrial and residential markets商用，家用和工业市场的产品和服务市场领导市场领导品牌品牌 Market-leading Brands#1 US#2 WorldwideC

5、ommercial HVAC Equipment#1 Worldwide golf cars#1 Worldwide transport refrigeration#1 North America air compressors,air toolsComfort and Climate Control BrandsIndustrial Brands新产品研发新产品研发流程流程 New Product Development ProcessConcept DevelopmentConceptValidationDesign&TestLaunchPreparationLaunch&SupportR

6、apid Learning Cycles概念设计Product Lifecycle Management Process概念验证设计与测试产品发布准备发布与支持新产品研发特性:持续的变化与沟通What the customer wanted.How the customer described it.How the product mgr understood it(PRD)How the engineers designed it(PDD)How manufacturing built it.When it was delivered.新产品研发流程新产品研发流程精益研发：项目范围管理精益研

7、发：项目范围管理产品经理的要求：多而且全MRD“wish-list”by PM requested 项目时间是受限制的Project schedule is constraint 项目经理的对策:只有在必需时才去寻找新的方案Solution:Go for new only when needed知识的再利用Knowledge re-use模块化设计Modular design项目范围管理:项目需求分析，需求匹配优势 Benefit 功能验证Function validation 性能测试和模拟Performance testing and simulation 部件的合格和可靠性 Parts

8、qualification and reliability知识的再知识的再利用利用 Knowledge Reuse知识的再利用知识的再利用Knowledge Reuse核心：知识的理解Knowledge Understanding 关键部件Key component 子系统Subsystem 系统集成System integration 生产工艺Manufacturing processair-cooledcondensercompressorevaporatorpropeller-typecondenser fans模块化设计模块化设计Modular design优势 Benefit 开发时

9、间Developing cycle time 工作量Work load 部件重用性Common parts 部件用量 Parts volume精益研发：风险控制精益研发：风险控制设计失效模式分析DFMEA(Design Failure Model Analysis)Characteristic or Part Characteristic or Part FunctionPotential Failure ModePotential Failure EffectsSEVPotential CausesOCCCurrent Design Evaluation or ControlDETWhat

10、is the Characteristic or Part under evaluation?What is the purpose of the characteristic or part?In what ways does this characteristic lose its functionality?What is the impact to the Customer(Internal or External)?How Severe is the effect to the cusotmer?What causes the loss of function?How often d

11、oes cause or FM occur?What are the tests,methods or techniques to discover the cause before design release?How well can you detect cause or FM?评估评估部件部件部件部件功能功能潜在潜在失效失效模式模式失效失效影响影响严重严重度度失效失效影响影响失效失效原因原因频率频率检测，检测，控制控制方法方法可检可检测性测性加速产品研发机会加速产品研发机会 Accelerate Product Development产品测试验证是关键路径 Product Testin

12、g/Verification is critical path技术探索测试概念验证详细设计验证50%time实际产品测试Physical Testing周期长 Long cycle time成本高 High cost 难以协作 Difficult to collaborate部件模拟(3D)Component Simulation数值仿真与数值仿真与模拟模拟 Modeling and Simulation缩短开发时间 Reduce Cycle Time提高产品性能和可靠性 Improve Product Performance and Reliability积累组织过程资产 Accumulat

13、e Organizational Assets系统仿真(1D)System Modeling仿真应用仿真应用 Simulation Application 概念设计 Concept Design 方案选择 Concept selection 风险评估 Risk assessment 详细设计 Detailed Design 性能、结构验证 Performance and Structure verification 控制系统设计 Control system design 产品应用 Product Application 产品选型 Product selection 控制与优化 Control

14、 and optimization设计测试通过？设计仿真通过？测试否否PHASE 1 CONCEPT DEVLOPMENT PHASE 2 CONCEPTVALIDATIONPHASE 5 LAUNCH SUPPORT PHASE 3 DESIGN&TESTPHASE 4 LAUNCHPREPGate1Gate2Gate3Gate4Gate0DFMEA,DVP&RFEA&Test PlanFEA Driven DesignConcept Unit S&V TestDesign Verification with FEA and TestELC test supportFEA project l

15、eader and NPD Project Lead to sit together to review and update the DFMEA,DVP&R in terms of structural integrity and Acoustics as necessarySME in Mechanics and Acoustics to help FEA project leader develop the FEA&Test Plan(scope,priority,engineer,schedule)Designer to provide the CAD model of the con

16、cept design to FEA engineer including the component level model and the unit level model FEA engineer to perform the structural analyses according to the FEA/test plan and communicate to team where designs are deficient,explain why,provide guidance and innovative ideas on how to resolve issues.Test

17、engineer to perform the S&V test on the concept unit,risk assessment for the sound requirement and come up with the potential solution plan.FEA project leader or subtask leader to manage the FEA/test efforts and update the task status(scope,priority and schedule).SME in Mechanics and Acoustics to gu

18、ide FEA/test engineer,review results as needed.Designer to implement the design changes as proposed by FEA in phase 2 and provide the CAD model of other tonnage units to FEA engineer.FEA engineer to verify the structural integrity of the remaining layouts through FEA analyses and shaker table testTe

19、st engineer to perform the S&V test on the verification unit,verify the effect of sound treatment,and conclude the sound level catalog for the product family.FEA project leader or subtask leader to manage the FEA/test efforts and update task status as appropriate.SME in Mechanics and Acoustics to gu

20、ide FEA/test engineer,review results as needed.Test engineer to help product team develop the ELC test plan as necessaryFEA驱动产品开发驱动产品开发 FEA in Product Development仿真案例仿真案例 Simulation Cases虚拟管路振动分析 Line Qualification 在样品制造前优化管路振动 Vibration Control仿真案例仿真案例 Simulation Cases风机盘管产品差异化 Fan Coil Product Dif

21、ferentiation 超薄设计 Compact design 风量提升5%Airflow increase 5%噪音降低 24 分贝 Noise reduction 2-4 dB仿真案例仿真案例 Simulation Cases截止阀热循环模拟 Thermal Cycle Simulation of Check Valve 基于有限元分析 FEA Analysis 减少了900小时测试时间 Reduced 900 Hours Testing总结 Summary 新产品研发聚焦于商业价值实现 Business Value Realization 研发特性：持续的变化与沟通 Change&Communication 精益研发方法、工具 LPD Approaches&Tools 知识的再利用 Knowledge Reuse 模块化设计 Modular design 设计失效模式分析DFMEA(Design Failure Model Analysis)数值仿真与模拟 Modeling and Simulation 谢谢！Thank You!