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Session WS1-4: Robust embodiment design. How to design location
schemes and part to part interfaces in a robust manner - Robust Design
SIG
Chairs: Thomas J. Howard, Technical University of Denmark, Denmark, Tobias Eifler, Technical University
of Denmark, Denmark
When: Monday, 27/Jul/2015: 9:30am - 12:30pm
Where: Room 8 small
Abstract
Robust Design Methodology & Robust Design SIG
In spite of well-described product development processes and considerable effort for quality initiatives, many
companies still experience immense challenges to efficiently account for variation of manufacturing/
assembly processes, material properties, loading conditions, ambient use conditions and time related
changes such as creep and wear. Frequently, the result is a reduced efficiency of products/ processess due to
overly specified tolerances, slow ramp-up times, late design changes , high scrap rates and a varying product
quality.
Robust Design Methodology (RDM) provides methods and tools to be used at all stages of design, from the
first design sketch to embodiment design, final detailing and the specification of tolerances, enabling
engineers to design products, devices, and production equipment so that their performance and function is
insensitive to variation. Available approaches link different perspectives on variation (Design, Production,
Metrology) and consequently offer an enormous potential to smooth the way from design to production and
use in terms of accelerated time-to-market, reduced ramp-up costs, improved product quality as well as
customer satisfaction.
The Design Society’s Robust Design SIG provides opportunities for Design society members and nonmembers to network, to collaborate and to share ideas, experience and knowledge within the field of Robust
Design. The SIG offers an extremely important platform to identify actual as well as future challenges of
Robust Design for Industry and Academia.
Workshop abstract & format:
While a variety of well described development processes is available, it is the organisers' impression that
there is no well-accepted embodiment design approach how to systematically detail the layout, geometries,
materials, etc. of conceptual solutions. In spite of numerous design rules, principles and guidelines provided
by standard literature, a coherent process for an application in case of complex products and/or numerous
trade-off decisions seems to be still missing. At the same time, the embodiment design phase is essential to
achieve robustness of products and processes. Overconstraint design solutions, ambiguous interfaces
between components, unfavourable material combinations, etc. are largely susceptible to variation and
therefore frequently experience production/assembly issues, reduced performance, excessive and nonpredictable wear-rates, etc.
Based on own research as well as a summary of existing approaches (e. g. Design Clarity, location schemes,
etc.), the workshop raises the question of an Embodiment Design Process for Robustness. For this purposes,
the participants will be provided with an actual use case of a consumer product including design files,
drawings, samples, etc. which will be used to illustrate and evaluate the applicability/suitability of existing
approaches. In combination with presentations of robust design and embodiment design theory, guided
tutorials as well as structured discussions, the workshop will provide a hands-on experience and a platform
for ACADEMICS and PRACTITIONERS to discover the state of the art in robust design, to exchange
knowledge on experiences as well as solutions and to discuss challenges faced.
The format and content of the workshop will be designed to suit the organisational roles of the participants,
and their experience in the topic of Design Methodology and Robust Design. We will therefore request that
the participants fill out a short survey in advance.
Bio‐sketch of organisers:
Tobias Eifler – Tobias Eifler graduated from the Technische Universität Darmstadt with a PhD in 2014. As
postdoctoral researcher he is currently part of the Robust Design Group at Technical University of Denmark
(DTU) focusing on a coherent implementation of Robust Design Methodology across functional borders and
the ability to communicate and manage manufacturing variation across the whole supply chain.
Thomas Howard – Associate Professor Thomas J. Howard is the current head of the Robust Design Group at
DTU and the Chair of the Design Society’s Special Interest Group on Robust Design. He has publications and
PhD projects in the fields of Robust Design, Process Capability Analysis and Innovation & Product
Development. In 2014 he won the DTU Innovation prize and in 2005 a BMW European scientific award on
passion for innovation. Thomas J. Howard is keynote speaker at numerous events, frequent lecturer on the
European Innovation Academy, was Co‐Chair of the ICED11 conference and has formed two spin-out
businesses from DTU.