Integrated Product and Process Development

Overall Perspective of IPPD Workshop

Integrated Product/Process Development (IPPD), along with the use of Integrated Product Teams (IPTs), are seen as key enablers for everything from acquisition reform to assuring a focus on affordability in Science and Technology (S&T) program management. IPPD is being implemented in the commercial sector as part of the ongoing Quality revolution to produce world-class competitive products. The Defense Manufacturing Council (DMC) has proposed "An Integrated Strategy for Cost Reduction" to provide Affordable and Supportable Defense Systems. IPPD is seen as a key for implementing this Strategy through providing Affordable Product and Process Technology and Lean Weapons Systems Development, Production and Support. IPPD was defined in 1993 in a National Center for Advanced Technologies (NCAT) industry white paper, prepared by the IPPD Working Group as "a management methodology that incorporates a systematic approach to the early integration and concurrent application of all the disciplines that play a part throughout a system's life cycle." A proposed advanced development IPPD process was also included in the NCAT white paper which provided entrance criteria and exit criteria for an advanced technology demonstration An IPPD management approach, consisting of an IPPD Team, IPPD Process (Methodology) and IPPD Tools.

Working with NCAT and industry, Georgia Tech, in its Aerospace Systems Design Laboratory (ASDL) and Systems Realization Laboratory (SRL), has developed a generic IPPD Methodology that is used for education, research and training. Faculty and researchers from these laboratories will be the Georgia Tech presenters at this Workshop. This IPPD Methodology consists of the integration of four key elements: Systems Engineering Methods and Tools, Quality Engineering Methods and Tools, a Top-Down Design Decision Support Process, and a Computer Integrated Environment. This IPPD Methodology provides the means for conducting parallel process/product (cost/performance) design trades at various levels (system, component, part). System Design for Affordability through IPPD is the current thrust at Georgia Tech, using this Methodology.

The Workshop is organized around this generic IPPD Methodology, using the sub-elements of the Top-Down Design Decision Support Process to illustrate how various methods and tools from Quality Engineering and Systems Engineering are utilized. The Seven Management and Planning Tools, in conjunction with Quality Function Deployment (QFD), are utilized to translate the established need (customer requirements) into a defined problem (design requirements). In addition, several exercises and case studies will be presented to highlight certain important aspects of IPPD. One of the most effective Quality Engineering methods is Robust Design Assessment and Optimization. Two different, but closely related approaches will be presented. One is based on Robust Design Simulation (RDS) where technology targets and upper and lower specification limits are determined using a combination of Design of Experiments (DOE), Response Surface Methodology (RSM) and Monte Carlo Simulation Techniques. The second will be based on a Six Sigma approach, where process variations are reduced and controlled. The presentation on the Six Sigma approach and an exercise using Six Sigma measures will be provided by an instructor from Texas Instruments, Inc.

While IPPD in general and the generic IPPD Methodology can be exercised by IPTs using manual methods there are considerable advantages for using automated tools. These advantages include cycle time reduction and distributed (across entities) design and development. Distributed design is considered essential in today's competitive and resource constrained environment. The rapid development of information-based technologies, along with virtual/rapid prototyping, are providing a better computer integrated environment for distributed design and development. Presentations on emerging techniques in these areas, along with the utilization of activity-based and process-based costing methods, will also be included.

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