Robust Engineering System - RES I RD8

RD8 RES: Robust Engineering System

Stop relying on designers' gut feelings...

A data driven approach is more appealing

Robust Design

We know what good looks like! Upgrade your product development with RD8 Robust Engineering System

The RD8 Robust Engineering System is a 360 add-on to your product design approach to increase engineering productivity by +25%.

Engineering Productivity

We believe in more than +25% engineering productivity by the implementation of the Robust Engineering System

By Robust Design

Best-in-Class Ambitions

RD8 robust design services enhance innovation, product reliability, and organizational productivity - supporting product professionals and production with systems to achieve being best-in-class ambitions.

Sustainability

Product Innovation

What is R&D? New and smarter solutions! Embedding of new technologies & sustainable solutions.

Repeatability

Product Reliability

High quality of products, again and again. No customer complaints, no recalls.

Predictability

Professional Product Development

Streamlined development flow; no surprises, project on budgets, data-driven decisions, meeting launch dates, cost-optimized solutions, aligned with assembly & operations

RES

Robust Engineering System

RD8 RES supports being best-in-class when working with professional product development and enables R&D organizations to work smarter.

GREENER. SIMPLER. FASTER. SMARTER.
The RD8 way of working aims to develop and produce physical products in a greener, simpler, faster, and smarter way. 

Sustainability

GREENER

Example:

Complexity reduction

SIMPLER

Example:

Engineering Productivity

FASTER

Example:

Product Performance

SMARTER

Example:

Change of components from virgin to recycled materials
Cost reduction on component prices
Reduced development timeline
Improved sealing force between components

HOW TO ACHIEVE RESULTS?

To enable organizations to realize the benefits of robust design, we introduce the RD8 Robust Engineering System [RES]. A resolution to link robust design tools, processes, governance, and people together to enhance the robust way of working. It is an R&D upgrade.

RES

A scalable engineering toolbox: RD8 RUN Tools.

Methods and processes to guide designers and teams in the development of new products – See the RD8 Framework Portal.

Management and transparency – Objective metrics for project development tracking and portfolio tracking (product performance in production, sourcing, and the market).

Competence – Development of teams, individuals, and leaders.

RD8 RES results in sustainable solutions; by changing the way designers design products and components and how they are sourced, manufactured, and put together!

Sustainability

GREENER

Design for green components, manufacturing, use and disposal

Complexity reduction

SIMPLER

Simpler part drawings - fewer tolerances and less strict tolerances.

Engineering Productivity

FASTER

A systematic and data driven approach to product developments guided by unique robust design metrics and processes.

Product Performance

SMARTER

Updated product architecture and system design to yield performance of primary functions

Robust Design

Quantification of a Mechanical Interface example

Before and after example of two parts (grey and green) are shown in a section cut to illustrate some mating features in the interfaces.

Move the slider to see the before (sensitive design) and after (robust design) example.

The interface score for the first interface is 4 – meaning 4 additional and unnecessary geometry features that add complexity to the product. A score of 0 is ideal – the interface is in equilibrium – and has exactly the amount of information/constraints that it needs.

RD8 Index

Data Driven Product Development

Unique Metrics for Robustness. RD8 offers a unique metric to score the mechanical design of a product (the robustness of the design).

RD8 Index illustration. An index close to 0 equals ideal robustness. Index +40 equals a complex and sensitive design.

The metrics are leading indicators (not lagging/retrospective) and used to guide the design process towards ideal robustness the first time. A low score reflects a robust design. A high score reflects a complex and sensitive system. If a product is brought from a high to a lower score a potential within the topics can be released:

GREENER

    • Change of material towards a green solution (e.g. virgin plastic to recycled plastic)
    • Reduction of material use (less over-engineering)
    • Reduction of scrap
    • Design for reuse/circularity/recycling/disassembly
    • Higher product efficiency (less energy/CO2 consumption)
    • Increase product lifetime

SIMPLER

    • Enablement of faster machining times/cycle times
    • Enablement of low-cost suppliers
    • Reduction of customer complaints/returns
    • Reduction of material cost (material type and amount)

FASTER

    • Reduction of development time
    • Reduction of change requests
    • Reduction of tooling iteration
    • Enablement of faster assembly times/automation levels

SMARTER

    • Enable less weight
    • Enable longer product lifetimes
    • Enable better energy efficiency
    • Enable better visual appearances
    • Enable better seals/IP rating

The RD8 Index is based on 8 disciplines of robust design.

Disciplines

Robust Design Optimization

8 Robust Design Principles and Disciplines for Simpler. Faster. Smarter. Greener. Product Development

RD8 Robust Design Disciplines

In RD8 Robust Engineering System (RES) and RD8 Index – we redefine robust design – by coverage of 8 crucial disciplines of mechanical design – while keeping the design process and outcome as simple and structured as possible.

The 8 disciplines are:

Kinematics – The foundation. Kinematic design on the system and detailed level.

Functions – Product function is key! Ensure healthy concepts with low sensitivity – high robustness.

Couplings – Reduce complexity! Remove dependencies by decoupling.

Tolerances – Ensure short tolerance chains and feasible tolerances (to match process capabilities)

Structure – Ensuring match between requirements, function, cost, and mechanical properties.

Materials – Ensure the right selection of materials – their complexity and link to adjacent components.

DFM – Ensure optimized manufacturability of parts

DFA – Ensure ease of assembly and link to product design

Engineering Metrics & High Level Product Development Stages

The 8 robust design disciplines are visited and matured at each stage.

Stages are typically tailored to our clients development model. The “Concept” –> “System” –> “Detailed” approach can be aligned with most models.

See the RUN Tools section for an overview of supporting tools for each development stage.

How to Improve Engineering Efficiency

Working smarter in R&D

For each discipline, there is a unique objective metric that can be scored across all product types and industries and be normalized to be compared across products.

The metrics are used actively during the product development process and bring objective values to evaluate the maturity and quality of a design. This ensures healthy design first time and often prevents detours (extra project loops, change orders, costly test programs, etc.) – and hereby project cost. 

Insight into each discipline adds transparency and supports the decision-making and project focus to reduce risk and communicate to stakeholders and in the development team.

More than 25% reduction of timeline by next-level integrated product development is the goal for our robust design way-of-working.

Breakdown of the RD8 Index by the robust design disciplines

The illustration below illustrates how mastering the 8 Robust Design disciplines can benefit engineering product development projects.

Five generic phases are plotted along the first axis: “Concept” –> “System Design” –> “Detailed Design” –> “Ramp Up” –> “Production”.

Step 1: INDEX 100 is defined as the projected development cost.

Step 2: The “design freedom” or “ease of change” is plotted onto the second axis of the graph. The later the change occurs the more expensive it is to correct or implement a solution.

Step 3: Plot of the typical project cost. Typically at the end of the design phase or after design release (after detailed design) cost exceeds the projected budget. Unexpected issues occur. As mentioned in “Step 2” these changes are often costly and cause the project costs to drift. Late project changes can lead to +INDEX 150 cost impact.

Step 4: The RD8 RES way – enabling transparency along the design process and ensures healthy technical solutions the first time. Result: lower risk of budget drifts & possibly cost/time/resource reductions.

At any time of the product development process, the RD8 RES can give you ONE NUMBER for the condition of the mechanical design. The number is an aggregate of the score from each robust design discipline.

Illustration of product tracking by RD8 Index

At each stage of the product development process the robustness can be tracked by the RD8 Index to measure the health of the mechanical design.

The metrics can be used for project gates and to monitor the project portfolio.

In the illustration, it might be risky to continue with the development of Product C without improving the design before entering into a detailed design. If the score is not lowered by robust design mitigations there is a high risk of design and ramp-up detours.

Robustness Philosophy

Axiomatic design & classic robust design on top of a foundation of kinematic design.

Design for sensitivity, complexity reduction and decoupling – based on a kinematic design foundation.

RD8 Robust Design Philosophy