Design for Flexibility: Performance and Economic Optimization of Product Platform Components

Abstract

Embedding flexibility into physical products or manufacturing processes has been a research topic of great interest. Embedding such flexibility allows manufacturers to respond to changing market preferences or regulations with minimum increase in product complexity and investment cost. In this paper, a multidisciplinary optimization design process for embedding and evaluating flexibility in product components is introduced. The components are assumed to be part of an existing or planned product platform. The design process starts with generation of multiple design alternatives for embedding flexibility into product components. The generated flexible designs are then optimized for component performance maximization and cost minimization. The optimized designs are then evaluated for economic profitability using a Monte Carlo simulation. At the end, the most profitable flexible component design is selected. The proposed design process is demonstrated through a detailed case study, where flexible design alternatives for an automotive floor pan are generated and optimized.

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