MATERIALS • PROCESSES • FINISHES
PRODUCTION T
PRIORITISING
Alan Francis details a new approach to prototyping
he importance of accurate prototype manufacture cannot be overstated. Te subject of detailed testing and performance validation,
a prototype part reveals whether any further design modification is needed, as well as providing vital data on the part’s published performance attributes, warranties and service intervals. For these reasons, it needs to be the best part you ever make. Unfortunately, production prototypes
are often expensive, and approaches to their development have not always kept pace with other areas of design, engineering and manufacture. Tere are a number of pitfalls associated with traditional prototype manufacture. However, a new method – based on prioritising final production – can both speed up time to market and reduce costs.
Te accurate manufacture of prototype
parts and assemblies is vital for almost every engineering sector. In most instances, the prototype will be the only component subjected to every testing and performance validation procedure, which ultimately influences key decisions on design modifications, published performance attributes, warranties and service intervals. At this stage, consistency and accurate
process documentation are key. In the testing stage, for example, it’s important for prototypes to remain as faithful to the original design as possible. Any deviations – whether in shape, thickness or material – can render test results unreliable, or even invalid. Tese results are vital to the progression of a design, which is why they need to be as accurate as possible. If not, individual parts, or even the whole assembly, must be examined, remanufactured and
52
www.engineerlive.com
reconfigured, all of which can lead to substantial delays and additional costs. Worse still, if inaccurate data is carried forward into the next stage of production, the ramifications can be severe: from a shortened service life or a failure to meet warranted standards, to a catastrophic failure while in service. For these reasons, a prototype must be the best and most accurate part a company ever produces.
THE PROBLEM WITH PROTOTYPING Unfortunately, this field has not always received the attention it deserves. Tis is for a variety of reasons. For one, production prototypes are often expensive, particularly when compared to the cost-per-unit of the component in its final form. Tere has also, arguably, been an inconsistent approach to prototype development, which has meant that it has not kept the pace with its design, engineering and manufacturing counterparts. Unlike the mass-production of finished
parts – which involves detailed operations sheets, photos, precise written instructions and guidance on correct handling and fixing – prototype assembly often works based on a CAD representation at best. As a result, quality and repeatability can suffer. With most projects working to strict deadlines, re-engineering a component at a later stage incurs project delays and budget overruns. Why, then, has the manufacture
of prototypes been so neglected? Traditionally, prototypes have been
TOP: A Dearman engine prototype RIGHT: Accurate prototypes are crucial for all engineering sectors
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40 |
Page 41 |
Page 42 |
Page 43 |
Page 44 |
Page 45 |
Page 46 |
Page 47 |
Page 48 |
Page 49 |
Page 50 |
Page 51 |
Page 52 |
Page 53 |
Page 54 |
Page 55 |
Page 56 |
Page 57 |
Page 58 |
Page 59 |
Page 60 |
Page 61 |
Page 62 |
Page 63 |
Page 64 |
Page 65 |
Page 66 |
Page 67 |
Page 68 |
Page 69 |
Page 70 |
Page 71 |
Page 72 |
Page 73 |
Page 74 |
Page 75 |
Page 76
