Each step in the prototype
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,
manufacture and assembly process
must be driven by the objectives of
final production. Overall risk, cost
and time can be reduced, while
increasing the chances of accurate
production, reducing final assembly
time and lowering the cost of re-work.
Production Oriented Prototyping
(POP) is a novel approach to
prototype development that involves
both the individual component and
full assembly designers from the
start of the application development
phase. The aim is to build production
standards into the prototype, while
minimising cost and delivery time, as
well as optimising safety.
Using virtual builds, simulation and
validation via CAD, manufacturers
can ensure that all the components fit
together for each design release and
can be accessed and manipulated
during the build. Any issues with
component compatibility, design or
accessibility can be tackled at a much
earlier stage and, crucially, before
time and money have been invested
in one-off component manufacture for
the prototype.
Using this methodology, the team
can develop operation sheets as
they go, making the final assembly
process easier and more intuitive.
Fixturing and work-holding are
also considered at an earlier stage,
meaning that manufacturers have
more time to specify and produce a
bespoke system, if required. This
is especially true when dealing
with larger or more complex
assemblies, which do not
lend themselves to easy
movement or manipulation.
In effect, assembly
process design – including
process, flow, tooling and
fixturing – is completed
before the physical
components are ready to be
assembled.
By adopting this holistic approach,
it’s easier to identify and fix issues
faster than would be achieved during
final assembly, with programme time
savings of over 25% often achievable.
What’s more, the extra efficiency
afforded by POP allows assembly
technicians to identify cost reduction
opportunities for components and
processes through ‘practice runs’ for
future assembly.
Productiv has been developing
and testing this method, and the
results have been impressive. In one
instance, we were able to reduce the
assembly time for the first prototype
build of a complex transmission for an
automotive manufacturer from their
typical eight weeks, to just eight days.
The benefits of the POP approach
can be applied in any sector for
which precision and replicability are
vital to enable accurate testing and
validation. In fact, any engineering
business can achieve lower costs
and a faster route to market. We hope
this will finally give prototypes the
attention they deserve. !
when adding remaining components
is often the first to go in the drive
to reduce project costs. This is, of
course, a false economy: awkward
working processes caused by
incorrect fixturing can result in
both damage to, and sub-standard
assembly of, the prototype.
A SOLUTION TO THE
PROTOTYPE PROBLEM
It’s clear that prototype development
needs a new approach. By focusing
on wider objectives of getting
a product to market and into
production, the solution is challenging
but achievable.
or even invalid
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