A framework for analytical cost estimation of mechanical components based on manufacturing knowledge representation

This paper presents a novel framework for manufacturing and cost-related knowledge formalization. This artefact allows industries to capitalize the knowledge of experienced practitioners in the field of manufacturing and assembly, so that it can be used by designers for quickly and analytically estimating the production costs of components during product development. The framework consists of the following: (i) a cost breakdown structure used for splitting out the manufacturing cost, (ii) a data model ( cost routing ) to collect the knowledge required to define a manufacturing process, (iii) a data model ( cost model ) for collecting the knowledge required to compute the manufacturing cost of each operation within a manufacturing process, and (iv) a workflow to define the manufacturing process. The proposed framework provides several advantages: (i) knowledge formalization of product manufacturing cost, (ii) knowledge sharing among design/engineering departments, and (iii) knowledge capitalization for decision-making process. The proposed framework is used to formalize the knowledge required for analytically estimating the manufacturing cost of open-die forged components. Results highlight that the framework addresses the most important requirements for a knowledge-based cost estimation system.

[1]  J. Kulon,et al.  A knowledge-based engineering design tool for metal forging , 2006 .

[2]  Gaoliang Peng,et al.  Research on ontology-based integration of product knowledge for collaborative manufacturing , 2010 .

[3]  C. Ou-Yang,et al.  Developing an integrated framework for feature-based early manufacturing cost estimation , 1997 .

[4]  H. S. Wang.  Application of BPN with feature-based models on cost estimation of plastic injection products , 2007, Comput. Ind. Eng..

[5]  Kadir Çavdar,et al.  Development of a knowledge-based expert system for solving metal cutting problems , 2006 .

[6]  David Cebon,et al.  Materials Selection in Mechanical Design , 1992 .

[7]  Z. Bouaziz,et al.  Cost estimation system of dies manufacturing based on the complex machining features , 2006 .

[8]  Chong Li,et al.  An analytical method for cost analysis in multi-stage supply chains: A stochastic network model approach , 2014 .

[9]  W. T. Chan,et al.  Feature-based cost estimation for packaging products using neural networks , 1996 .

[10]  Essam Shehab,et al.  Manufacturing cost modelling for concurrent product development , 2001 .

[11]  Karl T. Ulrich,et al.  Product Design and Development , 1995 .

[12]  Young K. Son,et al.  A cost estimation model for advanced manufacturing systems , 1991 .

[13]  Essam Shehab,et al.  An Intelligent Knowledge-Based System for Product Cost Modelling , 2002 .

[14]  S. P. Leo Kumar,et al.  Knowledge-based expert system in manufacturing planning: state-of-the-art review , 2019, Int. J. Prod. Res..

[15]  KEINVORNAME;;; Nagahanumaiah,et al.  An integrated framework for die and mold cost estimation using design features and tooling parameters , 2005 .

[16]  B. Ravi,et al.  Casting cost estimation in an integrated product and process design environment , 2006, Int. J. Comput. Integr. Manuf..

[17]  Hong Zhang,et al.  A knowledge representation for unit manufacturing processes , 2014 .

[18]  Michele Germani,et al.  How to Support Mechanical Product Cost Estimation in the Embodiment Design Phase , 2010, ISPE CE.

[19]  J. Kulon,et al.  Applying knowledge-based engineering to traditional manufacturing design , 2006 .

[20]  Bernhard Mitschang,et al.  The Manufacturing Knowledge Repository - Consolidating Knowledge to Enable Holistic Process Knowledge Management in Manufacturing , 2014, ICEIS.

[21]  W. L. Chen,et al.  A new process knowledge representation approach using parameter flow chart , 2011, Comput. Ind..

[22]  P. H. Lowe,et al.  Computer-aided tool cost estimating: an evaluation of the labour content of injection moulds , 1985 .

[23]  Cezary Grabowik,et al.  The method of knowledge representation for a CAPP system , 2003 .

[24]  G. Boothroyd,et al.  Approximate cost estimates for typical turned parts , 1989 .

[25]  Wankhade Nitesh Prakash,et al.  NEW PRODUCT DEVELOPMENT BY DFMA AND RAPID PROTOTYPING , 2014 .

[26]  Jae Kwan Kim,et al.  Selection and sequencing of machining processes for prismatic parts using process ontology model , 2016 .

[27]  Li Qian,et al.  Activity-based cost management for design and development stage , 2003 .

[28]  Jian S. Dai,et al.  Product Cost Estimation: Technique Classification and Methodology Review , 2006 .

[29]  Wolfgang Beitz,et al.  Engineering Design: A Systematic Approach , 1984 .

[30]  François Vernadat,et al.  Cost estimation in mechanical production: The Cost Entity approach applied to integrated product engineering , 2006 .

[31]  Ángel García-Crespo,et al.  A review of conventional and knowledge based systems for machining price quotation , 2011, J. Intell. Manuf..

[32]  W. A. Knight.  Simplified early cost estimating for hot-forged parts , 1992 .

[33]  Ángel García-Crespo,et al.  Conceptual model for semantic representation of industrial manufacturing processes , 2010, Comput. Ind..

[34]  Navee Chiadamrong,et al.  The development of an economic quality cost model , 2003 .

[35]  Andrew Kusiak,et al.  Cost evaluation in design with form features , 1996, Comput. Aided Des..

[36]  H.J.J. Kals,et al.  A generic framework for cost estimation and cost control in product design , 1998 .

[37]  JungHyun Han,et al.  Manufacturing feature recognition from solid models: a status report , 2000, IEEE Trans. Robotics Autom..

[38]  Martin Fischer,et al.  An analytical method to estimate the total installed cost of structural steel building frames during early design , 2018 .

[39]  A. Macioł,et al.  Knowledge-based methods for cost estimation of metal casts , 2017 .

[40]  Salvatore T. March,et al.  Design and natural science research on information technology , 1995, Decis. Support Syst..

[41]  M. S. Parvez,et al.  Integrated manufacturing features and Design-for-manufacture guidelines for reducing product cost under CAD/CAM environment , 2013, Comput. Ind. Eng..

[42]  Jacky Akoka,et al.  Artifact Evaluation in Information Systems Design-Science Research - a Holistic View , 2014, PACIS.

[43]  Michele Germani,et al.  Analytical Cost Estimation Model in High Pressure Die Casting , 2017 .

[44]  Yuchun Xu,et al.  Cost Engineering for manufacturing: Current and future research , 2012, Int. J. Comput. Integr. Manuf..

[45]  Sergio Cavalieri,et al.  Parametric vs. neural network models for the estimation of production costs: A case study in the automotive industry , 2004 .

[46]  Kai Cheng,et al.  Extending the product portfolio with ‘devolved manufacturing’: methodology and case studies , 2006 .