Modularization method based on creation of new layout structure

Abstract

This paper describes a modularization method based on the creation of a new layout structure by combining topology optimization using beam elements and clustering analysis. By setting candidates for frame members in smaller units than parts and performing topology optimization using beam elements, a frame structure of new layouts as an aggregate of fine frame members can be created. For each fine frame member, connectivity as a structure in the entire frame structure is expressed as Design Structure Matrix (DSM). By performing hierarchical clustering on this DSM, clusters of fine frame members are formed as parts, and modules as these aggregate can be found out. Since this is hierarchically determined as a dendrogram, it is possible to determine the number of module divisions of the product configuration depending on the granularity of the cluster. Furthermore, by advancing each fine cluster towards the trunk above the tree diagram, an assembly process with less rework is obtained. Unlike the method of deriving the optimal solution for the product with existing structure, this research proposes a method to derive concurrently the new frame structure and construction of parts and module decomposition which minimizes rework. By validation analysis using a simple box structure, the effectiveness of this proposed method has been confirmed.