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CHAPTER VIII.
CLOSURE 288
8.1 DEVELOPING THE HPPRM – ADDING NEW KNOWLEDGE?...........................................290
8.1.1 Revisiting the Research Questions and Hypotheses.......................................... 290
8.1.2 Validating New Scientific Knowledge – an Overview ......................................292
8.1.3 Testing the Theoretical Structural Validity (TSV) ...........................................295
8.1.4 Testing the Empirical Structural Validity (ESV)..............................................298
8.1.5 Testing the Empirical Performance Validity (EPV).......................................... 301
8.1.6 Testing the Theoretical Performance Validity (TPV) ....................................... 303
8.2 DEVELOPING THE HPPRM – ACHIEVEMENTS AND CONTRIBUTIONS........................305
8.2.1 Contributions to the Field of Engineering Design.............................................305
8.2.2 Original and Significant: Completing the Criteria for a Ph.D. .......................... 305
8.3 CRITICAL ANALYSIS – RESEARCH LIMITATIONS..........................................................309
8.3.1 The HPPRM – Limitations to its Constructs and Framework........................... 309
8.3.2 The HPPRM – Its Robustness ........................................................................ 311
8.3.3 The HPPRM – Limitations to the Validation Process ......................................312
8.3.4 The HPPRM – Limitations to Implementation................................................. 313
8.4 RECOMMENDATIONS – AVENUES FOR FUTURE WORK ...............................................315
8.4.1 Industrializing the HPPRM – the Industrial Avenue.........................................315
8.4.2 Improving the HPPRM Constructs – the Academic Avenue............................. 318
8.5 CONCLUDING REMARKS....................................................................................................320
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ii
LIST OF FIGURES
FIGURE 8-1 HOW THE RESEARCH QUESTIONS AND HYPOTHESES CONNECT TO THE HPPRM
................................................................................................................................................... 291FIGURE 8-2 HYPOTHESES TESTING GUIDE: WHERE THE ANSWERS ARE PROVIDED........... 294
FIGURE 8-3 THE THEORETICAL STRUCTURAL VALIDATION PROCESS – A PICTORIAL
REPRESENTATION .................................................................................................................. 297
FIGURE 8-4 THE EMPIRICAL STRUCTURAL VALIDATION PROCESS– A PICTORIAL
REPRESENTATION .................................................................................................................. 300
FIGURE 8-5 THE EMPIRICAL PERFORMANCE VALIDATION PROCESS – A PICTORIAL
REPRESENTATION .................................................................................................................. 302
FIGURE 8-6 THE THEORETICAL PERFORMANCE VALIDATION PROCESS – A PICTORIAL
REPRESENTATION .................................................................................................................. 304
FIGURE 8-7 THE CONTRIBUTIONS TO THE FIELD OF ENGINEERING DESIGN .............. ......... 308
FIGURE 8-8 THE RESEARCH AVENUES STEMMING FROM THE HPPRM FRAMEWORK......... 317
LIST OF TABLES
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CHAPTER VIII
8. CLOSURE
NumTax TechDiff c-DSP HPPRM Closure, demonstrating
• research validity
• research originality
• research significance
XXX Xx
x x
x x
x x
x x
x x
x
In this dissertation a framework has been developed, presented, and tested to facilitate the
realization of large, complex and expensive MTO systems that are traditionally produced in small
numbers using much of the same technology. Our objective in this chapter is then to bring the
development and presentation of this framework to a closure. By closure we mean to demonstrate that we
have achieved the principal research objective and answered the questions we posed in Chapter I, in a
satisfactory manner.
We do this by first demonstrating (by means of the validation square) that we have added newknowledge to the field of engineering design. Then, we evaluate this new knowledge in terms of its
originality and significance, in order to fully demonstrate that this research comply with the requirements
posed for the Doctor of Philosophy degree in Mechanical Engineering.
Finally, we discuss the limitations of the HPPRM framework in terms of its constructs, its
robustness, its validity, and its industrial implementation. Based on this, we give recommendations on
“This must n ot be taken as the end;
i t may poss ib ly be the beginn ing of the end;
but i t is cer ta in ly the end of the beginn ing” – Winston Churchill
In speech at the Mansion House in London City in late 1942
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future research building on this framework, both in academia and in industry, before we close this
dissertation.
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8.1 DEVELOPING THE HPPRM –
ADDING NEW KNOWLEDGE?
In this section we demonstrate by means of the validation square (see Section 1.6.2) that the
HPPRM gives reliable and useful output for valid input, hence, that it adds new knowledge to the field of
engineering design. In Section 8.1.1 we revisit the research questions and hypotheses that were posed in
Section 1.5. For reference, in Figure 8-1 we show where the research questions and hypotheses are
embedded in the HPPRM structure. In Section 8.1.2 we give an overview of the procedure for
substantiating that new scientific knowledge has been added to the field of Engineering Design, and in
Sections 8.1.3 through 8.1.6 we demonstrate that that new scientific knowledge has been added to the
field of Engineering Design. Adding originality and significance in Section 8.2, we can assert compliance
with the Ph.D. requirements as given by the GWW School of Mechanical Engineering.
8.1.1 Revisiting the Research Questions and Hypotheses
Validation in context of Ph.D. research rests on (1) having answered the posed questions, (2)
the answers being in accordance with the hypotheses, and (3) the answers being acceptable from a Ph.D.
requirement perspective. Hence, we start the validation procedure presentation by revisiting the questions
and the hypothesis posed for this research.
Fundamental Research Question: How can large and complex made-to-order systems produced in smallnumbers using much of the same technology be realized more effectively and efficiently for different
applications?
Fundamental Hypothesis: Large and complex made-to-order systems as characterized above can be
realized more effectively and efficiently for different applications by developing Hierarchical Product
Platforms (see Section 1.3.3) from an evolutionary perspective (see Chapter II).
As stated in Section 1.5, the fundamental question has been partitioned into three questions,
where each question deals with some fundamental aspects regarding how to develop a Hierarchical
Product Platform from an Evolutionary Perspective. These questions and their corresponding hypotheses
are formulated as follows.
Research Question 1: Based on a firm’s existing designs; how can HPPs be defined in terms of what
physical entities to standardize for which products?
Hypothesis 1: Numerical Taxonomy (Sneath and Sokal 1973) provides a good framework for defining
HPPs in terms of what physical entities to standardize for which products (answering Research
Question 1 acknowledging Path-Dependence).
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… By designing Hierarchical Product Platforms
from an Evolutionary Perspective, characterized
by Path-dependence, Population-thinking, and
Probabilistics.
… By designing Hierarchical Product Platforms
from an Evolutionary Perspective, characterized
by Path-dependence, Population-thinking, and
Probabilistics.
How can large and complex made-to-order systems produced in
small numbers using much of the same technology be realized
more effectively and efficiently for different applications?
How can large and complex made-to-order systems produced in
small numbers using much of the same technology be realized
more effectively and efficiently for different applications?
The HPPRM
Gather Data
Cluster Data
For each Assembly Level (AL)
P h a s e
I : D E F I N E
( R e s e a r c
h Q u e s t i o n 1 )
Establish
Design Requirements
Partition Realization
Processes
P h a s e I I : M O D E L
( R e s e a r c h Q u e s t i o n 2 )
Model Relationships
and formulate c-DSPs
Establish ScenariosSolve for each
Scenario
P h a s e I I I : S O L V E
( R e s e a r c h Q u e s t i o n 3 )
Decide on HPP
For each Assembly Level (AL)
For ALL Assembly Levels (AL)
Hypothesis 1
Hypothesis 2
Hypothesis 3
Numerical Taxonomy
(Sneath & Sokal 1973)
Technology Diffusion
(Silverberg, Dosi et al. 1988)
Compromise DSP
(Mistree, Hughes et al. 1993)
The Research Hypotheses
THE FUNDAMENTAL QUESTION THE FUNDAMENTAL HYPOTHESIS
Figure 8-1
How the Research Questions and Hypotheses Connect to the HPPRM
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Research Question 2: In order to better adapt products to their requirements we want to consider
realizing them with alternative processes; how can we evaluate the effects such a transition may have
on a product’s operational performance, its cost and its schedule, accounting for the learning that has
to take place in a transition phase?
Hypothesis 2: Technology Diffusion (Silverberg, Dosi et al. 1988) is a viable concept to include learning
when evaluating the effects of transferring to new processes (answering Research Question 2 from a
Population-Thinking perspective).
Research Question 3: How can products and processes be synthesized in a mathematical model,
acknowledging that it is based on limited information and ‘volatile’ assumptions?
Hypothesis 3: The c-DSP (Mistree, Hughes et al. 1993) provides a structure and an anchoring that is well
suited for solving models that are acknowledged to be based on incomplete information and ‘volatile’
assumptions (answering Research Question 3 acknowledging the Probabilistic nature of the problem)
As stated, the validity of the research in context of Ph.D. requirements rests on having
answered the questions according to the hypotheses in an acceptable way. In this research, the answers
correspond to the hypotheses, and hypotheses tested valid according to the process given in Section 1.6,
are asserted to constitute new scientific knowledge. In addition, hypotheses found to be significant and
original in addition to being valid are considered to be contributions to the field of Engineering Design,
see Section 8.2.
8.1.2 Validating New Scientific Knowledge – an Overview
In general a research question is answered when the corresponding hypothesis is validated.
However, in this dissertation there is a hierarchical organization of questions and hypotheses, where a
fundamental question and hypothesis is partitioned into three supporting questions and hypotheses. The
hierarchical organization implies that the answer to the fundamental question lies in validating the
fundamental hypothesis; validating the fundamental hypothesis lies in answering the supporting
questions; answering the supporting questions lies in validating the supporting hypotheses. Hence, in
order to answer the fundamental question, we validate each of the supporting hypotheses. This is done
according to the process given in Section 1.6, where each of the quadrants in the
Validation Square to the right are tested separately for each supporting
hypothesis. Then, by adding additional information, the validity of the
fundamental hypothesis – i.e., the validity of the HPPRM – is asserted through
induction. In the following, we present the procedure for testing each hypothesis
according to the process outlined in Section 1.6, and in Figure 8-2 we present a
THEORETICAL
STRUCTURAL
VALIDITY
EMPIRICAL
STRUCTURAL
VALIDITY
EMPIRICAL
PERFORMANCE
VALIDITY
THEORETICAL
PERFORMANCE
VALIDITY
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guide to where the various testing takes place in the dissertation (where the answers to the questions are
provided).
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Ch. I
NumTax TechDiff c-DSP HPPRM Demonstrating• Originality of the HPP: Sc. 1.3.5
Ch. V
NumTax TechDiff c-DSP HPPRM
x
Ch. IV
NumTax TechDiff c-DSP HPPRM
xXx x
Xx x
Xx x x
Demonstrating that constructs are
• accepted in general: Sc. 4.1.5, 4.2.4, 4.3.3
• accepted in HPPRM: Sc. 4.1.6, 4.2.5, 4.3.4
• useful in HPPRM: Sc. 4.1.7, 4.2.6, 4.3.5
X X X x
Ch. VI
NumTax TechDiff c-DSP HPPRM
X X x x
Case Study, demonstrating that
• HPPRM fits problem: Sc. 6.1• usefulness of Num Tax: Sc. 6.6
Ch. VIII
NumTax TechDiff c-DSP HPPRM Closure, demonstrating
• research validity: Sc. 8.1
• research originality: Sc. 8.2.2
• research significance: Sc. 8.2.2
XXX Xx
x x
x x
x x
x x
x x
x
Ch. III
NumTax TechDiff c-DSP HPPRM Demonstrating internal consistency
of the HPPRM by Flow Charts
- Phase I Define: Sc. 3.2
- Phase II Model: Sc. 3.3- Phase III Solve: Sc. 3.4
x
Ch. VII
NumTax TechDiff c-DSP HPPRM
X X x
Case Study, demonstrating
• usefulness of Tech Diff: Sc. 7.4.5
• usefulness of c-DSP: Sc. 7.5
• usefulness of HPPRM: Sc. 7.10
NumTax TechDiff c-DSP HPPRM
Ch. II
Demonstrating applicability of
• Evolutionary approach: Sc. 2.1-3
• Numerical Taxonomy: Sc. 2.4
• Technology Diffusion: Sc. 2.5
• c-DSP: Sc. 2.6X X X x
xxx xxx
x
Demonstrating internal consistency
of the HPPRM by Example Problem
- Phase I Define: Sc. 5.2
- Phase II Model: Sc. 5.3
- Phase III Solve: Sc. 5.4x x xx x x
x
x
Figure 8-2
Hypotheses Testing Guide: Where the Answers are Provided
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8.1.3 Testing the Theoretical Structural Validity (TSV)
The hypothesis-testing starts with the Theoretical Structural
Validity (TSV) – the main pillar in the bridge over the ‘chasm of new
knowledge’ – and the process of demonstrating the TSV of the HPPRM is
illustrated in Figure 8-3.
In context of a design method, this validity rests on (1) the
‘correctness’ of the individual constructs constituting the complete method and (2) the internal
consistency in the way the constructs are organized within the method. Together this validates that the
results are obtained in a correct and consistent manner, implying that for valid input the output can be
trusted. The specific approach to demonstrate ‘correctness’ of the individual constructs is by literature
referrals, and the specific approach to demonstrate internal consistency is by flow-chart representation of the method.
The design method to be tested is the HPPRM. Embedded in this method are the three
hypothesized constructs, namely, Numerical Taxonomy, Technology Diffusion, and the compromise DSP.
Hence, testing the Theoretical Structural Validity of the HPPRM lies in testing the Theoretical Structural
Validity of each of these constructs in addition to testing the internal consistency of the HPPRM. The
Theoretical Structural Validity of the key constructs is demonstrated as follows.
§ The Theoretical Structural Validity of Numerical Taxonomy is demonstrated in Section 4.1 in
general and in Section 4.1.5 in particular. This is done by demonstrating that Numerical Taxonomy not only is generally accepted for revealing the inherent structures / pattern in data-sets, but it is used
to benchmark new methods as well.
§ The Theoretical Structural Validity of Technology Diffusion is demonstrated in Section 4.2 in
general and in Section 4.2.2 in particular. This is done by demonstrating that Technology Di ff usion
is accepted for simulating the impact on market shares when firms transfer to new technology within
the same industry.
§ The Theoretical Structural Validity of the compromise-DSP is demonstrated in Section 4.3 in general
and in Section 4.3.2 in particular. This is done by demonstrating that the compromise-DSP is
generally accepted as a construct for multi-objective optimization used in searching for ‘satisficing’
rather than optimal solutions.
The internal consistency of the HPPRM is demonstrated in Sections 3.2 through 3.4, where
each phase is elaborated and visualized in a separate flow-chart. In doing so, the information flow is
emphasized and the consistency is demonstrated in terms of (1) there is no redundant information being
generated and (2) the underlying assumptions are identified, evaluated and found valid.
T S V
EPVTPV
E S V
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Taking the Theoretical Structural Validity of the hypothesized constructs together with the
internal consistency of the HPPRM, it is asserted that the HPPRM is Theoretical Structural Valid.
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Numerical
Taxonomy:
Sneath & Sokal, 1973
Keller, 1992
…ü
Technology
Diffusion:
Hall, 1994
Silverber, Dosi et al. 0988
…ü
c-DSP; Mistree et al. 1990
Lewis et al. 1995
Chen et al. 1996
…ü
HPPRM
Theoretical
Structural
Validü
CRITERIA
Theoretical Structural Validity
Tools / Methods Used in
HPPRM Considered Valid
within their Specified Ranges, i.e., for Certain Applications
The Internal Structure of
HPPRM Considered
Consistent
ü
ü
I
I
I
TI
I
I T
I
TI
I T
?
T
I
I
I
I
T
TI
I
T
I
T
I
I I
I T
I
I
I
T
T
I
I
T
I
T
I
I
I
Figure 8-3
The Theoretical Structural Validation Process –
A Pictorial Representation
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8.1.4 Testing the Empirical Structural Validity (ESV)
The hypothesis-testing continues with the Empirical Structural
Validity (ESV) – the other pillar in the bridge over the ‘chasm of new
knowledge’ – and the process of demonstrating the ESV of the HPPRM is
illustrated in Figure 8-4.
In context of a design method, this validity refers to (1) applying
the method within acceptable ranges of the method-constructs, (2) the proposed case studies being
appropriate, and (3) adequate quality of the data associated with the case studies. Together this validates
that the problem fits the method, that the case studies fit the problem, and that the testing fits the case
studies, i.e., that the input intended for the method is valid. The specific approach to demonstrate that the
problem fits the method is by comparing the intended problem to the problems for which the constructsare generally accepted. The specific approach to demonstrate that the case studies fits the problem is by
comparing the characteristics of the chosen case studies to the characteristics of the general problem as
given in Section 1.5.1. The specific approach to demonstrate that the available data for the case studies
have sufficient quality to support a conclusion is by induction.
First of all, does the problem fit the method? In other words, is the problem suited for the
constructs constituting the method? This is elaborated in Chapter IV, where the applicability of each of
the key constructs in the HPPRM is critically evaluated. The applicability of Numerical Taxonomy is
elaborated in Section 4.1.6; the applicability of Technology Di ff usion is being elaborated in Section 4.2.5;
and the applicability of the c-DSP is being elaborated in Section 4.3.4.
Secondly and thirdly, do the case studies fit the problem, and does the testing fit the case
studies? In other words, are the case studies appropriate for demonstrating the usefulness of the method?
For the purpose of testing the method performance, one Example Problem and one Case Study is used,
namely, a Family of Gravitational Separators (Chapter V) and a Family of Marginal Field Vessels
(Chapter VI and VII). The appropriateness of the Example Problem is elaborated in Section 5.1.3,
demonstrating that the Gravitational Separators are representative of the general problem and that the
data, being ‘tailored’ to test the clustering algorithm, is suited to demonstrate the methodology. Note that
even if the data is ‘tailored’ to test the clustering algorithm, it also demonstrates the usefulness of the
method for the hypothetical design portfolio. The appropriateness of the Case Study is elaborated in
Section 6.1.2, demonstrating that the Marginal Field Vessels are representative of the problem and that
the data, being real life data, is suited to demonstrate the usefulness of the method.
EPVTPV
E S V
T S V
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Given that the Gravitational Separator example problem and the Marginal Field Vessel case
study are appropriate for testing the Empirical Performance Validity of the HPPRM, we assert that the
HPPRM is valid for its intended input, hence, the HPPRM is Empirical Structural Valid.
ü
CRITERIA
Empiri cal Structural Validity
Intended Application ofTools / Methods in HPPRM
within their Specified Ranges
Examples / Case studies
Representative for Problem
Able to Support Conclusions
ü
ü
Numerical
Taxonomy: Sneath & Sokal, 1973
Keller, 1992
…
Valid Applications
Classification
Pattern recognition
… ü
ü
Technology
Diffusion: Hall, 1994
Silverber, Dosi et al. 0988
…
Valid Applications
Discounting Performance
Learning
… ü
ü
c-DSP; Mistree et al. 1990
Lewis et al. 1995
Chen et al. 1996
…
Valid Applications
Multi-Objective optimization
Distance to Target
… üü
ü HPPRM TheoreticalStructural
Valid
Empirical
Structural
Validü
ü
ü
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Figure 8-4
The Empirical Structural Validation Process–
A Pictorial Representation
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8.1.5 Testing the Empirical Performance Validity (EPV)
Having demonstrated that the HPPRM is likely to provide
trustworthy output for its intended and validated input, the next step is to
validate the usefulness of this output; i.e., to test the Empirical Performance
Validity (EPV). This is viewed as the first stone paving the bridge over the
‘chasm of new knowledge’, and the process of demonstrating the EPV of
the HPPRM is illustrated in Figure 8-5.
In context of testing the HPPRM, EPV refers to whether the HPPRM is able to produce useful
results for the chosen Example Problem and the chosen Case Study, and whether the key HPPRM
constructs (Numerical Taxonomy, Technology Diffusion and the compromise-DSP) contribute positively
to this usefulness. Usefulness in this context refers to whether the resulting HPP contributes to reducingcost and time while maintaining acceptable operational performance (increase competitiveness).
First of all, the usefulness of the Hierarchical Product Platform (HPP) synthesized from the
HPPRM is demonstrated in Section 5.4.4 for the Example Problem and in Section 7.10 for the Case Study.
Having answered the major performance validity question, the remaining issue is whether the key
constructs are contributing to this usefulness.
Numerical Taxonomy is anticipated to contribute to the HPPRM usefulness by identifying the
potential for standardization in an existing design portfolio, hence, reducing the combinatorial problem to
a manageable size. This is demonstrated in Section 4.1.7.
Technology Diffusion is anticipated to contribute to the HPPRM usefulness by facilitating
evaluation of alternative processes for various steps in the fabrication process, hence, advocating a
continuous improvement approach. This is demonstrated in Section 4.2.6.
The compromise DSP is anticipated to contribute to the HPPRM usefulness by integrating the
product and process model, hence, facilitating solving for multiple objectives and advocating robust and
adaptive solutions. This is demonstrated in Section 4.3.5
Having demonstrated that Hierarchical Product Platforms are useful in terms of saving time
and cost for large and complex made-to-order systems, and that the key constructs in the HRRPM
contributes to this usefulness, we assert that the HPPRM is useful at least for the chosen Example Problem
and Case Study. Hence, we assert that the HPPRM is Empirical Performance Valid,
EPV
T S V
TPV
E S V
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c-DSP:
“Probabilistic”
…
Purpose:
Gain appreciation .
about problem to
support decisionüü
ü
Technology
Diffusion:
Hall, 1994 “Population-
… Thinking”
Purpose:
Discount process
performance as
learning takes
place
ü
ü
ü
Numerical
Taxonomy:
Sneath, 1973
Keller, 1992 “Path-… Dependence”
Valid App… Purpose:
Classification Find potential for
Pattern rec… standardization
… within existing
portfolio ü
ü
CRITERIA
Empir ical Perf ormance Vali dity
Numerical Taxonomy to find
potential for Standardization
Technology Diffusion useful to
discount process performance
c-DSP useful to gain apprecia-
tion about problem
HPP useful to reduce cost and
time while maintaining oper. perf.
ü
ü
ü
ü ü
ü
HPPRM
Theoretical
Structural
Valid
Empirical Empirical
Structural Performance
Valid Validü
ü
ü
...
ü
Figure 8-5
The Empirical Performance Validation Process –
A Pictorial Representation
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8.1.6 Testing the Theoretical Performance Validity (TPV)
Having demonstrated validity for a selected set of case studies,
what is left is to build confidence in the validity beyond this set of case
studies, i.e., to build confidence in generality. This validity is termed
Theoretical Performance Validity (TPV), and is viewed as the last stone
paving the bridge over the ‘chasm of new knowledge’. This process of
demonstrating the TPV of the HPPRM is illustrated in Figure 8-6.
In context of testing the HPPRM it refers to the HPPRM being capable of producing useful
results beyond the Gravitational Separator Family example problem and the Marginal Field Vessel Family
case study. In order to substantiate a generality claim for the HPPRM, we apply a piecewise strategy: The
Theoretical Performance Validity of the HPPRM rests on three pillars, namely;
1. that the key method-constructs are applicable for problems beyond the Example Problem and
the Case Study. Their generality and applicability is demonstrated in Sections 4.1.5, 4.2.4 and
4.3.3, and in Sections 8.1.3 and 8.1.4 as part of the Theoretical and Empirical Structural
Validation.
2. that the Example Problem and Case Study are representative for the general problem. This is
part of the Empirical Structural Validation, see Sections 8.1.4.
3. that the HPPRM is useful for at least some selected case studies. This is part of the Empirical
Performance Validation, see Sections 8.1.5.
However, the final acceptance of the HPPRM being Theoretical Performance Valid requires a ‘ leap of
faith’ , where the three other bridge elements (Theoretical Structural Validity, Empirical Structural
Validity, and Empirical Performance Validity) are viewed as ‘leap facilitators’. This is illustrated in
Figure 8-6, and it concludes the validation of the Hypotheses and hence, the answering of the questions in
compliance with the requirements of the GWW School of Mechanical Engineering for Ph.D. research.
If we have been successful in facilitating a ‘leap of fai th ’, this research is accepted as having
added new scientific knowledge to the field of Engineering Design. Further, we assert that we have
achieved the principal objective of this dissertation, namely, that we have
developed a conceptual framework for realizing Hierarchical Product Platforms from which a family
of products using much of the same technology can be designed and realized for different
applications.
What is left to demonstrate is that the HPPRM is significant and original. This demonstration
starts with identifying the specific contributions to the field of Engineering Design from developing the
EPVTPV
‘Leap of Faith’
E S V
T S V
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HPPRM, i.e., from achieving the principal objective. Then, we evaluate these contributions in terms of
their significance and originality. This is done in the next section.
HPPRM
Theoretical
Structural
Valid
Empirical Empirical
Structural Performance
Valid Valid for
case study
ü
ü
ü
CRITERIA
Empir ical PerformanceValidity
HPPRM valid beyond
example problem and
case study
ü
HPPRM
Theoretical Theoretical
Structural Performance
Valid Valid
Empirical Empirical
Structural Performance
Valid Validü
ü
ü
ü
HPPRM
Theoretical
Structural
Valid
Empirical Empirical
Structural Performance
Valid Valid for
example problem
ü
ü
ü
Through the process we
hope to have built
confidence in generality
“a Leap of Faith ”
Figure 8-6
The Theoretical Performance Validation Process –
A Pictorial Representation
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8.2 DEVELOPING THE HPPRM –
ACHIEVEMENTS AND CONTRIBUTIONS
Assuming that developing the HPPRM adds new scientific knowledge to the field of
Engineering Design, what is left to demonstrate (according to the Ph.D. research requirements) is that this
added scientific knowledge is significant and original. This demonstration is based on (1) identifying
potential contributions to the field of engineering design, and evaluating these potential contributions in
terms of their (2) significance and (3) originality. If the potential contributions are found to be both
significant and original, we assert that developing the HPPRM is a contribution to the field of Engineering
Design, and hence, this research complies with the Ph.D. requirements as given by the GWW School of
Mechanical Engineering.
8.2.1 Contributions to the Field of Engineering Design
First of all, in Section 8.1 we demonstrate that we have achieved our principal goal, namely, to
develop a framework for realizing Hierarchical Product Platforms from an Evolutionary Perspective.
From this achievement we derive the following contributions to the field of engineering design, see Figure
8-7:
1) the Hierarchical Product Platform Realization Method (HPPRM);
2) an Evolutionary Approach to engineering systems development;
3) the Validation Square anchored in the relativistic school of epistemology;
8.2.2 Original and Significant: Completing the Criteria for a Ph.D.
The three contributions are apparently interconnected, however, we will evaluate them
separately for their significance and originality. This is based on the assumption that even if one or more
of the three potential contributions are found not to be significant and / or original, the others still may be.
The significance and originality are demonstrated in the following.
The HPPRM – Original and Significant?
The originality of the HPPRM lies in the Hierarchical Product Platform concept and the
method-constructs, namely, Numerical Taxonomy and Technology Diffusion. In Section 1.3.4 we
demonstrate the originality of the HPP by pointing to how the HPP is an advancement to current product
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platform and product family design. In Section 2.4.3 we demonstrate the originality of Numerical
Taxonomy in the context of engineering design, by pointing to how it integrates Group Technology,
clustering and Product Platform thinking. In Section 2.5.2 we demonstrate the originality of Technology
Diffusion by pointing to its origin being in the economics, and that it have not been applied in engineering
design before.
The significance of the HPPRM lies in the usefulness of the HPP from the perspective of
reducing cost and schedule while maintaining operational performance at an acceptable level. In Table 7-
22 we show the CAPEX savings to be around 6 mill USD and the time saving to be around 8 months for
the CAPEX driven HPP. In Table 7-23 we show the CAPEX savings to be around 3 mill USD and the
time saving to be around 1.5 years for the Marginal Field driven HPP. In context of developing marginal
fields, we consider these figures to be significant, and hence, we assert that the HPPRM is both an original
and significant contribution to the field of engineering design.
The Evolutionary Approach – Original and Significant?
The originality of the evolutionary approach lies in the fact that it is adopted from an entirely
different domain, namely, from biology. Even if taken from a different domain, it does not seem to
contradict conventional knowledge in the field of engineering design, and in Section 2.3.2 we explicitly
demonstrate that the evolutionary approach actually compliments it.
Since the HPPRM is based on the evolutionary approach, its significance is directly linked to
the significance of the HPPRM. The contribution from the evolutionary approach comes from introducing
a new perspective where adapting to change becomes the imperative objective, and where variation is seen
as the key to become increasingly adaptive. Based on this, we assert the evolutionary approach to be both
an original and significant contribution to the field of engineering design.
TheValidation Square – Original and Significant?
The originality of the Validation Square lies in the application rather than the origin. The
Validation Square comes from the realm of system dynamics testing (Richardson and Pugh 1988), then it
was used in (Bailey 1997), before we expand it in this dissertation to comprise design method testing.
The significance of the Validation Square lies in its comprehensiveness where all aspects of
verification / validation is covered. Based on this we assert that the Validation Square constitutes an
original and significant contribution to the field of engineering design.
We have now demonstrated that the HPPRM represents new knowledge to the field of
Engineering Design, and that the contributions stemming from developing this framework are original
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and significant. Hence, we assert that this research complies with the Ph.D. requirements as given by the
GWW School of Mechanical Engineering.
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FOUNDATION FOR RESEARCHFOUNDATION FOR RESEARCH
THE “EVOLUTIONARY APPROACH”THE “EVOLUTIONARY APPROACH”
THE “HPPRM”THE “HPPRM”
BIOLOGY
Evolution
ECONOMY
Technologydiffusion
ENGINEERING
Optimization
NumericalTaxonomy
(Hypothesis 1)
EvolutionaryTechnology Diffusion
(Hypothesis 2)
Compromise DecisionSupport Problems
(Hypothesis 3)
AssemblyTaxonomy
Performancediscounting
C-DSP formulationfor HPPs
HPP definition(RQ1)
Process Modeling
incl. learning (RQ2)
Product
Model
HPP c-DSP;an Integrated Product
and Process Model
Process
Model
Synthesis of Product
and Process (RQ3)
Standardization
Taxonomy
StandardizationTaxonomy
Theoretical TheoreticalStructural Performance
Validity Validity
Empirical Empirical
Structural PerformanceValidity Validity
Theoretical TheoreticalStructural PerformanceValidity Validity
Empirical EmpiricalStructural PerformanceValidity Validity
THE “VALIDATION SQUARE”
PHILOSOPHY
Epistemology
Social / holistic /relativistic School
of Epistemology
Process of
building confidencein usefulness
Figure 8-7
The Contributions to the Field of Engineering Design
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8.3 CRITICAL ANALYSIS –
RESEARCH LIMITATIONS
Our objective in this section is to identify the limitations to the presented research. We do this
by first evaluating (in Section 8.3.1) the limitations of the method-constructs themselves and what
limitations this imposes on the total framework. Then, in Section 8.3.2 we evaluate the robustness of the
framework by asking ‘what-if’ questions regarding the objective (the what) and the approach (the how).
Then, in Section 8.3.3 we take a critical look at the HPPRM validity to identify its most significant
weaknesses. Finally, in Section 8.3.4 we evaluate what it will take to implement such a structure in, for
example, Kvaerner. The information from this exercise is then used to identify avenues for future work,
which is dealt with next in Section 8.4.
8.3.1 The HPPRM – Limitations to its Constructs and Framework
The HPPRM is a framework intended for identifying a direction into the future based on
leveraging the past – a process that rests on the following core assumptions.
§ The HPPRM is developed for the Offshore Oil and Gas industry, based on the existence of a
portfolio of similarly but not identically configured products;
§ Standardization improves cost and schedule while compromising operational performance, and
we are seeking the standardization level that gives the best compromise;
§ When seeking the standardization level that gives the best compromise, we prefer robust
solutions to optimized solutions, i.e., we seek solutions that are significantly better than what
we started out with and not likely to change for relatively small changes in the environment;
§ In addition to seeking a standardization level, we seek a corresponding process that enhances
the benefits of standardization, hence, we assume the existence of information to support the
estimates of learning rates and initial skill levels.
Based on these assumptions, we analyze the product portfolio, at various levels of assembly, to
identify where there is a potential for standardization. In other words, we identify parts / assemblies that
are so similar that it seems justifiable to reduce the number of options to one, i.e., to standardize for this
particular part / assembly. We recognize that the mentioned similarities can appear at different levels of
assembly and can involve different end products at the various assembly levels. Hence, at different levels
of assembly there can be items standardized for different end products. This is the premise for the
Hierarchical Product Platform, and the following discussion will be in context of the above. Note,
however, that this approach is very much linked to how much is invested in the past, hence, the HPPRM
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is not intended for industries where product changes can be made without substantial consequences to the
project execution.
Numerical Taxonomy – Limitations
We use Numerical Taxonomy to identify the potential for standardization by quantifying the
similarities between the parts we compare. Numerical Taxonomy is a stand-alone method based on one
initial phase for determining what is to be compared (the OTUs), one intermediate phase for clustering,
and a final phase for construction of taxa. The first and last phase involves the use of heuristics, which
have not been formalized in this research, hence, affecting the repeatability. This constitutes a problem
from the scientific method perspective, where repeatability is normally seen as part of verification /
validation. However, this is only a major limitation in the cases where we look for one particular solution,
e.g., an optimum. In the intermediate phase involving clustering, we do not involve heuristics, but we
have only considered the UPGMA clustering algorithm and the similarity coefficient of Gower, see
Section 4.1. Nevertheless, the consequence is the same as for applying heuristics; we cannot claim
optimality for our proposed solution(s).
Technology Diffusion – Limitations
We use Technology Diffusion to discount (i.e., reduce) the anticipated benefits of
implementing new technology / processes / etc., to reflect the true benefits during a transition period
where an organization learns how to utilize the changes to their full potential. The Technology Diffusion
operator (see Section 4.2.1) takes learning rate and initial skill levels as input. The learning rate is linked
to the speed with which the organization is able to acquire skills, while the initial skill level refers to the
amount of skills that are directly transferable to the new situation.
The learning rate and initial skill levels are not trivial to estimate, and we have used heuristics
in this research based on comparing the situation at hand with a known benchmark situation in terms of
the time it takes to reach a certain level of skills. Further, we have only considered Technology Diffusion
as given in (Silverberg, Dosi et al. 1988; Silverberg 1991), and hence, there may be other and better ways
of modeling learning for the purpose of evaluating the true benefits of changing to new processes. Thus,
optimality cannot be claimed.
c-DSP – Limitations
We use the compromise DSP as a construct to organize our multi-objective model. Solving a
multi-objective model implies finding some sort of compromise between the various objectives. To help
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find a compromise that comes closest to satisfying all the goals, we use scenarios that are based on non-
formalized heuristics. Hence, a solution found by one designer may not be the same as the solution found
by another, everything else being equal, i.e., the input to the method is person dependent, which affects
repeatability.
Further, we have not considered alternative ways to organize and solve our model. Hence, we
cannot claim optimality in terms of the solving correctness nor the solving speed. The example problem
and the case study represent discrete ‘optimization’ problems and are small enough to allow enumeration.
Hence, we have not solved these problems by means of an optimization routine, which a bigger problem
may require. In such a situation, we do not know how the compromise DSP would work, especially if we
have to use DSIDES, the computer infrastructure in which the compromise DSP normally is solved.
The HPPRM Framework– Limitations
Being an integrator of the previously elaborated constructs, the major limitation to the HPPRM
in its present state is repeatability, stemming from the use of non-formalized heuristics. However, we try
to alleviate this lack of repeatability by giving detailed examples of our calculations in Appendix C.
Further, the lack of comparison of alternative constructs implies that optimality cannot be claimed, which
makes the HPPRM a non-rigorous framework for realizing Hierarchical Product Platforms. However, we
believe that rather having a solution that is optimal for a short time, if ever, we hope our solutions are
robust and applicable as the world is changing, and when no longer applicable, that they can by adapted to
the new situations in an affordable way. To say it with Robin Cooper (the father of Activity Based
Costing); we prefer the solution to be “approximately right rather than exactly wrong.”
When it comes to comparison of alternatives, we believe there is a right time for everything.
The scope in this research has been firstly to identify what kind of products we should be seeking to
facilitate reuse in a marginal field context (i.e., product platforms and product families). Secondly, to
identify how to realize the identified products (i.e., the evolutionary approach). Thirdly, to develop a
framework to facilitate the right realization of the right products (i.e., the HPPRM). Hence, the issue of
comparing the initially chosen constructs to other alternatives, is viewed as part of the next phase –
continuous improvement by changing the process.
8.3.2 The HPPRM – Its Robustness
The HPPRM is based on some principles, namely, clustering of existing data, modeling of
alternative processes, and solving based on the compromise DSP construct. What if we for some reasons
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cannot use one or more of these principles; will the HPPRM still hold as a framework? We answer this
question by first looking at the clustering.
Clustering is a means of identifying a potential for standardization. As the pool of items to
compare increases, and as the characters for which they are to be compared increases, the need for
clustering also increases. However, if there are other ways of identifying / quantifying similarities in order
to identify a potential for standardization, these may be interchanged with clustering at any time.
Evaluating alternative processes is part of increasing the ‘adaptiveness’ of an organization.
This is a preferred but not a crucial task. What is crucial, however, is the ability to link proposed
standardization schemes to cost and schedule impacts, so as to evaluate their goodness’. If this
information is not readily available, or if this information cannot be estimated, the usefulness of this
approach becomes very limited. The reason why is that the HPPRM rests on the very assumption that
standardization (i.e., reduce the number of options) will improve cost and schedule, while compromising
operational performance. Hence, we would like to find the right compromise, and without any means of
comparing benefits with drawbacks, there is little point in doing this exercise.
The compromise DSP construct is used to organize the problem in order to prepare it for
solution, i.e., organization and preparation for solving is the main issue. Hence, any construct that can
facilitate this can be used in the HPPRM framework with the right amount of adjustments. In this context,
the solution we seek is a Hierarchical Product Platform, i.e., the variables we want to FIND are the level
of standardization at each assembly level and the processes that gives he best combination of cost,
schedule and operational performance. If we for some reason want another solution, this is easily adjusted
in the FIND and he MINIMIZE part of the compromise DSP. Based on this we assert that the HPPRM
framework is quite robust when it comes to accommodating changes and / or alternative constructs.
8.3.3 The HPPRM – Limitations to the Validation Process
In Section 8.2 we have validated the HPPRM framework by means of the validation square
process. In this process, the assumption that has the weakest base is the Empirical Performance Validity
(the usefulness). The reason why, is that it is based on our subjective estimates of benefits and operational
scenarios. In order to alleviate this situation we have used the available information to establish upper and
lower limits for what is possible, and have tried to operate conservatively between these limits to make
sure we are not painting a too optimistic picture. In that respect, we see that standardization improves
schedule and increase initial CAPEX, as would be expected. However, we see that downstream
conversions are where the true benefits take place, as would be expected too. (This is confirmed by the
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Lockheed strategy for the C-130 Hercules). Hence, being the weakest link in the validation process, it is
still strong enough to support the overall validity.
8.3.4 The HPPRM – Limitations to Implementation
The HPPRM is developed for one particular industry, namely, the offshore oil and gas industry,
and we now estimate what it will take to implement this framework in this very industry. Firstly, the
information to be clustered has to be available in some, way, shape or form. The level of readiness will
vary, and this will impact the usefulness of clustering in terms of saving time and money to reduce the
combinatorial problem. In this research, the information has been taken off of drawings and manually put
into a database. We believe that as design increases the usage of centralized databases, it should not be too
difficult to get hold of the raw data from which aggregated characteristics can be derived.
If clustering is chosen to identify potentials for standardization, we recommend using a
commercial software package. From such software one gets all kinds of information about the goodness of
the clustering itself, and normally, different similarity coefficients are available to choose from. Hence, as
long as the data is available, we don’t see a big problem in getting it clustered.
Evaluating the clusters require experienced people, that can identify which parts are not
compatible for standardization, e.g., ship side and double bottom as discussed in Section 6.6.7. This
assumption is valid in the case of Kvaerner, but may not be valid in other cases. However, analyzing a
portfolio of existing designs indicates that there is. Over time, the expertise held by the experienced
persons can be transformed into formalized heuristics and computerized, increasing the automation level.
Regarding the latter, estimating learning rates and initial skill levels is a challenge, and will
constitute a problem that has to be addressed. The important thing, however, is that we advocate to
continuously look for better ways of executing a project. If alternatives are proposed, the effect of
implementing them should get attention. Furthermore, by demonstrating that the learning rate has an
impact, we hope to emphasize that design is truly human-centered, and that continuous learning at the
individual level may be the single most important thing that can improve an organization’s performance.
In addition, by demonstrating that the initial skill levels also has a substantial impact, we hope to
encourage small and frequent steps rather than few and large ones, i.e., we advocate evolution over
revolution.
Regarding modeling and solving of problems in industry, this does not constitute a dramatic
departure from existing practices. The type of problem may be different, and the input information may
have to be generated, hence, consuming resources. Further, the solving scheme may not have an adequate
infrastructure (discrete optimization problem), and the interpretation of the results may have to be learnt.
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What is important, however, is that if a company finds is worth while to pursue this strategy, they may do
so without having to dramatically change their ways – it pretty much boils down to believing in the
benefits.
Finally, the HPPRM is not to be constantly applied, but at certain points in time where the
product portfolio proliferates due to introduction of new family members and / or sub-systems addressing
completely new applications, etc. In these instances, Path-Dependence is still applicable and the task
becomes to look at the new items and compare them to the standardized ones.
Based on this, we are ready to recommend some avenues for future work that in our opinion
will improve this framework.
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8.4 RECOMMENDATIONS –
AVENUES FOR FUTURE WORK
Having critically evaluated the research presented in this dissertation, our objective in this
section is to identify some fruitful ways of expanding this work. Since this research is conducted in an
academic setting based on an industrial problem, we see the road forking when it comes to future
research. One avenue goes into industry dealing with implementation and further validation of our
research, and one goes into academia dealing with further refinement of domain independent issues risen
by our research, see Figure 8-8. Hence, in Section 8.4.1 and 8.4.2 we examine the industrial and academic
avenues respectively.
8.4.1 Industrializing the HPPRM – the Industrial Avenue
Further validation of the HPPRM framework is linked to a successful industrial
implementation; first in one industry, then in other industries. However, we only make recommendations
regarding how to implement the HPPRM in the offshore oil and gas industry. We still assume that the
objective is to find the level of standardization and the corresponding process(es) that gives the best
combination of cost, schedule and operational performance. In this context
§ we recommend to revisit what to compare for similarities; there might be something more
promising than plates, stiffeners, girders, etc. For example, maybe topside is more interesting
from a standardization perspective than the hull.
§ Having established what to compare, we recommend to look at how to make the required input
readily available. This is directly affecting how to design and how to document the design.
§ Having clustered the input, we recommend to look at meaningful interpretations of the
clustered data from an industrial perspective. This should be linked to clustering research in
academia, especially to the formalization of how to construct taxa, see Section 8.4.2.
§ Regarding process partitioning, we recommend to identify which parts of the realization
process(es) are more interesting from an improvement perspective. This should be linked to
research regarding how to represent process partitioning in academia, see Section 8.4.2.
§ Regarding the standardization itself, we recommend to formalize a set of heuristics in order to
comply with ISO 9000 requirements regarding tractability of design decisions.
§ Regarding modeling, we recommend evaluating the availability of required information. If not
readily available we propose to change either the modeling or the performance variables. This
should be linked to research regarding model representations in academia, see Section 8.4.2.
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§ Regarding solving, we recommend to research what scenarios represent our customers best;
what objective function(s) addresses the customer requirements best; and what solutions
(robust / optimized) gives the best overall economy. This should be linked to research in
academia regarding solving algorithms, see Section 8.4.2.
THE HPPRM FRAMEWORK --
BASIS FOR SUGGESTING
FUTURE RESEARCH
Establish
Scenarios
Establish
Scenarios
THE ACADEMIC
RESEARCH AVENUE
(domain independent)
THE INDUSTRIAL
RESEARCH AVENUE
(domain dependent)
What to standardize
Information availability
What to partition
Info availabilityMetrics for evaluation
What to model
Info availabilityMetrics for evaluation
Mapping of customers
- weighting schemes
- operational scenarios
Decision criteria
- robust / optimized
How to cluster
- similarity coefficients
- clustering algorithms
- cluster representation
- construction of taxa
How to partition
- division criteria- metrics
How to model:
- cost/time/performance- learning
How to solve- discrete problems
- integer problems
Research validation
Metrics for evaluation
What to solve for - objective functions
Formalize heuristics
Gather DataGather Data
Standardize
Designs
Standardize
Designs
Decide on HPPDecide on HPP
Solve for eachScenario
Solve for each
Scenario
PartitionProcesses
Partition
Processes
Model
Relationships
Model
Relationships
Cluster DataCluster Data
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Figure 8-8
The Research Avenues Stemming from the HPPRM Framework
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8.4.2 Improving the HPPRM Constructs – the Academic Avenue
Having presented some recommendations regarding how to implement the HPPRM in the
offshore oil and gas industry, we now present the corresponding domain independent research aspects. All
of these aspects should be researched in parallel with research in industry in order harmonize the
WHAT’s and the HOW’s regarding the HPPRM framework. Based on this we elaborate on some of the
generalized concepts stemming from the HPPRM framework, see Figure 8-8 and Section 8.4.1.
Clustering – How to Improve the Identification of Standardization Potentials
Clustering is used to identify potentials for standardization by quantifying similarities. In our
research we have only considered the UPGMA clustering algorithm, the similarity coefficient of Gower
and the dendrogram representation, see Section 4.1. We recommend to evaluate whether other alternatives
are better suited for the purpose of identifying potentials for standardization, i.e., to evaluate which
alternatives are better for which situations.
Having a clustering, the next thing is construction of taxa. In our research we did this by trial
and error, applying our experience to evaluate when a good partitioning appeared. We recommend to look
into how to formalize a set of heuristics in order to computerize this process.
Process Partitioning – How to Represent a Process
Process partitioning is introduced to identify where the process can be improved in general,
and where standardization creates new opportunities for process improvements in particular. In our
research we partition the process along a timeline, i.e., design, fabrication, installation, operation and
maintenance, etc. From the perspective of improving the processes, there might be other partition schemes
and we recommend looking into this. On the same token, metrics for evaluating how well a partitioning
suits a given purpose also needs attention, and we recommend this as a future research area as well.
Modeling – Revealing the Performance of the Proposed Standardization Schemes
The purpose of modeling is to investigate the impact of standardization on cost, schedule and
operational performance. In this research, we estimate deviations from a base-case for the various
standardization schemes. However, this can only be done where detailed accounts for a base case exists,
an assumption that rarely holds in academia. Hence, we recommend to look for other indicators that can
be used to quantify how standardized systems compare to non-standardized systems in terms of cost, time
and operational performance.
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In particular, we recommend to look at learning within an organization, not only from a
process change perspective, but from a more general adapt-to-change perspective. In this respect, we
recommend to look at ways of estimating learning rates and initial skill levels; what organizational
characteristics are good indicators of learning rate, and what are good indicators of how much can be
leveraged from current processes to new processes.
Solving – Arriving at Acceptable Solutions
The purpose of solving is to find the set of free variables that give the best performance for the
system as described by an objective function. In this research, we have used the compromise DSP
construct to facilitate solution, and we have solved by enumeration for both the example problem and the
case study. However, we foresee situations where a search approach may be more appropriate, and we
recommend further research regarding implementation of search algorithms into the HPPRM. In this
respect, gradient based search does not seem too promising considering the nature of the discrete problem.
Hence, we have indicated Genetic Algorithms or the Foraging ALP as given in (Lewis 1996) as
promising starting points.
Validation – Supporting the Decisions
The purpose of validation is to build confidence that we make the right decisions, whether it is
final decision on a standardization scheme or on implementing alternative processes. In this research, we
have introduced the validation square, but the final step requires a ‘leap of faith’. We recommend to look
into how this leap can be made even shorter, i.e., how can we improve documentation of usefulness with
respect to a purpose. We have suggested documentation by means of example problems and case studies,
however, in academia example problems and / or case studies often become hypothetical and / or trivial.
These potential avenues for further research are just a sample of the realm of topics waiting to
be addressed. It is our hope that at least some of these topics are indeed taken on by researcher’s to come,
so that this work may live on. Based on this we proceed to give a concluding remark in Section 8.5 to sum
up the whole ‘shebang’.
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8.5 CONCLUDING REMARKS
Before we conclude we look to Bob Mandel’s words:
“Every Problem Was Once A Solut ion To A Previous Problem ”
- Bob Mandel
We certainly hope that the HPPRM is not an end in itself, but a stepping stone for future
research work in many fields of engineering – that we have created future problems for future researchers.
We belive that the evolutionary approach shows prospects of providing an overall perspective on design
that can help designers from different disiciplienes come together to ‘co-evolve’ products rather than sub-
optimizing them.
With this we conclude this dissertation to the words of Krishnamurti:
“The wor ld wi l l change only w hen we have changed ourse lves and
– mo st signi f icant ly – abandon ed our resis tance to change” Krishnamurti
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Silverberg, G., G. Dosi and L. Orsenigo (1988). “Innovation, diversity, and diffusion: a self-organisation
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