© 2004 Hewlett-Packard Development Company, L.P. The information contained herein is subject to change without notice

HP UniversityProduct Architecture

Xavier Bruch & Elizabeth Zapata

07 March, 2008 2

Index

1) What is a product architecture ?

2) Architecture stepsa)Customer needsb)Translation to product specificationsc)Functional analysis and definition of “basic” problemsd)Creation of solution principles for the “basic”

problemse)Selection of evaluation criteriaf) Synthesis of primary conceptsg)Evaluation of primary concepts for further

developmneth)Design, architecture, analysis and improvement of

main concept.

07 March, 2008 3

Architecture definition

•“The architecture of a product is the scheme by which the functional elements of the product are arranged into physical chunks and by which the chunks interact”*−Includes the definition of energy (all types), data/signals, geometrical and material interfaces

• GEMS: geometry, energy, materials, signal

−Includes defining the coupling & cohesion of elements

−Includes the definition of the level and type of Modularity

* from Product Design & Development, Ullrich and Eppinger, 2nd edition, McGraw-Hill, Inc.2000

1

07 March, 2008 4

Types of architecture

By definition all products have an architecture (functions, mapping to physical chunks and interactions)− The difference is having implicit or explicit architecture− Explicit architecture: one developed for a family of products and/or a product platform before detailed design started on 1st product

1

07 March, 2008 5

Types of architecture:deployment into products

− A family of products is one architecture that simultaneously fits the needs of several products launched in a short time window; it minimizes the need for multiple designs

− A platform is an architecture that will enable evolution of a product line as market demands changes; it minimizes the need for redesign, but requires projections to the future than are not easy to make

− We plan to develop an architecture for the copiers that is both a family AND a platform

1

07 March, 2008 6

Product Architecture Team

• MULTIDISCIPLINARY team with experience is a MUST: need to have enough knowledge in the following design areas:− Firmware & Software− Electronic and communication Engineering, − Mechanical Engineering, − Writing system engineers,− Manufacturing, assembly and packaging engineering,− Supply chain,− Marketing.− Customer experience & Usability

1

07 March, 2008 7

Customer Needs

• Phase Objective: Identify the customer, the user and the whole spectrum of needs this system is intended to fulfill.

• A team effort is best suited for this step, in which a multi-disciplinary view will expose all required information.

• The tools serving this activity are market researches, customer /user interviews and focus groups.

2a

07 March, 2008 8

Case Study – Customer Needs

USE CASES - PROBLEMS TO

SOLVE

Print with nice and realistic colors with photo paper

Sharp monochrome and color lines to show small details

Get quickly one draft of the working drawing

Can print overnight without intervention (unnatendness)

High uptime - works reliably

Use cheap paper for drafts, coated papers for final and

photo papers for renders

Store the output

Easy to use and quiet

Fit in my environment

Connectivity Access printer from many workstations

Affordable cost

Cost per copy

Safe operation Meet safety and international standards

USER REQUIREMENT

Image Quality

Productivity

Media flexibility

Easy of use

Operating costs

Print a nice render image to bid for the

office building project.

Prints a draft of the drawing to review

content.

Prints N copies of the whole project for

constructor companies to bid.

2a

The information shown here is just an example that might not be the best or the real ones

07 March, 2008 9

Translation to product specs

• Phase Objective: Identify a list of product specifications from most important to less that impacts the user requirements.

• Quality Function Deployment (QFD) can be used. They translate the Voice of Customer into the system specification.

• The QFD outputs are the target values for the system characteristics.

CASE STUDY – Exercise 1 – NEW PLATFOMR LARGE FORMAT PRINTER FOR THE TECHNICAL MARKET (Architect, Engineers, …)

TRANSFORM USER NEEDS TO PRODUCT SPECS

2b

07 March, 2008 10

Customer needs to product specs

HOUSE OF QUALITY

Perc

eiv

ed IQ

Colo

r gam

ut

Image

Dura

bility

Dra

ft p

rint tim

e

Multic

opy p

rint

tim

e

MPB

I

Equip

ment

cost

Ink u

sage p

er

print

Maxim

um

print

wid

th

Paper lo

ad

access

Basket/Bin

capacity

Connectivity

capacity

IMP

OR

TAN

CE

Print with nice and realistic colors with photo

paper9 9 3 3 1 3 3 4

Sharp monochrome and color lines to show

small details9 3 3 9 3 3 3 5

Get quickly one draft of the working drawing 3 1 1 9 3 1 3 3 3 9 5

Can print overnight without intervention

(unnatendness)9 9 3 3 9 9 4

High uptime - works reliably 9 9 9 3 9 4

Use cheap paper for drafts, coated papers for

final and photo papers for renders3 3 3 9 9 3 9 9 3 4

Store the output 3 9 9 3 9 2

Easy to use and quiet 9 9 3 9 3

Fit in my environment 1 9 9 9 2

Access printer from many workstations 3 1 9 9 3

Affordable cost 9 3 3 9 3 9 9 9 3 1 9 2

Cost per copy 1 1 3 9 1 1

Meet safety and international standards 3 3 3 3 3 5

TOTAL IMPORTANCE 133 75 68 159 159 131 197 55 148 99 98 177 1499

RELATIVE IMPORTANCE 9% 5% 5% 11% 11% 9% 13% 4% 10% 7% 7% 12%

RANK 6 10 12 3 4 7 1 11 5 8 9 2

2b

07 March, 2008 11

Product Specs

W

TR

AD

E O

FF'S

REFER

EN

CE

PR

OD

UC

T

TH

RES

HO

LD

GO

AL

A Equipment cost 13% 1000 1000 700

B Connectivity capacity 12% A 200 Mpixels/sec 375 300

C Draft print time 11% A,B 35 sec 25 30

D Multicopy print time 11% B 60 / hour 80 70

E Maximum print width 10% A 36 " 42 36

F Perceived IQ 9% A,C DJ 1100 DJ1100 >DJ1100

G MPBI 9% A,B 800 900 1100

H Paper load access 7% A Back Front Front

I Basket/Bin capacity 7% D 30 40 60

J Color gamut 5% F 82% pantone 82% 85%

K Ink usage per print 5% F 0.5 cc 0.5 0.4

L Image Durability 4% F DJ 1100 DJ1100 >DJ1100

PRODUCT SPEC

2b

The information shown here is just an example that might not be the best or the real ones

07 March, 2008 12

Functional analysis and definition of “basic” problems

• In this step, the tools of abstraction enable a deeper and more thorough understanding of the nature of the problem.

• The common tools are functional analysis, flow charts or block diagrams.

• In addition, basic quantitative analyses, modeling and logical evaluations are performed during this step.

• A "basic problems" list is produced. These problems are to be solved by the new system.

2c

07 March, 2008 13

List of basic problems to solve

We call these basic problems: USER SCENARIOS

• Install printer in less than 1 hour.

• Print a nice render image to bid for the office building project.

• Prints a draft to review content.

• Prints N copies of the whole project for constructor companies to bid unatended.

CASE STUDY – Exercise 2 – NEW PLATFOMR LARGE FORMAT PRINTER FOR THE TECHNICAL MARKET (Architect, Engineers, …)

FUNCTIONS NEEDED TO SOLVE “BASIC PROBLEMS”

2c

07 March, 2008 14

Color pipeline

Halftone Measure & adjust

Media path

UI

Driver, appl int

Digital pipeline

Printhead

I/O

WS pipeline

Media/ink

Drying, heating

Languajes Pen Drive

Pick & load

Ink delivery

Scan axis

Waste

Finish

Power & safety

Service PH

Structure Look & feel

Control

Printer Architecture: Functional Blocks

Geometry

Energy

Material

Signal

Control

GEMS MODEL

2c

07 March, 2008 15

Digital Pipeline Formatter Digital Pipeline Engine

Backup: Formatter & Engine boundaries

Ink/Media

WS PipelineColor Pipeline

CPUIO

Storage

Scaling& Image

Processing

DigitalArchitecture

ColorMapping & Separation

HalftoningHalftone

Ops

CompressionDecompression

Masking

Alignment

Mech Ctr& Sensors

Engine FWCPU

Carriage Interface

Etc,. . .

Languages& Wkflows

2c

07 March, 2008 16

Printer Architecture – Functional blocks - IR&D SECTION FUNCTION OBJECTIVE

Print from driver Create Image File to print (Windows, MAC)

I/O Transmit, Direct Connectivity & Networking

Languages & Job Mgmt Render, PDL, JPEG, …

Printer administration & user interactionLocal printer user interaction, alerts and status, …FP, EWS, SNMP,

Color Workflows Color SW engine, profiling, certifications, …

Open Systems Enable third party applications, RIP's.

Digital Pipeline (ASIC's) Process data from raster to dot, implement ASIC, interfaces with print mechs & sensors

Formatter & engine controlDigital architecture to provide processing power, storage and interfaces (IO, engine

internal)

Power Provide power to components

Low level and data control Control of data and engine components

WS Pipeline (Color, HT, Printmodes) Optimize image, Pass ready bitmap (mask, error hiding, ...)

Ink & media (form image) Form image on media, heating in printzone

IQ correct Adjust system (auto), Troubleshoot (user, service)

Service Printhead Maintain Printhead health.

Waste Management Aerosol, wasted ink management.

Scan axis Position PH in Y&Z, PPS control, PPS adjustment, ...

Pen Drive Drive Printhead (power, data, thermal)

Ink Delivery System Deliver ink from supply to printhead, ink gauge

COLOR &

SOLUTIONS

SECTION

DIGITAL

MANAGEMENT

SECTION

PRINTING

SYSTEMS

2c

07 March, 2008 17

Printer Architecture – Functional blocks - II

R&D SECTION FUNCTION OBJECTIVE

Pick and load Pick and load media. Skew control.

Media Control Keep paper flat in print zone

Finish (cutter) Finish job (cut, laminate, store)

Drying and heating Dry media

Media Advance Position paper accurately in X

Measure Measure system state (nozzle health, color, …). HW sensors and digital signal process

Structure & Layout Position HW components accurately.

Look & Feel Provides a pleasant design. HW user interaction design

TIJ TEAM Printhead (eject drop) Eject drop. Good directionality, drop volume, …

Safety Meet regulatory and safety standards

SW Quality FW and SW quality and stability

Reliability & Performance Printing performance (speed) and overall system reliabiltiy

Customer interactions & ID Industrial Design and Human Factors (usability)

CUTOMER

EXPERIENCE

SECTION

MEDIA

SYSTEMS &

STRUCTURE

SECTION

2c

07 March, 2008 18

Creation of solution principles for basic scenarios

• In this step, the team uses creative tools to generate solution principles to each scenario

• Brainstorming, TRIZ and design manuals are used to create verbal or visual solution.

• This step is could be summarized using a morphological table [Zwicky, 1976] that contains a row of solution principles to each basic problem.

2d

CASE STUDY – Exercise 3 – Find possible options for basic functions required to solve the scenario: “Prints N copies of the whole project “

07 March, 2008 19

Example of morphological table with possible solutions for each function

2d

PRINT FROM DRIVER - WIN DRIVER - MAC RIP

I/O LAN USB

LANGUAGES RASTER HPGL2 PS

FORMATER PROCESSOR 1 + HD PROCESSOR 2 DISKLESS

DIGITAL PIPELINE ASIC 1 ASIC 2 SW

WS PIPELINE 1 PASS - 35 IPS 1 PASS - 50 IPS2 PASS BIDIR 35 IPS

NON UNIFORM ADVANCE

PRINTHEAD 0.85 INCH - 6 COLORS 1.7 INCH - 4 COLORS 0.85 INCH - 6 COLORS

SERVICE PRINTHEAD FIXED SERVICE REPLACEABLE USER REPLACEABLE

SCAN AXIS FIXED PPS VARIABLE PPS

INK DELIVERY ON AXIS OFF AXIS

PICK AND LOAD ROLL IN THE BACK ROLL IN THE FRONT

MEDIA CONTROL VACUUM STARWHEEL SYSTEM MIXED

MEDIA ADVANCERUBBER ROLLER +

ANALOG ENCODER

RUBBER ROLLER +

MEDIA ADVANCE SENSOR

GRIT ROLLER +

ANALOG ENCODER

The information shown here is just an example that might not be the best or the real ones

07 March, 2008 20

Selection of evaluation criteria

• Evaluation criteria are the important system characteristics and their target values, stated in the QFD step. Criteria can be organized into two groups:

• Group A is used for the first evaluation phase and includes relatively few (but important) criteria that can be used without any further analysis. This criteria group must cover at least 70% of the customer satisfaction according to their rating.

• Group B includes more criteria and covers at least 95% of the customer satisfaction. These criteria are used for the final concept selection phase. These criteria may require further analysis of the alternative concepts.

• In group B we MUST include company internal requirements (the “bilities”): manufacturability, serviceability, ease of use and installation, reliability.

2e

07 March, 2008 21

Evaluation Criteria ExampleA B TARGET VALUE

1 Technological knowledge gaps Y Y

2 Equipment cost Y Y 700

3 Connectivity capacity Y Y 300

4 Draft print time Y 30

5 Multicopy print time Y Y 70

6 Maximum print width Y Y 36

7 Perceived IQ Y Y >DJ1100

8 MPBI (reliability) Y 1100

9 Paper load access Y Front

10 Basket/Bin capacity Y 60

11 Color gamut Y 0,85

12 Ink usage per print Y 0.4

13 Image Durability Y >DJ1100

14 Manufacturability Y

15 Usability (Ease of Use) Y Y >=DJ1100

16 Installation time Y

17 Serviceabiltiy Y

18 Industrial Design Y

CRITERIA

2e

The information shown here is just an example that might not be the best or the real ones

07 March, 2008 22

Synthesis of primary concepts

• This step produces whole concepts out of single solutions.

• The visualization of the concept can be using a morphological table. A concept is a combination of one solution principle from each row of the morphological table. Many solutions can be combined, but only a few actually form a feasible set.

• Among those, the ones with the best potential must be selected.

2f

CASE STUDY – Exercise 4 – Find feasible concepts from basic function solutions to solve the scenario: “Prints N copies of the whole project “

07 March, 2008 23

Example of morphological table with 2 possible concepts

PRINT FROM DRIVER - WIN DRIVER - MAC RIP

I/O LAN USB

LANGUAGES RASTER HPGL2 PS

FORMATER PROCESSOR 1 + HD PROCESSOR 2 DISKLESS

DIGITAL PIPELINE ASIC 1 ASIC 2 SW

WS PIPELINE 1 PASS - 35 IPS 1 PASS - 50 IPS2 PASS BIDIR 35 IPS

NON UNIFORM ADVANCE

PRINTHEAD 0.85 INCH - 6 COLORS 1.7 INCH - 4 COLORS 0.85 INCH - 6 COLORS

SERVICE PRINTHEAD FIXED SERVICE REPLACEABLE USER REPLACEABLE

SCAN AXIS FIXED PPS VARIABLE PPS

INK DELIVERY ON AXIS OFF AXIS

PICK AND LOAD ROLL IN THE BACK ROLL IN THE FRONT

MEDIA CONTROL VACUUM STARWHEEL SYSTEM MIXED

MEDIA ADVANCERUBBER ROLLER +

ANALOG ENCODER

RUBBER ROLLER +

MEDIA ADVANCE SENSOR

GRIT ROLLER +

ANALOG ENCODER

OPTION 1: HIGH PERFORMANCE

OPTION 2: LOW COST

2f

The information shown here is just an example that might not be the best or the real ones

07 March, 2008 24

Evaluation of primary concepts for further analysis

• The concepts created in the former step can be evaluated using KT analysis tool or just a Pugh table [Pugh, 1981] and the group A variables .

• The evaluation process yields a few main concepts for further development.

• In addition, new improved concepts can be generated at this step by merging and synthesizing ideas from other concepts or by improving some disadvantages of the most promising concepts.

2g

07 March, 2008 25

Example of a Pugh Table to compare concepts.

TARGET

VALUE

LOW COST

(Reference)

HIGH

PERFORMANCE

MID

PERFORMANCEMAX IQ

1 Technological knowledge gaps 0 -1 -1 1

2 Equipment cost 700 0 -1 0 -1

3 Connectivity capacity 300 0 1 1 0

5 Multicopy print time 70 0 1 0 -1

6 Maximum print width 36 0 1 0 -1

7 Perceived IQ >DJ1100 0 0 0 1

15 Usability (Ease of Use) >=DJ1100 0 0 1 -1

0 1 1 -2

CRITERIA

2g

The information shown here is just an example that might not be the best or the real ones

07 March, 2008 26

Design, architecture, analysis and improvement of main concept

• In this step the team members further developed the main concepts for the final selection.

• The first draft system design is prepared, together with basic form and architecture.

• Conceptual decisions are made concerning production, materials, technologies, storage, handling, logistic support, etc.

• In addition, some analyses are performed, upon consulting group B of the evaluation criteria (step 2e).

• For each criterion, a quantitative or semi-quantitative evaluation is required.

2h

07 March, 2008 27

Conceptual Failures Mode Analysis

• CFMA is based on functions and specific organizational experience rather than on components and detailed design.

• The purpose of this tool is to prevent failures from reaching the customer.

• The analysis detects the earliest step in the design process when countermeasures can be taken to prevent the failure.

• Three parameters were defined: − S (Severity), − F (Frequency of occurrence) and − D (Detection capability).

• For each function, some significant failure modes and their results should be quantified along with possible actions to reduce S, F or improve D.

• You can also show the potential improvement of the preventive action in that table.

2h