The 9th Intemational Conference on Computer Supported Cooperative Work in Design Proceedings
Kiowledge Based Distributed Product Design and Manufacturing
mgo Mendikoa, Dr.Mlkel Sorli, Jose I.Barbero, Ana Carrill0
Foundation LABEIN Spain
mendikoaalabein. a,sorIi@iilabein.es, iosemlabein.es, ana@Yabeia.es
Abstract
Currently most of the design and manufacturing
management systems of an enterprise deal with local
and stafic database systems and do not consider all the
involved pro&ct/process knowledge from the whole
value chain. The approach presented in this paper
mainly focus on those techniques that can support multi
dishibuted clients and provide a lfynamic database
service. thus making possible a Qnamic distributed
design and manufacturing process. The core
application of the system presented manages the
diswibufed design and manufacturing process through
the internet between direrent reams. including the
management of all the relevant product knowledge for
design and manufacturingprocesses.
Keywords: Distributed Design-Manufacturing,
Dynamic Database, Knowledge Management, Internet.
I. Introduction
With globalisation, enterprises are strategically
distributing their design and manufacturing activities in
different regions to remain competitive. Therefore,
there is the need for a platform to facilitate the product
development and manufacturing requiring collaboration
among disparate parties in different geographic
locations to cost effectively win customers in a short
time. Cotlaboration is particularly vital for product
design since this upstream activity in the product life
cycle has a decisive impact on the success of the
particular product [l], [Z].
In addition, it is becoming more or less obvious that
it is not possible to l l f i l the new requirements solely
based on conventional CAD-CAE systems and the
present Internet facilities [3]. The current.Internet-based
systems show poor functionality and perfamame
compared to conventional standalone systems. New
infrastructure, toots, methods and knowledge are
needed. A distributed cooperative product design
capability [4] is therefore necessary, which is both a
managerial and a technical challenge.
New ways of working move ineluctably towards the
extended enterprise [ 5 ] , [6]. Extended enterprise
concept in parallel with the Concurrent Enterprising
679
looks for how to add value to the product by
incorporating to it knowledge and expertise coming
from all participants on the product value chain.
Manufacturers need to benefit fiom Extended
Enterprise techniques by involving all actors
throughout the very critical phase of productfprocess
development including suppliers, designers from
different sites and companies in a collaborative way of
work, production, servicing.
They will provide their own product knowledge to
enhance product development, and this knowledge
needs to be saved and managed. Loss of this knowledge
results in increased costs, longer time-to-market and
reduced quality of products and services. This new
paradigm implies a quite new scenario: knowledge
capturing and sharing, new forms of interrelationship
between companies and persons, etc.
As we know engineering design is a multi-
disciplined environment, a highly integrated and
integrating process. Designers deal with many
constraints to balance manufacturability and functional
objectives within a marketable product specification.
The designers must transcend their perceived view of
the world, to overcome the narrow boundaries of
specification, while exploiting specialised technical
problem solving skills and be open to external
information at all stages o f the design cycle. This
requires the integration and utilisation of information,
supplied from many sources both internal and extemal
and in many formats. The designs created by a
Knowledge Based Engineering (KBE)application have
a predictable structure, which contains individually
identifiable objects. This means that it is possible to
include additional rules, in the generative model, to
create alternative views to support a wide spectrum of
product development activities [7], [8j.
The noveIty of the approach here is to focus the
distributed product design and manufacturing on
product knowledge, which is not completely managed
today in the whole value chain, and which comes from
suppliers, customers and employees (and tacit or
informal knowledge generated by internal staff-)
involved in the development process. It represents the
next evolution of product information systems, taking
standards and practices forward to support co-operative
working and partnerships.
This paper presents a Knowledge based Distributed
Product Design and Manufacturing System developed
 The 9th International Conference on Computer Supported Cooperative Work in Design Proceedings
inside the Asia-Europe collaboration project Web-
Enabled Collaboration in Intelligent Design and
Manufacture. The system presented in this paper
manages the distributed design and manufacturing
process among different distributed teams over the
internet, including all the relevant knowledge for design
and manufacturing processes. A central Dynamic
Database residing in a server including all the
product/process knowledge of the value chain is
controlled by a local application performing all the
main Product Data Management features. The Dynamic
Database is accessible for the different teams during the
design and manufacturing process, thus making
possible a real collaborative work, being all the
necessary knowledge shared by the distributed teams.
2. System description
In this section the basic structure of the system
developed for distributed product design and
manufacturing is described, which includes Dynamic
Database, Product Data Management (PDM) and
Knowledge Based Engineering (KBE) modules.
It has been developed specifically for this project
and resides in a central Server, managing the Dynamic
Database (which includes the necessary knowledge,
such as design rules parameters), as well as main
Product Data Management features. The database is
based on MS Access for Windows and is accessible for
the different partners during the design and
manufacturing process.
Figure 1 shows the system basic structure. CAD and
CAM users interact with the server through the
Middleware. This server includes a software application
which performs the basic PDM features and interacts
with the Dynamic Database, residing in the server as
well, thus centralizing the design and manufacturing
process.
The Dynamic Database is linked to the KBE
modules, therefore including all the necessary
knowledge for product design and manufacturing, i.e.
the design rules, process parameters, etc. The basic
PDM features are imptemented in a software
application which performs the connection between
CAD and CAM users, as well as the KBE and Dynamic
Database for which it manages reading and writing
permissions. This central serve? contains all the
project information, i.e., every file related to the
product (geometry, process parameters, etc) and
external users can interact with it through this specific
PDM application.
There are specific KBE modules for specific part
families and production processes. Different KBE
modules are available for different kinds of parts and
production processes (such as forging, machining, etc.)
since different processes have different type of tules
related. The set of rules includes the necessary
680
knowledge for the complete design and manufacture
of the part.
On the other hand API applications are developed
for specific CAD users packages, so that design rules
can be automatically applied by the CAD users in their
local CAD system. The users select the remote KBE
module and with the correspondent AP1 wilI be able to
work within the local CAD package.
From the users point of view, the users CAD
includes a specific Graphical User Interface through
which relevant data can be introduced and visualised.
The Middleware includes the necessary tools in order to
ensure the correct communication and visualisation of
data. The technologies included in the Middleware are
based on COMA [9] for a collaborative environment,
X M L [lo] transmissions, Web services to use a specific
KBE module, or Applets of Java.
2.1 Distributed design and manufacturing
methodology
The distributed design and manufacturing basic
methodology is described in the following paragraphs.
Designers (CAD users) will interact with the main
PDM apptication in the Server, which interacts with the
Dynamic Database and KBE specific modules, both
residing in the Server. Therefore, CAD users will be
able to perform the design according to the design
rules previously defined based on manufacturing
criteria (among other possible criteria to be considered).
There is not direct interaction between CAD and CAM
users, but collaborative work among designers can be
performed through the central PDM in the server.
Once designers reach a design that fulfils the
rules, CAM users will be able to get from the central
store in the Server the geometry file (neutral formats are
used) corresponding to the final design. CAM users are
then able to generate the necessary CAM files from that
geometry, in order to check any possible manufacturing
problem. If problems arise, part geometry should be
modified, for which designers receive-the appropriate
notification fiom the Server. In some cases some design
rules could probably need modification, and the
correspondent D E module and the Dynamic Database
could undergo modification by an authorised user.
Geometry files will be reiated with the correspondent
CAh4 tiles in the PDM, and every update in any file
will be registered and co-ordinated by the PDM
application in the Server.
The manufacturing processes considered in this
prototype in terms of KBE modules and CAM files are
forging (for some specific families) as well as
machining with Parallel Kinematic Machine (PKM).
Further developments will include other manufacturing
processes.
 The 9th International Conference on Computer SupportedCooperative Work in Design Proceedings

developed, so that the CAD user can automatically

incorporate the manufacturing rules in the design.
Neutral formats are used as standard for geometry,
since the system is intended to be used by teams using
I different platforms and CAD systems. ,
I
I Later on during the project the system will be
I
I adapted to other CAD systems like Solid Edge or I-
DEAS (for both UNIX and Windows), developing their
correspondent APl applications.

2.2.3 CAM. PKM (Parallel Kinematic Machine) related

software is the main C A M system in this first
prototype. It works off-line (IocaI for the CAM user),
and checks if the product geometry fdfils the
manufacturing requirements. A short description of
PKM CAM operations is presented in section 3.

2.3 Modules developed

The main modules developed for this prototype are

the PDM application and the KBE modules for the
manufacturing processes considered, both residing in a
central Server.

2.3.1 Product Data Management (PDM). This

Figure 1. Structure of distributed product design
and manufacturing system
2.2 Software tools selected
The specific software tools used in this prototype are
based in MS Windows operating system. Later on
during the project other operating systems like UNIX or
LINUX will be considered in order to achieve a
multiplatform system.
2.2.1 Dynamic database. Dynamic Database will
contain the assembly, parts and related documents
information as well as the values of the design rules
parameters based on the specific manufacturing
process. Different manufacturing processes have
different manufacturing rules, so there are as many
databases as different processes considered. Reading or
writing permissions for external users are managed by
the PDM application in the Server.
The database software is based on MS Access,
where the design rules parameters values are
implemented through the PDM application. In
subsequent developments other systems like MySQL
will be used.
2.2.2 CAD. The CAD system selected for the f i s t
prototype is Solidworks for Microsoft .Windows, for
which the necessary API application has been
application performs the basic product data
management features and manages the KBE modules
and the Dynamic Database.
Modifications in the files and databases in the Server
are done hierarchically and controlled by this PDM
application, which has been specifically developed with
the specific features required in this project.
The main PDM features performed by the
application in the Server are the following:
Management of the classification of components
and documents. Documents are classified and
managed as components of an assembly.
Creation of new users and new projects and
subprojects related.
Management o f the information related to
documents, such as name, type of document,
project, description, current owner, state of
revision, date of last modification, current
configuration, documents related.
Files update and product lifecycle control,
considering different states for the documents
(design, manufacturing, pending revision,
obsolete, etc). The manager or an authorised
user is able to change the state of a document.
Management of documents ownership.
File access, reading and writing permissions for
external users with the knowledge database in
the server.
Figure 2 shows the graphic user interface developed,
where the information can be read and introduced by a
remote user. Some actions are not active for non-
administrator users, for these users the graphical user

681
 The 9th International Coufermce on Computer Supported Cooperative Work in Design Proceedings
interface will not even show the icons related to these
actions.
Figure 2. PDM Graphic user interface
Figure 3.Assembly information is stored in.a MIS
Access database
In figure 2, the left part of the screen (left panel)
shows the current project (if PDM is selected, & it is
by default) with the following structure: Assembly,
Sub-assembly, Part and Document. An assembly has a
C A D file associated and may be composed of different
sub-assemblies, each of one is in turn composed of
different parts. Every part has different files associated,
corresponding to geometry (CAD files, includmg a
neutral format), C A M files as well as any other file
containing information relevant to the design and
manufacturing process for that part.
When a document is selected in the left part o f the
screen by the user, the information related to that
document can be visualized in the right part of the
screen (right panel), selecting Document. In
addition, the information related to the part to which
that document is related can be seen selecting Parts
data, and finally the information related to the
assembly to which that part belongs can be seen
selecting Assembly data in that right panel.
682
PDM is linked to a MS Access database, like that
represented in figure 3, where all the relevant
information related to the assemblies, parts and
documents is stored. This database cannot be directly
seen by the user, whose only interaction with it is
through the PDM tool.
2.3.2 Knowledge Based Engineering W E ) . As it is
well known, Knowledge Based Engineering KBE is a
special type of Knowledge-Based Systems with a
particular focus on product engineering design and
downstream activities such as analysis and inspection,
manufacturing, cost estimation and even sales
engineering etc. It allows companies to capture and
reuse the knowledge and experience of their engineers,
together with manufacturing best practice, legislation,
costing, and other rules for the product development.
In this system prototype for distributed product
design and manufacturing, different modules are
developed for each process and for each part family, in
order to implement the specific design rules and process
parameters. These modules are implemented in
connection with the dynamic database where the design
rules parameters values are stored.
KBE modules basicaily consist of a set of files
containing all the information related to the product
design and manufacturing, as well as the graphical user
interfaces that alIow remote users accessing and
modifying the information. Parameters values are stored
in the dynamic database, and can be read or modified
by authorised users through the user interfaces
developed.
Designers can in this way get the parameters values
in order to apply the design rules in the product design.
These data will be automatically used inside the CAD
system through the appropriate MI application
deveIoped for that specific CAD package.
In the left panel of the PDM application, KBE tab
can be selected in order to access to productlprocess
knowledge (design rules, etc) as shown in figure 4,
where the graphical user interface is shown. It allows
an authorised external user to read or write the values
of some design rules parameters corresponding to a
typical forging process. These parameters are such as:
- flash land geometry,
- preform volume,
- drafiangles,
- convex radius,
 The 9th International Conference on Computer Supported Cooperative Work in Design Proceedings
Flgure 4. Design rules for a forging process
3. Case study
A real case study will be performed in order to show
a collaborative process for part design and
manufacturing between Europe and China. After
European partners have completed the design of an
indussial part, according to the requirements and
constraints imposed by the Parallel Kinematic Machine
(PKM) manufacturing process, it will be fabricated
using the P K M facilities located at Harbin Institute of
Technology (HIT) in China. The design process will
have been performed according to the manufacturing
specifications as well as the knowledge related to the
product that has to be taken into account as well.
PKM is a multi-axis and high-speed machining
process that can machine compIex surface with
accuracy. Figure 5 shows a picture of a PKM machine
that will be used in this case study.
The PKM CAM system resides in the manufacturer
and includes the necessary modules to get the NC file,
i.e. the Cutter path planning module, Interference
calibrating module, Cutter Path Simulating module, and
NC code generating module. The interference
calibration is done on the CAM user, but the
manufacturability assessment result is sent to the CAD
designers. CAM user sends the CAM files to PDM
server, and PDM manages the properties of the files
like files name, directory, creation date, creators
name, using eligibility, etc.
4. Conclusions
As stated in the introduction, distributed design and
manufacturing needs to be focused in product
knowledge, captured from the whole value chain
(designers, manufacturers, suppliers, customers, etc), no
matter how geographically dispersed they may be.
The application described above represents a step to
achieve this goal, making possible a collaborative
design process and manufacturing of a real part
683
between different working teams located in Europe and
China.
L*-.--.- . 3
Figure 5. PKM Machine (Courtesy of HIT)
5. Future work
Possible approaches for detecting product/process
problems are to be incorporated as part of the
collaborative design and manufacturing process.
Classical approaches related include topics such as
Statistical Approaches (Statistical Process Control,
Process monitoring methods, etc), Learning approaches
(neural networks), Problem solving methods, Ruled
based and Case based reasoning, Fuzzy Control or
FMEA, among others.
The inclusion of a methodology for failure causes
analysis and failure prediction in even not-yet-existing
systems will be considered by means of AFD
(Anticipatoy Failure Determination), which is based on
TRIZ methodology (Theory o f the Solution of
Inventive Problems) [ll]. The AFD System supports
these applications by providing a disciplined, rigorous
process by which the user can thoroughly analyse given
failure mechanisms, obtain an exhaustive set of
potential failure scenarios, develop inventive
sohtions to prevent, counteract, or minimise the impact
of the faiIure scenarios. The main objectives of this
methodology are: Analyse previous failures and be able
to understand how to invent such failures; Identify an
exhaustive list of potential failure scenarios as well as
any negative, harmful or undesired effects or
phenomenon; Transform the process of problem
analysis from asking why a failure occurred to how can
a failure be produced; Incorporate the full complement
of TRIZ operators to develop innovative solutions [12],
~31.
 The 9th Iatemational Conference on Computer Supported Cooperative Work inDesign Proceedings
Acknowledgement
Project Web-Enabled Collaboration in Intelligent
Design and Manufacture is funded by the European
Commission under the Europe-Asia collaboration
program (Project contract: ASVB7-301/3 152-
99/72553). The authors wish to acknowledge the
contribution of the consortium partners.
References
111 J. Yeol Lee, H. Kim, K. Kim A web-enabIed approach to
feature-based modelling in a distributed and collaborative
design environment. Concurrent Engineering Research and
Applications, 2001,9(1): 74-87.
[2] I. Horvith, J.S.M.Vergeest and 2.Rusak. Six ingredients
of collaborative virtual design environment, Internafiunal
Design Conterence, Dubrovnik, 2002.
[ 3 ] A. Chaudhari, V. Patil Future Trends in Collaborative
Product Data Management Systems. Tuta Consultancy
Services, 2002.
[4] M. Sorli, LA, Gutitrrez mew Paradigms in product
Development. EDC2002 (Engineering Design Conference).
London, July 2002.
IS] B. Konsynski: Strategic control in the extended
enterprise,IBMSysrems Journol, vol. 32, no. 1, pp. 11 1-145.
684
[6] D. Stockic, M. Sorli, L. Urosevic Product Knowledge
Management Support System for Dynamic Extended SMEs
Prague e-ZOO2 Conference (e-Business & e-Work). Prague,
November 2002.
[7] D. Su. Internet-Based Engineering. The Nottingham
Trent University,2000.
[SI C. Gilman, M. Aparicio, J. Barry, T.Dumial, H. Lam and
R. Ramnath Integration of design and manufacturing in a
virtual enterprise using enterprise rules, intelligent agents,
STEP and workflow. NIIIP S M R T consoriium.
[9] R. Ben-Natan. CORBA.A guide to the Common Object
Request Broker Architecture. McGraw Hill, 1995.
[IO] M. Storga, D.Pavliz, D. Marjanoviz XML-based Web
Service for Collaborative Product Data Management; 8th
International Conference on Concurrent Enierprising -
ICE2002; Centre for Concurrent Enterprising, University of
Nottingham; Nottingham; UK; 2002.; 405-412.
[ l l ] G. S. Altshuller, Creativity as an Exact Science.
httD://www.ideationtriiz.comi
[12] V. Mitrofanov,From Manufacturing Defect to Scientific
Discovery. St. Petersburg: TRIZ Association of St.
Petersburg, 1998.
[13] B. Zlotin and A. Zusman, An Integrated Operational
Knowledge Base (System of Operators) and the Innovation
Workbenchm System Software, 1992 (in Russian).