David O. Kazmer, P.E., Ph.D.
Specializing in plastic product design and polymer process development.

Plastic Product Design Research

Overview

The term "good" in design is fraught with subjectivity. Generally, a design should at least satisfy the needs of the customer at the lowest possible cost. Given different preferences of the customer regarding cost and quality, "good" designs can vary completely from a low cost Chery to a high cost Mercedes.

Past Advances

Robust Design

The term "robust" generally means that the design or process is insensitive to variation. A frequent measure of robustness is the process capability index, which is the ratio of the specification range to the observed variation. Our strategy for design is to first clarify customer's needs, then characterize the expected input variation, evaluate the value of the performance specifications, understand the functional relations between the decision variables and performance measures, estimate the expected output variation through moment matching or Monte Carlo methods, and ultimately derive a Pareto optimal set of solutions from which a preferred design may be selected. As shown in the following figure, the robustness of a design (as measured by combined yield) can generally be improved by increasing the cost (though we readily admit that the most significant gains are most frequently made through robust concept design!). 

More recently, we have explored the concept of design flexibility in the event of performance failure. This concept suggests that it may be better to choose a design that is lower cost and not so robust, but may be easily improved in the event of failure. Currently, we are working to systematize these concepts in product and process design tools.

Economics

Cost estimation plays a vital role in product and process development. The question should not be "can it be done?" but rather "should it be done?" The cost almost always plays a significant role in the answer.

In particular, our research related to cost estimation is directed to robust product design and process development. With respect to robust design, the optimization issue is determining the robustness to uncertainty (availability) as a function of increasing cost. In general, cost estimation is required on an application by application basis to ensure that an appropriate level of robustness is found. The following figure shows two designs with different levels of component integration. Our research has shown that the minimum cost and optimum level of component integration is a strong function of the process capability, and may not occur at total consolidation as implied by rules of Design for Manufacturing and Assembly.

Quality and Design for Six Sigma

With respect to process development, the optimization issue is determining the marginal cost as a function of the investment cost. In general, marginal cost can be decreased by increasing up-front investment. Cost estimation is required on an application by application basis to ensure that an appropriate level of process development is found. As shown in the following figure, there is a minimum cost of quality that may not occur at zero defect levels since the conformance costs are too high. It is our philosophy that the plateau around this minimum may be quite broad, and it is important for manufacturers to understand where they are on this figure and determine a proper balance.

Current Research

Cost Optimization

We are continuing our research related to cost estimation in the following areas: 1) low volume manufacturing using rapid prototyping methods such as fused deposition modeling, 2) low level estimation of injection mold tooling and processing costs; and 3) high level estimation of production costs with varying levels of automation. We plan on embodying this research in new cost estimation and optimization tools in the next few months.

Related Publications

  1. Irani, R. I., Kodiyalam, S., Kazmer, D. O., “Runner System Balancing for Injection Molds using Approximation Concepts and Numerical Optimization,” Proceeding from the 18th Annual ASME Design Automation Conference, 1992. 

  2. D. Kazmer, “Advanced Methods for Plastic Product Design and Process Control,” Toyota Motor and Suppliers Meeting, Lowell, MA, April 22, 2005.

  3. Roser, C. and D. O. Kazmer, “Defect Cost Analysis,” Plastics Failure Analysis and Prevention", J. Moalli Ed. , 2001.

  4. R. Karania and D. Kazmer, “Low Volume Plastics Manufacturing Strategies,” Submitted to ASME Journal of Mechanical Design.

  5. Kazmer, D., Lotti, C., Breta, R. E. S., Zhu, L., "Tuning and Control of Dimensional Consistency in Molded Products," Advances in Polymer Technology, v. 23, n. 3, Fall, 2004, p. 163-175.

  6. L. Zhu and D. O. Kazmer, “An Extended Simplex Method for Global Feasibility Evaluation,” Journal of Engineering Optimization, v. 35, n. 2, p. 165-176, 2003.

  7. D. Kazmer, D. Kapoor, C. Roser, L. Zhu, and D. Hatch, “Definition and Application of A Process Flexibility Index,” ASME Journal of Manufacturing Science, v. 125, p. 164-172, 2003.

  8. C. Roser, D. Kazmer, and J. Rinderle, “An Economic Design Change Method,” ASME Journal of Mechanical Design, v. 125, n. 2, p. 233-239, 2003.

  9. Zhu, L. and D. Kazmer, “A Performance-Based Representation for Engineering Design,” ASME Journal of Mechanical Design, v. 123, n. 4, p. 486-493, 2001. 

  10. H. Xu and D. Kazmer, “Tight Tolerance Thermoforming,” International Polymer Processing, v. 16, n. 2, p. 208-215, 2001.

  11. J. Reilly, M. Doyle, and D. O. Kazmer, “An Assessment of Dynamic Feed Control in Modular Tooling,” Journal of Injection Molding Technology, September, 2001, 5 (1), p. 52-61.

  12. A. Fagade and D. O. Kazmer, “Early Cost Estimation for Injection Molded Parts,” Journal of Injection Molding Technology, September, 2000, 4 (3), p. 97-106.

  13. Xu, H. and D. O. Kazmer, “Productivity Evaluation with a Stiffness-Based Ejection Criterion of Injection Molding,” Journal of Injection Molding Technology, 1999, 3 (4), p. 211-218.

  14. Kazmer, D.O. and C. Roser, “Evaluation of Product and Process Design Robustness,” Research in Engineering Design, 1999. 11 (1), p. 21-30.

  15. Kazmer, D.O. and D.S. Roe, “Exploiting Melt Compressibility to Achieve Improves Weld Line Strenths,” International Journal of Plastics, Rubber and Composites Processing, 1998. 27 (6), p. 272-278.

  16. Kazmer, D.O., “Best Practices for Injection Molding,” Journal of Injection Molding Technology, 1997. 1(1): p. 10-17.

  17. R. Karania and D. Kazmer, “Low Volume Plastics Manufacturing Strategies,” Submitted to Design for Manufacturing Symposium at the 2005 ASME International Mechanical Engineering Congress and Exposition..

  18. David O. Kazmer, "Wall Thickness Optimization In Molded Product Design," Proceedings of the 2005 Society of Plastics Engineers Annual Technical Conference, 2005.

  19. David O. Kazmer and Mahesh Munavallia, "Design and Performance Analysis Of A Self-Regulating Melt Pressure Valve," Proceedings of the 2005 Society of Plastics Engineers Annual Technical Conference, 2005.

  20. D. Kazmer and L. Zhu, "An Integrated Performance Modeling System," Design for Manufacturing Symposium at the 2004 International Mechanical Engineering Congress, Anaheim, CA, 2004.

  21. Karania, R., Kazmer, D., and C. Roser, "Plastic Product and Process Design Strategies," ASME DETC 9th Design for Manufacturing Conference, 2004.

  22. Kazmer, D., Manek, K., Lotti, C., Breta, R. E. S., Zhu, L., "Dimensional Tolerancing and Control in Molded Products," Proceedings of the 2003 ASME International Mechanical Engineering Congress & Exposition, Design for Manufacturing Symposium, Washington, D.C., November 16-21, 2003.

  23. Zhu, L. and D. O. Kazmer, “An Evolving, Model-Based Quality Function Deployer,” ASME DETC 8th Design for Manufacturing Conference, v 3, 2003.

  24. Kazmer, D., C. Roser, et al. (2003), “Hedge Strategies for Plastics Part Design,” Society of Plastics Engineers Annual Technical Conference: Product Design & Development Division, Nashville, TN. 

  25. Zhu, L., and D. O. Kazmer, “A Method for Multi-Criteria Decision Making,” Proceedings of the 4th National Science Foundation Design & Manufacturing Conference, 2002. San Juan, Puerto Rico

  26. L. Zhu and D. O. Kazmer, “An Extended Simplex Method for Global Feasibility Evaluation,” ASME Design Automation Conference, 2002.

  27. D. Kazmer, “The Development of Robust & Confident Decision Spaces,” Proceedings of the 4th National Science Foundation Design & Manufacturing Conference, 2002. San Juan, Puerto Rico. 

  28. Kazmer, D. O.,  Hatch, D., and L. Zhu“An Investigation of Variation and Uncertainty in Six Sigma,” ASME DETC 7th Design for Manufacturing Conference, v 3, p 21-29, 2002. 

  29. Zhu, L., and D. O. Kazmer, "An extensive simplex method mapping the global feasibility," Proceedings of the 28th Design Automation Conference, ASME Design Engineering Technical Conferences, v 2, 2002, p 765-771 Sep 29-Oct 2 2002, Montreal, Que., Canada. 

  30. Lang, J. and D. Kazmer, “How Increased Control in Plastic Melt Delivery Increases Productivity,” Accepted to Society of Plastics Engineers Annual Technical Conference, May 2002. 

  31. Kazmer, D. and L. Zhu, “Qualitative Reasoning for Decision Synthesis,” Proceedings of ASME DETC 6th Design for Manufacturing Conference, 2001. Pittsburgh, PA. 

  32. Doughty, M., Kazmer, D., “Dynamic Feed – Precision Molding in a Family Tool Application,” Plastics Odyssey 2001, Rochester, NY, Sept. 24-25, 2001.

  33. Hawk, L, Kazmer, D., “Commercial Applications for Dynamic Feed™ Providing Dimensional Control for Each Injection Cavity,” K-Plast Processing Innovations, Düsseldorf/Neuss, Germany, 2001. 

  34. Kazmer, D. O., Zhu, L., Roser, C., “Some Advances in Design Representation and Feasibility Analysis,” Proceedings of the 3rd National Science Foundation Design & Manufacturing Conference, 2001. 

  35. Zhao, Y., Zhu, L., and D. O. Kazmer, “A Method for Multi-Criteria Decision Making,” Informs Decision Systems, 2000. Austin, TX.

  36. D. O. Kazmer, A. Fagade, C. Roser, and L. Zhu, “Advances in Mechanical Systems Synthesis,” Proceedings of the 3rd National Science Foundation Design & Manufacturing Conference, 2000. Tampa, FL. 

  37. D. Kazmer, “Axiomatic Design Of The Injection Molding Process,” Proceedings of the First International Conference on Axiomatic Design, 2000. Cambridge, MA. 

  38. Kazmer, D. O., Fagade, A., Roser, C., Xu, H., and L. Zhu, "Incorporation of Engineering Analysis within Design Synthesis," Proceedings of the 2nd National Science Foundation Design & Manufacturing Conference, 2000. Monterrey, Mexico. 

  39. L. Zhu and D. Kazmer, “A Performance-Based Representation Of Constraint Based Reasoning And Decision Based Design,” Proceedings of the 12th Design Theory & Methodology Conference, ASME Design Engineering Technical Conferences, 2000. 

  40. Roser and D. Kazmer, “Flexible Design Methodology,” Proceedings of the 5th Design for Manufacturing Conference, Proceedings of the 5th Design for Manufacturing Conference, ASME Design Engineering Technical Conferences, 2000. 

  41. Roser and D. Kazmer, “A Method For Robust Flexible Design,” Proceedings of the Annual Technical Meeting of the Society of Plastics Engineers, Orlando, FL, 2000. 

  42. Fagade, A. and D. O. Kazmer, “Optimal Component Consolidation in Plastic Product Design.” Proceedings of the 4th Annual ASME Design for Manufacturing Conference, 1999. Las Vegas, NV. 

  43. Roser, C. and D. O. Kazmer, “Risk Effect Minimization using Flexible Design,” Proceedings of the 4th Annual ASME Design for Manufacturing Conference, 1999. Las Vegas, NV. 

  44. Zhu, L. and D. O. Kazmer, “A Performance-Based Representation for Engineering Design.” Proceedings of the 11th Annual ASME Design Theory and Methodology Conference, 1999. Las Vegas, NV. 

  45. Roser, C. and D. O. Kazmer, “Defect Cost Analysis.” in Proceeding of the Society of Plastics Engineers Annual Technical Conference, 1999. New York, NY. 

  46. Fagade, A. and D. O. Kazmer, “Effect of Complexity on Cost & Time to Market of Injection Molded Parts.” in Proceeding of the Society of Plastics Engineers Annual Technical Conference, 1999. New York, NY. 

  47. Xu, H. and D. O. Kazmer, “Validation of a Stiffness-Based Ejection Criterion for Injection Molding.” in Proceeding of the Society of Plastics Engineers Annual Technical Conference, 1999. New York, NY. 

  48. Fagade, A. and D.O. Kazmer. “Modeling The Effects of Complexity on Manufacturing Costs and Time-To-Market of Plastic Injection Molded Products,” in Proceedings of the Tenth Annual Conference of the Production and Operations Management Society, March 20-23, 1999. Charleston, S.C. 

  49. Carter, S. and D. O. Kazmer, “Studies of Plastic Boss Design and Methodologies.” in Proceeding of the Society of Plastics Engineers Annual Technical Conference, 1999. New York, NY. 

  50. Fagade, A. and D.O. Kazmer. “Economic Design Of Injection Molded Parts Using DFM Guidelines - A Review Of Two Methods For Tooling Cost Estimation.” in Proceeding of the Society of Plastics Engineers Annual Technical Conference, 1998. Atlanta, GA. 

  51. Kazmer, D. O., and C. Roser, “A Theory of Constraints for Design and Manufacture of Thermoplastic Parts.” in Proceeding of the Society of Plastics Engineers Annual Technical Conference, 1998. Atlanta, GA. 

  52. Kazmer, D. O., “Incorporation of Engineering Analysis into Design Synthesis,” NSF Division of Design, Manufacturing, and Industrial Innovation, Grantees Conference, Monterrey Mexico, January 1998. 

  53. Kazmer, D. O., “Beyond Analysis: Leveraging Computer Aided Engineering throughout Design and Processing,” First Gordon Conference for CAE in Polymer Processing, 1997. 

  54. Kazmer, D. O., Barkan, P., Ishii, K., “Quantifying Design and Manufacturing Robustness through Stochastic Optimization Techniques,“ Proceedings of the 22nd Annual ASME Design Automation Conference, 1996. 

  55. Kazmer, D. O., Roe, D. S., “Increasing Knit-Line Strength through Dynamic Control of Volumetric Shrinkage,” in Proceeding of the Society of Plastics Engineers Annual Technical Conference, 1994.

  56. Kazmer, D. O., “Advanced Design Methodologies for the Blow Molding Process,” 20th Annual Structured Products Conference, Society of the Plastics Industry, 1991.

  57. Hayes, C., Wood, W., Mekshat, L., Kazmer, D., “Design for Manufacturing: Future Directions for DfX,” ASME Design Engineering Technical Conferences, Salt Lake City, September, 2004.

  58. Kazmer, D., “Fundamentals of Plastic Part Design and Manufacture,” National Manufacturing Week Workshop, Chicago, IL, 2003. 

  59. D. Kazmer, “Decision Based Design: Some Questions,” NSF Open Workshop on Decision Based Design, 2000. Baltimore, MD. 

  60. Kazmer, D. O., “Engineering Systems Design: Gaining Controllability of Dynamic Processes,” Dartmouth Thayer School of Engineering Jones Seminar, May 2000.

  61. Danai, K., Kazmer, D. O., and B. Kim, "Polymer Part Design & Processing," University of Massachusetts Polymer Science & Engineering Symposium, 1999.

  62. Kazmer, D. O., "A Theory of Constraints for Molded Part Design and Manufacture," GE Research & Development, 1998. 

  63. Kazmer, D.O., “Automating Molded Product Development using the Web,” Society of the Plastics Industry PlasticWorld, 1998. McCormick Center, Chicago.

  64. Kazmer, D. O., “Robust Design Metrics,” GE Corporate Research & Development Center, 1996.

  65. D. Kazmer, “Lean Development,” Flow Front Magazine, Moldflow Inc., April, 2005.

  66. D. Kazmer, Book Review, Design of Machine Elements by M. F. Spotts, T.E. Shoup, L. E. Hornberger, Eighth Edition, Pearson Prentice Hall, Upper Saddle River, NJ, 2004 (ISBN 0-13-048989-1). Journal of Mechanical Design, 2003. 

  67. Kazmer, D. O., “An Optimization Primer,” paper written for Introduction to Engineering Course Reader, August 1, 2003.

  68. D. Kazmer, Invention Disclosure, Method for Dynamic Cost Estimation of Injection Molded Article, 2002.

  69. Kazmer, D., Hatch, D., Zhu, L., "Four Measures of System Performance," 2002. 

  70. Zhu, L., and D. O. Kazmer, "An Extensive Simplex Method for Mapping Global Feasibility," 2001. 

  71. Fagade, A., Kazmer, D., "Optimal Component Consolidation in Mechanical Systems," 2000. 

  72. Kazmer, D. O., Zhu, L., "A Performance Based Representation for Support of Multiple Decisions," International Application No. WO 00/72268, November 30, 2000.

  73. D. Kazmer, Invention Disclosure, A Performance Orientation Chart for Decision Support, 2000.

  74. Fagade, A., Kazmer, D., "Early Cost Estimation for Injection Molded Parts," 1999. 

  75. Fagade, A., Kapoor, D., and D. Kazmer, "A Discussion of Design and Manufacturing Complexity," 1998. 

  76. D. Kazmer, Invention Disclosure, Looking Glass: An Optimization System for Injection Molding, 1998.

  77. Kazmer, D. O., Injection Molding Cost Estimator (Java Software), 1995.

  78. Kazmer, D.O., “Injection Molding,” Encyclopedia of Chemical Processing, Marcel Dekker, Sunggyu (K.B.) Lee, Ed., 2005.