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1、System-LevelDesign:AMissingLink?DurwardK.Sobek,IIDepartmentofMechanicalandIndustrialEngineeringMontanaStateUniversityBozeman,MT59717-3800dsobek@ie.montana.eduIntroductionToyotaMotorCorporationisarguablythemostsuccessfulautomotivecompanyintheworld,outperformingi
2、tsUScompetitorsonmanyfronts,includingproductqualityand1engineeringproductivity.PriorresearchonToyota’sproductdevelopmentpracticehasrevealedanumberofstrikingdifferenceswiththoseofUSautomakers;however,froma2designprocessstandpoint,thedifferencesarerelativelyfew.A
3、llcarmakersstudythemarketanddevelopmanystylingalternatives.Allgraduallyeliminatealternativesuntilafinaldesignremains.Allthenengineerthedesign,conductmanufacturabilityreviewsandcrashsimulations,releaseengineeringdrawingsforprototype,andcreateandtestprototypevehi
4、cles.Theyallusecomputer-aideddesignandanalysistoolswithsimilarcapabilities.Interestingly,though,Toyotahasaphaseinbodyengineeringthatothersdonot:kozokeikaku,roughlytranslated‘‘designstructuresplan.’’Fromtheconceptdesign,ratherthanproceedingimmediatelytodetailede
5、ngineeringdrawingsandanalysis,bodyengineersdevelopthekeycross-sectionsofthesheetmetalparts,andspecifykeyinterfaces.Theycreateadocument(thekozokeikaku)incorporatingthesepreliminarydesignplansfortheentiresheetmetaldesignofthevehiclebody,anddistributeittoapproxima
6、tely80keyindividualsacrosstheproductdevelopmentorganizationforreviewandcommentbeforemovingtodetaileddesignofparts.ThisphaseisremarkablebecauseitseemstoplayapivotalroleinToyota’sprocess,yetitisaltogetherabsentinUSautomotiveprocesses.WhencoupledwithToyota’sspeed,
7、productivity,andmarketandfinancialsuccess,itcertainlyseemskozokeikakuisworthalook.WhatIbelieveToyotaispracticingwithkozokeikakuisaspecificinstanceofamoregeneraldesignpracticethathasreceivedsome,butperhapsnotenough,attentioninthedesignliterature.Itisastageinthed
8、esignprocessthatfalls(roughlyspeaking)afterconceptdesignandbeforedetaildesign.Someauthorsplaceitinaseparatephase(e.g.,‘‘system-34leveldesign’’inUlrichandEppinger,‘‘prelimina
