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Fuji Xerox Digital Work Way - Development/Production-Preparation Process Innovation -

Fuji Xerox has developed "Fuji Xerox Digital Work Way (FXDWW)," a production- preparation process that connects each process of research, technology,
development, and manufacturing by using consistent digital information. FXDWW mainly consists of the "Virtual" phase and the "Real" phase. In the "Virtual" phase, CAD data (drawings) are created by using design tools and through various simulations. In the "Real" phase, trial production and mass production are conducted based on the CAD data. We also employ front-loading development and concurrent development in the "Virtual" phase, so as to shorten the development period and improve the quality of final products.
Front-loading development is intended to clarify the basis of design and the basis of preparing for production at a very early stage of the "Virtual" phase, in order to prevent design changes in the "Real" phase that have great impact on cost and man-hours, and avoid inefficiencies caused by retrogression in each process. It also aims to improve product quality from the early stages of product development. The methods introduced below are used in front-loading development.
Concurrent development is intended to incorporate Digital Design Improvement (DDI) and such production preparation activities as assembly process design and jig design into the Virtual phase, and then implement DDI and said activities along with product design activities. DDI is a method of inspecting quality using a digital mock-up tool that has replaced conventional design quality inspection using actual machines. And before concurrent development was introduced, the production preparation activities were conducted only after CAD data were completed.

Fig. 1: Development/Production Preparation Process by FXDWW

Methods used in front-loading development of FXDWW

The actual activities are introduced below.

Quality Function Deployment (QFD)

Customer requests are converted into quality characteristics. Then, the characteristics are systematically linked to the quality of functional parts and the quality of individual parts.

Design Failure Mode and Effect Analysis (FMEA) and Fault Tree Analysis (FTA)

Design FMEA is a method of predicting the failure modes of major functional parts and assessing the impact of those modes on a system (product). FTA logically describes the process that results in the occurrence of certain failure, starting from that failure (the phenomenon).

Engineering-Parts list (E-P list) and Parts-Process list (P-P list)

The E-P list (E-P list) is used to determine parts-level design targets based on product functions. The P-P list contains the methods of production and quality assurance necessary to realize the design targets specified in the E-P list.

Mechanism design tool

Fuji Xerox standardized design procedures of highly experienced designers and provides all designers with a variety of information (e.g. design know-how, trouble lists, technical information) based on the procedure.

Simulation / Computer Aided Engineering (CAE)

This refers to the increasingly important technology used to simulate physical phenomena and conduct numerical analysis on a computer, in order to determine the basis of design without making an actual item.

Digital Design Improvement (DDI) by utilizing 3D data

Fuji Xerox developed and is utilizing Digital Design Improvement (DDI). DDI is a system for all members related to the design, preparing for production, logistics, manufacturing, and quality control of a product, in order to review relevant designs by using digital mockup tools before building an actual product.

Product Data Management (PDM) system

Fuji Xerox built the Product Data Management (PDM) system to manage digital data (e.g. 3D-CAD). The system is intended to seamlessly provide the data to every process from product design to preparing for production, and enable designers and engineers to access the latest information.

Mold requirement check tools

Fuji Xerox developed mold requirement check tools in order to prevent problems arising due to varying skill levels of engineers (levels of understanding mold characteristics), such as changes in parts design after the related drawings are issued and uneven molding quality, and thus improve product design quality.