Target weighing - A new approach for conceptual lightweight design in early phases of complex systems development

Abstract

This research suggests a new approach in early stages of product development, aiming at a lightweight orientated functional concept design. Based on the systematic approaches of target costing and value engineering a functional analysis is proposed to match mass and function. This allows the identification of where the most promising weight reductions could be achieved without focusing single components. Search fields for further investigation are identified based on the resulting weight of functions. By including the significance of functions for internal and external customers this approach points out opportunities for product optimizations. Furthermore, the created data enables a systematic way to evaluate the target weight of new concepts and makes a selection easier. This proposed approach was validated in two projects regarding a car climate control system and a high voltage battery for plug-in hybrid electric vehicles. This method raises the awareness to lightweight potential within early product design and determines target values for weight, cost and volume of new concepts.