Concurrent Engineering

Concurrent Engineering

Overview

Concurrent engineering is a cross-functional integration and simultaneous development approach that replaces the traditional “over the wall” sequential method. By involving manufacturing engineers and other stakeholders during the design stage, it enables parallel execution of tasks, reducing development flow time by up to 80%.

ELI5

Concurrent Engineering is like building a LEGO set with your friends ALL TOGETHER:

Old way (“Over the Wall”):

• You draw the plan → throw it over a wall → friend tries to build
• Friend yells: “This can’t be built!” → you have to redraw
• Wastes SO much time!

New way (Concurrent):

• You + builder + painter all sit at the SAME table
• You draw → builder says “that won’t work” → painter says “add color here”
• Everyone fixes problems TOGETHER, right away!

Simple analogy: Imagine a relay race where runners pass the baton (sequential) vs. a soccer team where everyone works together on the same play (concurrent).

Core Concept

Concurrent engineering is defined as cross-functional integration plus simultaneous development. It fundamentally changes how product development is organized.

The traditional approach, called “over the wall,” follows a “we design it, you build it” mentality. Design engineers complete their work, then throw the specifications “over the wall” to manufacturing. Manufacturing then discovers problems: the design is hard to build, requires expensive tooling, or cannot be produced with available equipment. This leads to costly redesign and delays.

In contrast, concurrent engineering follows a “let’s work together simultaneously” approach. Manufacturing engineers are consulted during the design stage. Quality, service, and suppliers are also involved early. This enables parallel execution instead of sequential handoffs.

The result is dramatic: concurrent engineering can reduce development flow time by up to 80%. It also reduces engineering changes, lowers product cost, and improves quality by catching problems early when changes are cheap.

Components / Framework

Component	Description	Source
Cross-functional Integration	Involving multiple disciplines from the start	MGH_book.pdf
Simultaneous Development	Parallel execution instead of sequential	MGH_book.pdf
”Over the Wall” Approach	Traditional sequential method: “we design it, you build it”	Chapter3.pptx, Slide 26
Concurrent Approach	”Let’s work together simultaneously”	Chapter3.pptx, Slide 26
Manufacturing Consultation	Consulting manufacturing engineers during design stage	MGH_book.pdf
Development Time Reduction	Up to 80% reduction in flow time	MGH_book.pdf

Example

From Slides:

• Traditional approach: “We design it, you build it” (over the wall)
• Concurrent engineering: “Let’s work together simultaneously”

Real-World Example - Boeing 777: Boeing used concurrent engineering with “working together” teams. Design engineers, manufacturing engineers, suppliers, and airline customers were all involved from the start. Result: First-time-ever successful aircraft launch with no major redesign needed.

Real-World Example - Toyota: Toyota’s Chief Engineer system puts one person in charge of the entire vehicle program, with representatives from all functions on the team. Design, manufacturing, purchasing, and quality all work together, achieving industry-leading development speed and quality.

Implications

• Reduces development flow time by up to 80%, enabling faster time to market
• Catches problems early when changes are still inexpensive
• Reduces engineering changes by 50-70%
• Lowers product cost by 10-30%
• Improves quality through early involvement of all functions
• Requires cultural change from sequential to collaborative mindset
• May require colocation of team members for effective communication

Related Concepts

• QFD (Quality Function Deployment): QFD uses cross-functional teams, which is a core practice of concurrent engineering
• Design for Manufacturing and Assembly (DFMA): A key technique within concurrent engineering that simplifies product design
• Waterfall: Sequential approach that concurrent engineering replaces
• Agile: Shares the iterative, collaborative spirit of concurrent engineering

Quick Summary

• Concurrent engineering = cross-functional integration + simultaneous development
• “Over the wall” approach: “we design it, you build it” (sequential)
• Concurrent: “let’s work together simultaneously” (parallel)
• Parallel execution vs. sequential
• Consult manufacturing engineers during design stage
• Reduces development flow time by up to 80%

Exam Tips:

• Concurrent = SIMULTANEOUS work by cross-functional teams
• If a scenario describes one department finishing before the next starts, that’s NOT concurrent
• Key benefit: up to 80% reduction in development time

Sources

• Chapter3.pptx [Slide 26]
• MGH_book.pdf