An innovative cost modelling system to support lean product and process development

Ahmad Wasim, Essam Shehab, Hassan Abdalla, Ahmed Al-Ashaab, Robert Sulowski, Rahman Alam

Research output: Contribution to journalArticlepeer-review

32 Citations (Scopus)


This paper presents a cost modelling system for lean product and process development to support proactive decision making and mistake elimination at the design stage. The foundations of the system are based upon three lean product and process development enablers, namely: Set-based concurrent engineering, knowledge-based engineering, and mistake proofing (Poka-yoke). The development commenced with an industrial field study of eleven leading European industries from the aerospace, automotive, telecommunication, medical and domestic appliance sectors. Based on the requirements of industrial collaborators, the developed system comprises six modules: value identification, manufacturing process/machines selection, material selection, geometric features specification, geometric features and manufacturability assessment, and manufacturing time and cost estimation. The work involved the development of a feature-based cost estimation method for the resistance spot welding process. The developed system was finally validated using an industrial case study. The developed system has the capability to provide estimates related to product cost and associated values concurrently, facilitate decision making, eliminate mistakes during the design stage, and incorporate 'customer voice' during a critical decision making stage.

Original languageEnglish
Pages (from-to)165-181
Number of pages17
JournalInternational Journal of Advanced Manufacturing Technology
Issue number1-4
Publication statusPublished - Mar 1 2013
Externally publishedYes


  • Cost modelling
  • Knowledge-based engineering
  • Lean product development
  • Mistake proofing (Poka-yoke)
  • Set-based concurrent engineering

ASJC Scopus subject areas

  • Control and Systems Engineering
  • Software
  • Mechanical Engineering
  • Computer Science Applications
  • Industrial and Manufacturing Engineering

Fingerprint Dive into the research topics of 'An innovative cost modelling system to support lean product and process development'. Together they form a unique fingerprint.

Cite this