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Table 4: Examples of Prototypes Used by Cummins Inc. at Various Stages of Product Development
In addition to using engineering prototypes during the product integration phase of product development, Cummins and other companies we visited used other prototypes-such as production representative prototypes-in the remaining product development phases before production, as shown in table 4, to demonstrate product reliability and process control.
Cummins built production representative prototypes of its engines to demonstrate that the design and the engine hardware would perform to requirements.
A Cummins representative stated that not using prototypes becomes a matter of "pay me now or pay me later," meaning that it is far less costly to demonstrate a product's design early in development with prototypes, concepts, and analyses than to incur the cost of significant design changes after a product has entered production-a much more costly environment to make changes.
In developing the new Signature 600 diesel engine, Cummins included manufacturing engineers and machine tool and fixture suppliers in the design decision process as the engine concept was first being defined.