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Professor Darek Ceglarek

PROFESSOR Darek Ceglarek joined WMG from the USA to strengthen its research and teaching directions at home and abroad.

He sees WMG’s unique infrastructure and multidisciplinary expertise encompassing cutting edge industry-wide research problems, life-long teaching and fundamental research as a model for other institutions to adopt.

Professor Ceglarek, an expert in digital simulation, is internationally known faculty recently recruited to Warwick’s new digital laboratory.

He has been wooed from the highly-respected University of Wisconsin-Madison, where he spent six years since 2000, and rose from the ranks of Assistant Professor in the Department of Industrial and Systems Engineering to Associate Professor and Professor in 2003 and 2005, respectively.

Throughout his academic career he has maintained close links with industry – while undertaking his PhD in mechanical engineering at the University of Michigan-Ann Arbor, he was never far from some of the world’s major automotive companies and their suppliers.

Professor Ceglarek specializes in addressing the gamut of life-cycle of new products and production systems, starting from design to manufacturing and service. He brings together research on manufacturing system CAD/CAM models, statistical methods for design, control, diagnostics and self-healing of multistage manufacturing processes; along with analysis of warranty and service data applicable to lean healthcare. In doing so he aims to address the following areas:

(1) Modeling: Product and production system architecture decomposition and analysis using the concepts of key characteristics, their relationship and causalities;

(2) Design: Design-for-Six-Sigma, manufacturing system design synthesis in early development phases; and optimization of distributed sensing network. Information and models developed are further applied to study manufacturing systems diagnosability and self-healing, convertibility (reusability, reconfigurability) and scalability.

(3) Manufacturing: Root cause diagnosis and self-healing of product and process variability (Six Sigma).

(4) Field Life: Data-driven methodologies for analysis, diagnosis and control of product field performance by integrating field data (service and warranty) with manufacturing measurements and design information.

His research has covered cutting edge issues pertaining to manufacturing in the aerospace, shipbuilding, automotive, consumer goods and healthcare industries, and he is impressed by the “unique spectrum” of activities at WMG.

The Digital Laboratory being built at Warwick offers enormous research opportunities for developing Professor Ceglarek’s ‘cradle-to-the-grave’ approach applicable to product and production system development, which is based on creating design synthesis methods that integrate product and process models along with diagnostic tools that identify root cause of Six Sigma failures of production system and products in field.

“In an industrial environment people are often only looking 18 months ahead,” he says. “Generally, people working on different phases of a product do not have opportunities to communicate efficiently with each other. Universities, on the other hand, are working with both shorter and long term objectives. By actively collaborating with industries, universities can help with solutions that address their immediate needs as well as issues that are of importance five or 10 years down the line. Such collaborations create synergistic learning opportunities for both sides and cut through many of the challenges that industries face on a day-to-day basis.”

Professor Ceglarek is also applying the same philosophy of examining product lifecycle in healthcare industry by developing diagnostic tools for healthcare equipment, areas with which WMG is becoming increasingly involved. His research adds to this focus by developing methods for early prediction of field failures in healthcare systems such as MRI, CT and cardiovascular systems.

The health care industry can benefit significantly by utilizing many of the methods and knowledge developed within the manufacturing sector. There is an opportunity for research as well as transfer of knowledge from manufacturing into healthcare.

Professor Ceglarek received his diploma in production engineering at the Warsaw University of Technology in 1987 before moving to the USA. He has received numerous academic and industrial awards including the 2007 EPSRC Star in Automotive Engineering Award; US National Science Foundation (NSF) CAREER Award; Best Paper Awards from ASME Manufacturing Engineering Division; and ASME Design Engineering Division, respectively; 1999 Outstanding Research Scientist Award from the University of Michigan-Ann Arbor; and, 1998 Dell K. Allen Outstanding Young Manufacturing Engineer of the Year Award from the US Society of Manufacturing Engineers (SME). He has published widely in internationally known journals and is a Fellow of the prestigious academic society, The International Academy for Production Engineering (CIRP).

His expertise is highly sought after by international societies. Previously, he was Chair of the Quality, Statistics and Reliability Section of the Institute of Operations Research and Management Sciences (INFORMS); Program Chair for the ASME Design-for-Manufacturing Life Cycle (DFMLC) Conferences, Associate Editor of the IEEE Trans. on Automation Science and Engineering. Currently, he serves as Associate Editor of the ASME Trans., Journal of Manufacturing Science and Engineering and on the editorial board of European Journal of Industrial Eengineering. He has graduated 11 Ph.Ds, majority of whom currently hold assistant and associate professors positions in top US and international research universities; others hold managerial posts in leading manufacturing companies such as: GM, DaimlerChrysler, GE and others.

His work has also been well received by industrial partners. His methodology on diagnostics of Six Sigma root causes helped to (i) accomplish the 2-mm dimensional variation level for automotive body, achieved for the first time by a US auto assembly (JNAP/DaimlerChrysler); and (ii) receive the 1998 J.D. Powers award by Bramalea Plant, DaimlerChrysler for best quality vehicle in the US market. Additionally, it became part of the Chrysler Operating System (COS) in 1998 for all new car and truck launches and of GM’s “BIW Data Analyzer” software. The implementation of his methodology for variation reduction of closure panel fit assembly process led to 50% improvement in quality of closure panel variation, and was awarded the prestigious 1995 Mfg. Excellence Award.

Recently, Dimensional Control Systems, Inc (Michigan, USA) implemented yet another one of his methods, Stream-of-Variation (SOVA), as a widely applicable computer simulation system used to model, analyze, predict, and optimize performance of multistage manufacturing processes requiring accurate parts alignment to improve production and product quality (;

His Fault Region Localization methodology, which integrates product field/warranty data with manufacturing parameters, was implemented by Motorola in their cell phone manufacturing. The initial application of the methodology in cell-phone manufacturing completely eliminated one of the top 5 warranty failures classified as a No-Defect-Found category for I-90 model.

He says: “WMG provides a unique environment for faculty to conduct research with rigorous industry collaboration, an opportunity that few universities can match.”