A geometrical framework for forecasting cost uncertainty in innovative high value manufacturing.

Increasing competition and regulation are raising the pressure on manufacturing organisations to innovate their products. Innovation is fraught by significant uncertainty of whole product life cycle costs and this can lead to hesitance in investing which may result in a loss of competitive advantage. Innovative products exist when the minimum information for creating accurate cost models through contemporary forecasting methods does not exist. The scientific research challenge is that there are no forecasting methods available where cost data from only one time period suffices for their application. The aim of this research study was to develop a framework for forecasting cost uncertainty using cost data from only one time period. The developed framework consists of components that prepare minimum information for conversion into a future uncertainty range, forecast a future uncertainty range, and propagate the uncertainty range over time. The uncertainty range is represented as a vector space representing the state space of actual cost variance for 3 to n reasons, the dimensionality of that space is reduced through vector addition and a series of basic operators is applied to the aggregated vector in order to create a future state space of probable cost variance. The framework was validated through three case studies drawn from the United States Department of Defense. The novelty of the framework is found in the use of geometry to increase the amount of insights drawn from the cost data from only one time period and the propagation of cost uncertainty based on the geometric shape of uncertainty ranges. In order to demonstrate its benefits to industry, the framework was implemented at an aerospace manufacturing company for identifying potentially inaccurate cost estimates in early stages of the whole product life cycle.