ch5(product design & process selection-manufacturing)

8/18/2019 Ch5(Product Design & Process Selection-Manufacturing)

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©The McGraw-Hill Companies,


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Chapter 5Product Design & Process

Selection-Manufacturing


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• Typical Phases of Product Design

Development

• Designing for the Customer

• Design for Manufacturability

• Types of Processes

• Process Flow Structures

• Process Flow Design

• lobal Product Design and Manufacturing

!"#$CT%$S


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Typical Phases of Product Design

Development• Concept Development

• Product Planning

• Product'Process $ngineering

• Pilot Production'(amp-)p


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Concurrent $ngineering

Defined • Concurrent engineering can be defined

as the simultaneous development of

pro*ect design functions+ with open andinteractive communication e,isting

among all team members for the

purposes of reducing time to maret+decreasing cost+ and improving .uality

and reliability


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Concurrent $ngineering/Continued0

• Teams provide the primary integrationmechanism in C$ programs

• There are three types of teams – Program Management Team

– Technical Team

– Design-Buil Teams• Time savings of C$ programs are created

by performing activities in parallel


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Designing for the Customer

Quality Function

Deployment

Value Analysis/

Value Engineering

Ideal

Customer

Product

House of Quality


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Designing for the Customer1

2uality Function Deployment

• %nterfunctional teams from mareting+ designengineering+ and manufacturing

• oice of the customer

• 3ouse of 2uality


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Designing

for the

Customer1

The 3ouse

of 2uality

Customer

#e$uirements

% m p o r t a n c e t o

C u s t &

'as( to close

)ta(s open on a hill

'as( to open

Doesn*t lea+ in rain

,o roa noise

%mportance eighting

'ngineering

Characteristi

cs

' n e r g ( n e e e

t o c l o s e o o r

C h e c + . o r c e

o n l e / e l

g r o u n

' n e r g ( n e e e

t o o p e n o o r

0 a t e r r e s i s t a n c e

1 6 6 2 3

!

5

3

3

2

Correlation

)trong positi/e

Positi/e

,egati/e)trong negati/e

Competiti/e e/aluation

7s8 Comp& 8B Comp& B95 is :est;

1 2 3 4 5

8B

8B

8B

8 B

8 B

#elationships

)trong

Meium 3

)mall 1Target /alues

# e u c e e n e r g

(

l e / e l t o ! & 5 . t


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Designing for the Customer1

alue 4nalysis'alue $ngineering /4'$0

• 4chieve e.uivalent or better performance at a lower

cost while maintaining all functional re.uirements

defined by the customer – Does the item have any design features that are

not necessary5

– Can two or more parts be combined into one5

– 3ow can we cut down the weight5

– 4re there nonstandard parts that can be

eliminated5


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Design for Manufacturability• Traditional 4pproach

– 67e design it+ you build it8 or 6!ver the

wall8

• Concurrent $ngineering

– 69et:s wor together simultaneously8


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Design for Manufacturing and 4ssembly

• reatest improvements related to DFM4 arise

from simplification of the product by reducing thenumber of separate parts1

;< During the operation of the product+ does the part

move relative to all other parts already assembled5=< Must the part be of a different material or be

isolated from other parts already assembled5

>< Must the part be separate from all other parts to

allow the disassembly of the product for

ad*ustment or maintenance5


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Types of Processes• Conversion /e,< %ron to steel0

• Fabrication /e,< Cloth to clothes0

• 4ssembly /e,< Parts to components0

• Testing /e,< For .uality of products0


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Process Flow Structures• #ob shop /e,< Copy center maing a single copy

of a student term paper0

• "atch shop /e,< Copy center maing ;?+???copies of an ad piece for a business0

• 4ssembly 9ine /e,< 4utomobile manufacturer0

• Continuous Flow /e,< Petroleum manufacturer0

1


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%=&

Continuous

>lo

%%%&

8ssem:l(?ine

%%&

Batch

%&

@o:

)hop

?o

=olumeA

ne o. ain

Multiple

ProuctsA

?o=olume

>e

Maor

ProuctsA

Eigher =olume

Eigh

=olumeA

Eigh

)tanar-iFation

Commercial

Printer

>rench #estaurant

Eea/(

'$uipment

8utomo:ile

8ssem:l(Burger ing

)ugar

#e.iner(

>leGi:ilit( 9Eigh;

7nit Cost 9Eigh;

>leGi:ilit( 9?o;

7nit Cost 9?o;

Exhibit 5.10Exhibit 5.10

These are

the maor

stages o.

prouct an

process li.e

c(cles

These are

the maorstages o.

prouct an

process li.e

c(cles

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irtual Factory

Defined 4 virtual factory can be defined as a

manufacturing operation where activities are

carried out not in one central plant+ but inmultiple locations by suppliers and partner

firms as part of a strategic alliance

1!


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"rea-$ven 4nalysis

• 4 standard approach to choosing among

alternative processes or e.uipment

• Model sees to determine the point in units

produced /and sold0 where we will startmaing profit on the process or e.uipment

• Model sees to determine the point in units

produced /and sold0 where total revenue andtotal cost are e.ual

1"


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"rea-$ven 4nalysis /Continued0

This .ormula can :e use to .in an( o. its

components alge:raicall( i. the other parametersare +non

Brea+-e/en DemanBrea+-e/en Deman

Purchase cost o. process or e$uipment

Price per unit - Cost per unit

or

Total .iGe costs o. process or e$uipment7nit price to customer - =aria:le costs per unit

Purchase cost o. process or e$uipment

Price per unit - Cost per unit

or

Total .iGe costs o. process or e$uipment7nit price to customer - =aria:le costs per unit

1


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"rea-$ven 4nalysis /Continued0

• $,ample1 Suppose you want to purchase a new computer

that will cost @A+???< %t will be used to process written ordersfrom customers who will pay @=A each for the service< The

cost of labor+ electricity and the form used to place the order

is @A per customer< 3ow many customers will we need to

serve to permit the total revenue to brea-even with ourcosts5

• Brea+-e/en Deman

Total .iGe costs o. process or e$uip&

7nit price to customer – =aria:le costs 5A


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Process Flow Design

Defined • 4 process flow design can be defined as a

mapping of the specific processes that rawmaterials+ parts+ and subassemblies follow asthey move through a plant

• The most common tools to conduct a process

flow design include assembly drawings+assembly charts+ and operation and route sheets

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$,ample1 4ssembly Chart /oBinto0

8-2)8-2

4

5

6

!

?oc+ring

)pacerA etent spring

#i/ets 92;

)pring-etent

8-5

Component


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$,ample1 Process Flow Chart

MaterialReceived

from

Supplier

Inspect

Material for

efects efects

found!

Return to

Supplier for

"redit

$es

%o#

"ontinue$

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lobal Product Design and Manufacturing

Strategies• #oint entures

• lobal Product Design Strategy

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Measuring Product Development

Performance

Measures•>re$& . ne proucts introuce•Time to mar+et introuction• ,um:er state an num:er complete

•8ctual /ersus plan•Percentage o. sales .rom ne proucts

•>re$& . ne proucts introuce•Time to mar+et introuction• ,um:er state an num:er complete

•8ctual /ersus plan•Percentage o. sales .rom ne proucts

%ime&to&mar'et%ime&to&mar'et

(roductivit)(roductivit)

*ualit)*ualit)

•'ngineering hours per proect

•Cost o. materials an tooling per proect•8ctual /ersus plan

•'ngineering hours per proect•Cost o. materials an tooling per proect•8ctual /ersus plan

•Con.ormance-relia:ilit( in use•Design-per.ormance an customer satis.action

•Hiel-.actor( an .iel

•Con.ormance-relia:ilit( in use•Design-per.ormance an customer satis.action

•Hiel-.actor( an .iel

Per.ormanceDimension

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ch5(product design & process selection-manufacturing)

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