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![Page 1: Development Processes and Organizations Teaching materials to accompany: Product Design and Development Chapter 2 Karl T. Ulrich and Steven D. Eppinger.](https://reader036.fdocuments.in/reader036/viewer/2022062314/56649dba5503460f94aab5a5/html5/thumbnails/1.jpg)
Development Processes and Organizations
Teaching materials to accompany:Product Design and Development
Chapter 2Karl T. Ulrich and Steven D. Eppinger5th Edition, Irwin McGraw-Hill, 2012.
![Page 2: Development Processes and Organizations Teaching materials to accompany: Product Design and Development Chapter 2 Karl T. Ulrich and Steven D. Eppinger.](https://reader036.fdocuments.in/reader036/viewer/2022062314/56649dba5503460f94aab5a5/html5/thumbnails/2.jpg)
Product Design and DevelopmentKarl T. Ulrich and Steven D. Eppinger5th edition, Irwin McGraw-Hill, 2012.
Chapter Table of Contents:1.Introduction2.Development Processes and Organizations3.Opportunity Identification4.Product Planning5.Identifying Customer Needs6.Product Specifications7.Concept Generation8.Concept Selection9.Concept Testing10.Product Architecture11.Industrial Design12.Design for Environment
13.Design for Manufacturing14.Prototyping15.Robust Design16.Patents and Intellectual Property17.Product Development Economics18.Managing Projects
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Concept Development Process
Id en tifyC ustom er N eeds
E stab lishTa rge t
S pec ifica tions
G ene ra teP roduct
C oncepts
Tes tP roduct
C oncep t(s)
S e tF ina l
S pec ifica tions
P lanD ownstreamD ev e lopm en t
D ev e lopm en tP lan
M iss ionS ta tem en t S e lec t
P roductC oncep t(s)
P e rfo rm E conom ic A na lys is
B enchm ark C om petitiv e P roducts
B u ild and Test M ode ls and P ro to types
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Generic Product Development Process
PlanningPlanning ConceptDevelopment
ConceptDevelopment
System-LevelDesign
System-LevelDesign
DetailDesign
DetailDesign
Testing andRefinement
Testing andRefinement
ProductionRamp-Up
ProductionRamp-Up
MissionApproval
ConceptReview
System SpecReview
Critical DesignReview
ProductionApproval
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Core development stages
• Solution approach
• Concept design
• Architectural design
• Detailed design
• Process design
• Fabrication and assembly
• Test and deployment
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Solution Approach
• Concept for solutions
• DFX
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Concept development
• A description of the form, function, and features of a product
• A set of specifications
• An economic justification of the project.
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System (architectural) design
• Definition of product architecture, with an assembly layout.
• Division of the product into subsystems and components, each with a functional specification.
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Detailed design
• Complete specification of the geometry, materials, and tolerances of each of the unique parts
• Identification of all standard parts to be purchased.
• Establishment of a process plan and tooling
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Test and refinement
• Construction and evaluation of multiple pre-production versions of the product.
• Early (alpha) prototypes are usually built with production-intent parts (but may not be with the intended production processes) for testing in the designer's environment, if the design intent and key customer needs are met.
• Later (beta) prototypes are built with parts supplied by the intended production processes (but may not be with the intended-assembly process), tested by customers in their environment, and to evaluate product performance and reliability.
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Production ramp-up
• The product is made using the intended production system.
• To train the work force and to work out any remaining problems in the production processes.
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A generic concept development process
1. Identifying customer needs2. Establishing target specifications3. Concept generation4. Concept selection5. Concept testing6. Setting final specifications7. Project planning8. Economic analysis9. Benchmarking of competitive products10. Modeling and prototyping
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Rapid Iteration PD Process
Many Iteration Cycles
PlanningPlanning ConceptDevelopment
ConceptDevelopment
System-LevelDesign
System-LevelDesign
MissionApproval
ConceptReview
Cycle PlanReview
DesignDesign
CycleReview
BuildBuild TestTest ProductionRamp-Up
ProductionRamp-Up
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Complex System PD Process
PlanningPlanning ConceptDevelopment
ConceptDevelopment
System-LevelDesign
System-LevelDesign
MissionApproval
ConceptReview
SystemReview
DesignDesign
ProductionApproval
TestTest
DesignDesign TestTest
DesignDesign TestTest
DesignDesign TestTest
Integrateand Test
Integrateand Test
Validationand Ramp-Up
Validationand Ramp-Up
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Concept Development Process
• Front-end of PD need not be a fuzzy process.• Structured methods exist for each process step
(see text chapters 4 to 8).• This is not strictly sequential -- generally a
parallel and iterative process.
IdentifyCustomer
Needs
EstablishTarget
Specifications
GenerateProduct
Concepts
SelectProduct
Concept(s)
Set Final
Specifications
PlanDownstreamDevelopment
MissionStateme
ntTest
ProductConcept(s)
DevelopmentPlan
Perform Economic Analysis
Benchmark Competitive Products
Build and Test Models and Prototypes
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Project Registration
ConceptDefinition
Feasibilityand Planning
PreliminaryDesign
FinalDesign
ProductVerification
ProcessVerification
LaunchPost-LaunchAssessment
RP1
RP2
RP3
RP4
RP5
RP6
RP7
RP8
RP0
Tyco Product Development Process
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Tyco Product Development Process
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Organizational types
• Strict functional organization
• Strict project organization
• Matrix organization
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Matrix organization
• A hybrid of functional and project organizations• Each individual is linked to others according to
both the project they work on and their functions• Each has two supervisors: project manager and
functional manager.• Two variants of the matrix organizations
– Heavyweight project organization (i.e., strong project links).
– Lightweight project organization (strong functional links).
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Factors for affecting an org. structure
• Importance of cross-functional integration
• Criticalness of cutting-edge functional expertise to business success
• Utilization of resources from each function
• Importance of product development speed
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Organizational linkages
Reporting relationship
Financial arrangement
Physical layout.
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Other Images
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Variants of the development process
• Market pull products• Technology push products• Platform products• Process-intensive products• Customized products• high-risk product• Quick build products• Complex systems
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Variants
• Market-pull products– The firm finds a market opportunity and a technology to
meet customer's needs. Thermo care.
• Technology-push products– The firm begins with a new technology and then finds a
market for it. Glue for “post-it.”
• Platform products – Use of a proven technology platform to build a new
product. Instant film used in Polaroid cameras.
• Process-intensive products– Develop product and process simultaneously.
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Variants
• Customized products– Build a new product by varying existing configurations.
• High-risk products– Intensive and early test and analysis
• Quick-build products– Rapid modeling & prototyping at testing phase
• Complex systems– Subsystems and integration worked by teams
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Traditional design methods
• Aggregation– (include new functions)
• Adaptation– (adapt to new conditions)
• Application– (apply a proven technology to a new area)
• analysis of properties– (thorough analysis of an existing design to improve)
• Brainstorming– (find many solutions to a problem)
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Traditional design methods
• systematic search of field– (obtain complete possible information)
• Questioning– (apply a system of questions to produce mental
simulation)
• mental experiment– (observe an idealized mental model at work)
• value analysis• Evaluation
– (find best variant among a few by point-counting)
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Traditional design methods
• invention
• Iteration– (to solve a system with complicated
interactions)
• experimentation
• division of totality
• math & computer modeling
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Chapter 2: Home work
• Exercise (Analysis of Properties)• Focus on materials selection for an existing product• Steps:• 1. Examine each component of a product (an incandescent bulb, stapler, can opener).• 2. Break the product or decompose it, avoiding injury to eyes or hands and damage to
the other components.• 3. Construct and complete a table consisting the following items on its columns.
– a. list each component of the product– b. define the function of each component– c. identify the material used– d. reason why it was selected– e. select possible alternative.
• 4. List five failure mechanisms