Product Design and Process Selection.ppt
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Types of Processes
Single stage or multiple stage Multiple stage process must be buffered
internally. Buffering refers to storage area
between stages. It allows the stages to operateindependently
Common problems are blocking and starving.
Blocking means activities must stop because
there is no place to deposit. Starving occurs when the activities in a stage
must stop because there is no work
Bottleneck : inventory buffer is placed; it limits
the capacity of the process 1Chapter Product Design and ProcessSelection
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Types of Processes continued
Make-to-order:A process that is activatedonly in response to an actual order.
Inventory is kept minimum. Services by
nature often use make-to-order process
Make-to-stock:A process that producesstandard products that are stored in
finished goods inventory.
2Chapter Product Design and ProcessSelection
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Types of Processes continued
Hybrid: combines the features of bothmake-to-order and make-to-stock. A
generic product is made and stocked at
some point in the process. These generic
units are customized in a final process to
meet actual order. Burger King- Have it
your way
Pacing: movements of items through aprocess is coordinated through a timing
mechanism. Most processes are not
paced but assembly lines are usually 3Chapter Product Design and ProcessSelection
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Designing for the Customer
Look at the design from users standpoint
Customers must not be forgotten
Many products have too manytechnological features- far more than
necessary sometimes confusing.
Where is the voice of customer?
Chapter Product Design and ProcessSelection
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Designing for the Customer
House of Quality
Quality FunctionDeployment
Value Analysis/Value Engineering
Ideal CustomerProduct
House of Quality
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Quality Function Deployment
A process of determining customer
requirements and translating them into the
attributes that each functional area can
understand and act on.
Determines what will satisfy the customer
Translates those desires into specificproduct characteristics
Product design process using cross-
functional teams 6Chapter Product Design and ProcessSelection
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Value Analysis/Value
Engineering Achieve equivalent or better performanceat a lower cost while maintaining all
functional requirements defined by the
customer Does the item have any design features
that are not necessary?
Can two or more parts be combined intoone?
How can we cut down the weight?
Are there nonstandard parts that can be 7Chapter Product Design and ProcessSelection
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House of Quality
Customer requirement information forms thebasis for a matrix called the house of quality
Customer feedback is used to make engineering, marketing and design decisions
Important characteristics and goals are jointlyagreed
This process encourages different department towork closely together and results in better
understanding. Customer requirements and product
characteristics are put in column and row.
Customers are asked to compare the product to
the competition 8Chapter Product Design and ProcessSelection
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House of Quality
Customerrequirementsinformationforms the
basis for thismatrix, usedto translatethem intooperating orengineeringgoal
Chapter Product Design and ProcessSelection
9
Customer
Requirement
sEasy to close
Stays open on a hill
Easy to open
Doesnt leak in rain
No road noise
Importance weighting
Engineering
Characteris
tics
Energyneeded
toclosedoor
Check
forceon
level
ground
Energyneeded
toopendoor
Waterresistance
10 6 6 9 2 3
7
5
3
3
2
X
X
X
X
X
Correlation:Strong positive
PositiveNegativeStrong negative
X*
Competitive evaluation
X = UsA = Comp. AB = Comp. B(5 is best)
1 2 3 4 5
X AB
X AB
XAB
A X B
X A B
Relationships:
Strong = 9Medium = 3
Small = 1Target values
Reduceenergy
levelto7.5ft/lb
Reduceforce
to9lb.
Reduceenergy
to7.5
ft/lb.
Maintain
currentlevel
Technical evaluation
(5 is best)
54321
B
A
X
BAX B
A
X
B
X
A
BXABAX
Doorseal
resistance
Accoust.Trans.
Window
Maintain
currentlevel
Maintain
currentlevel
The McGraw-Hill Companies, Inc., 2004
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House of Quality Example
hapter Product Design and
rocess Selection10
High relationship (5) Medium relationship (3) Low Relationship (1)
Target Values
Light weight
Easy to use
Reliable
What the customer desires
AluminumParts
AutoFocus
AutoExposure
CustomerRequirements
CustomerImportance
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House of Quality
hapter Product Design and
rocess Selection11
High relationship (5) Medium relationship (3) Low Relationship (1)
CustomerRequirements
CustomerImportance
Target Values
Light weight
Easy to use
Reliable
AluminumParts
AutoFocus
AutoExposure
3
4
59 27 27
Target values for engineeringcharacteristics (basement);
key output
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Designing Products forManufacture and Assembly
Traditional Approach
We design it, you build it or Over the
wall
Concurrent Engineering Lets work together simultaneously
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Designing forManufacturing
Minimize parts
Design parts for
multiple
applications
Use modular
design
Avoid tools
Simpler to
assemble 13Chapter Product Design and ProcessSelection
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Process Selection
It refers to strategic decision ofselecting which kind of productionprocess to have in manufacturing plant
Types: Conversion
Fabrication
Assembly Testing
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Process Flow DesignThis refers to organization of material flow using one or
more process technologies
Types of Major Process Flow structure:
Job shop: Production process of small batches of largenumber of products Such as plants that make custom-designed product
Batch shop: Standardized job shop such as Medicine
Assembly Line:Automobile manufacturer
Continuous Flow: Conversion or further processing ofundifferentiated materials such as Chemical manufacturer 15Chapter Product Design and ProcessSelection
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Service-System Design MatrixExhibit 7.6
Mail contact
Face-to-face
loose specs
Face-to-face
tight specsPhone
Contact
Face-to-face
totalcustomization
Buffered
core (none)
Permeable
system (some)
Reactive
system (much)
High
LowHigh
Low
Degree of customer/server contact
Internet &
on-site
technology
Sales
Opportunity
Production
Efficiency
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Service-System Design Matrix Buffered core: physically separated from
customers
Permeable system: penetrable bycustomer
Reactive system: penetrable and reactiveto customer requirements
The greater the amount of contact the
greater the chance of sales opportunity
Production efficiency decreases ascustomer has more contact on the
system 17Chapter Product Design and Process
Selection
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Emerging Issues in ProductsDesign
1. Robust Design2. Modular Design
3. Computer-Aided Design (CAD)
4. Computer-Aided Manufacturing (CAM)
5. Virtual Reality Technology
6. Value Analysis
7. Environmentally Friendly Designs
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Robust Design and ModularDesign
Robust Design: The product is designed insuch a way that small variations in production or
assembly do not adversely affect the product
Modular Design:A design in which parts orcomponents of a product are subdivided into
modules that are easily interchanged or
replaced. It is helpful because it makes product
development, production, and subsequentchange easier. The customization provided by
modularity allows customers to mix and match to
their own taste.Chapter Product Design and Process
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Computer-Aided Design
CAD: It is the use of computers tointeractively design products and prepare
engineering documentation.
CAD software allows designers to usethree-dimensional drawings to save time
and money by shortening development
cycles Faster development, better products,
accurate flow of information to other
departments- all contribute to tremendousChapter Product Design and ProcessSelection 20
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Computer-AidedManufacturing
CAM refers to the use of specialized
computer programs to direct and control
manufacturing equipment
Benefits of CAD and CAM: Product quality
Shorter design time
Production cost reduction Database availability
New range of capabilities
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Virtual Reality Technology and ValueAnalysis
Virtual reality is a visual form ofcommunication in which images substitute
for the real thing but still allow the user to
respond interactively
It has made drafting tables and modeling
clay a thing of the past
Value Analysis seeks improvements thatlead to either a better product or a product
made more economicallyChapter Product Design and Process
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Environmentally FriendlyDesigns
Goals:
Developing safe and more environmentallysound products
Minimizing waste of raw materials andenergy
Reducing environmental liabilities
Increasing cost effectiveness of complyingwith environmental regulations
Being recognized as good corporatecitizens
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Environmentally FriendlyDesigns
Guidelines
Make product recyclable
Use recycled materials
Use less harmful ingredients
Use lighter components
Use less energy
Use less material
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A li ti f D i i T t P d t D i
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Application of Decision Trees to Product Design
Sarah King, president of King Electronics, Inc.,has two design options for her new line of high
resolution cathode-ray tubes (CRTs) for CADwork stations. The life cycle sales forecast forthe CRT is 100,000 units. Design option A has0.9 probability of yielding 59 good CRTs per
100 and 0.1 probability of yielding 64 goodCRTs per 100. This design will cost $1000,000.Design option B has a 0.8 probability ofyielding 64 good units per 100 and a 0.2
probability of yielding 59 good units per 100.This design will cost $1,350,000. Good or badeach CRT will cost $75. Each good CRT will sell
for $150 Bad CRTs are destroyed and have nosalva e value We i nore an dis osal costChapter Product Design and Process
Selection25