product design and process selection.ppt

8/14/2019 Product Design and Process Selection.ppt

1/25

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


2/25

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


3/25

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


4/25

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

4


5/25

Designing for the Customer

House of Quality

Quality FunctionDeployment

Value Analysis/Value Engineering

Ideal CustomerProduct

House of Quality



6/25

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


7/25

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


8/25

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


9/25

House of Quality

Customerrequirementsinformationforms the

basis for thismatrix, usedto translatethem intooperating orengineeringgoal


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

9


10/25

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


11/25

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


12/25

Designing Products forManufacture and Assembly

Traditional Approach

We design it, you build it or Over the

wall

Concurrent Engineering Lets work together simultaneously



13/25

Designing forManufacturing

Minimize parts

Design parts for

multiple

applications

Use modular

design

Avoid tools

Simpler to

assemble 13Chapter Product Design and ProcessSelection


14/25

Process Selection

It refers to strategic decision ofselecting which kind of productionprocess to have in manufacturing plant

Types: Conversion

Fabrication

Assembly Testing



15/25

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


16/25

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



17/25

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


18/25

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


18


19/25

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

Selection19


20/25

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


21/25

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


21


22/25

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

Selection22


23/25

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


23


24/25

Environmentally FriendlyDesigns

Guidelines

Make product recyclable

Use recycled materials

Use less harmful ingredients

Use lighter components

Use less energy

Use less material


24

A li ti f D i i T t P d t D i


25/25

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

product design and process selection.ppt

Documents