Unit 9 Manufacturing Systems CHAPTER 21- PRODUCT AND PROCESS DESIGN

Product Design  Design is motivated by several factors: 1. The need for a specific product 2. The level of available technology 3. Production capability and production cost 4. Safety and Reliability 5. Marketability

Product Design 1. The Need for a specific product: Needs are usually identified by market research and/or customer requests Needs sell better than wants !

Product Design 1. The Need for a specific product: Needs are often created through the advertising of features and options, inducing a customer to buy Designers are engaged in a constant process of design and redesign to fulfill continuing needs

Product Design 2. The Level of available technology The capabilities of existing technology is very important in product design and development. “State of the Art” and “ Best Available Technology” (BET) are frequently used terms to describe available technology

Product Design 2. The Level of available technology The evolution of electronics are a good example of increasing levels of technology Design/implementation of a process or procedure is at times mandated by government regulations to include “ BET”

Product Design 3. Production Capability and Costs Most products made for general consumer use are only successful if they can be produced and marketed at affordable prices. The best product design is only as good as its ability to be competitively produced.

Product Design  Designers must consider the following: 1. Is the production capability presently available? 2. If not, will sales of the product justify development of new production technology? 3. Can the product be manufactured and marketed at a cost that will return investment and profits?

Product Design  Often times, these issues are determined at levels within an organization that are above the designer’s level … but, the designer’s input into these questions is necessary and should be considered.

Product Design 4. Safety and Reliability Critical to the design process Safety concerns should be #1 for the designer Reliability and safety are closed tied. Safety is often largely determined by reliability.

Product Design 4. Marketability Invention is one thing, successful distribution is everything. If a product cannot be properly marketed and sold, it will not be successful. The “market” in free enterprise economies is ruthless !

Product Design 4. Marketability Even if a product is well designed, cost-effectively manufactured, and readily available they may not be profitable if a successful marketing effort is not in place. Marketing can make up more than 90% of the costs of a product!

The Product Design Sequence  Product design generally begins with an idea that develops from a need determined in many cases by market research.  Designers must work just as closely with the marketing and distribution departments as they do with the manufacturing group.

The Product Design Sequence  Product design and development must be a company wide, integrated and coordinated effort that crosses department boundaries.  Each departmental entity within a company must be represented and heard from during the design process.

The Product Design Team  Members from each “department” within the company are part of the product design team.  A project/product manager is selected.  Usually from engineering or marketing  Team members rotate on and off the team depending upon the phase of the product development process

The Product Design Team MANAGEMENT SALES/MARKETING ACCOUNTING/FINANCE RESEARCH ENGINEERING MANUFACTURING SERVICE

The Product Design Sequence 1. Conception 2. Prototype and testing 3. Design evaluation and review 4. Manufacturing prototype 5. Manufacturing review 6. Beta testing – Initial release 7. Formal release 8. Service of the product 9. End of product life cycle

The Product Design Sequence 1. Conception  Market research / Market perspective  Preliminary product specifications  Brainstorming  Initial sketches / Designs  Tentative cost estimates / Target sales price

The Product Design Sequence 2. Prototype and Testing  Initial prototypes usually built by research or engineering and not manufacturing  Often not a full function unit  Used to “work out the kinks” and to refine the technologies/concepts

The Product Design Sequence 3. Design Evaluation and Review  The engineering prototype phase ends with a critical design review and evaluation.  Review session(s) attended by all members of product development team.  Critical review – no holds barred

The Product Design Sequence 3. Design Evaluation and Review  The engineering prototype can be redesigned, changed, modified, etc. and the Review process repeated until a formal approval is given by the Product Development team.  “Final” documents are handed over to manufacturing.

The Product Design Sequence 4. Manufacturing Prototype  The initial manufacturing “run”  Develop manufacturing documentation  Work out the manufacturing processes and procedures  Development cost estimates

The Product Design Sequence 5. Manufacturing Review  Similar to Engineering review – a critical, no holds barred review of the initial manufacturing run  Changes made to documents, processes, and procedures  “Production” documentation is released

The Product Design Sequence 6. Beta Testing – Initial Release  Cooperative customers receive the first production units to help the product developers to “wring out” the initial problems that occur with all products.  Favorable price concessions given to “beta” customers

The Product Design Sequence 7. Formal Release  The formal product release occurs after the beta testing and any changes in the engineering or manufacturing aspects of the product are made from the results from the beta sites.  Marketing efforts in full swing!

The Product Design Sequence 8. Service of the Product  Quality companies provide first class service of their products.  Service aspects of the product need to be built-in and/or considered during the product design and development process.

The Product Design Sequence 9. End of Product Life Cycle  What to do with the product after its useful life is over?  Safety/environmental concerns  Cost issues – regulations, disposal

Other Issues in Product Development Manufacturing Production Drawings  Finished drawings  Detailed part drawings  Assembly drawings  Bills of Materials

Other Issues in Product Development Estimating Costs:  Employee wages, salaries, benefits  Interest on borrowed money  Material prices  Tooling and production machinery  Packaging and shipping  Quality control and assurance

Other Issues in Product Development Estimating Costs:  Service/warranty costs  Sales/marketing costs  Plant/equipment maintenance/utilities  Product liability costs  Design expenses  Profits!  And more …