1. MINGGU KE 10: PENGEMBANGAN DESAIN RINCI

2. INTRODUCTION (Ulrich, 2000)
TO DEVELOP DETAILED DESIGN, THERE ARE SEVERAL ACTIVITIES REQUIRED :
DEVELOPMENT OF PRODUCT ARCHITECTURE.
DEVELOPMENT DETAILED DESIGN CONSIDERING THE PRINCIPLES OF
INDUSTRIAL DESIGN.
DFM (DESIGN FOR MANUFACTURING)
PROTOTYPING

3. DEVELOPMENT OF PRODUCT ARCHITECTURE (1) (Ulrich, 2000)
A PRODUCT CAN BE THOUGHT OF IN BOTH FUNCTIONAL AND PHYSICAL TERMS.
THE FUNCTIONAL ELEMENTS OF A PRODUCT ARE THE INDIVIDUAL OPERATIONS
AND TRANSFORMATIONS THAT CONTRIBUTE TO THE OVERALL PERFORMANCE
OF THE PRODUCT.
FOR EXAMP : A PRINTER, SOME OF THE FUNCTIONAL ELEMENTS ARE “STORE PAPER”
AND “COMMUNICATE WITH THE HOST COMPUTER”.
THE PHYSICAL ELEMENTS OF A PRODUCT ARE THE PARTS, COMPONENTS, AND SUB-
ASSEMBLIES THAT ULTIMATELY IMPLEMENT THE PRODUCT’S FUNCTIONS. SOME
PHYSICAL ELEMENTS ARE DICTATED BY THE PRODUCT CONCEPT AND OTHER BECOME
DEFINED DURING THE DETAIL DESIGN PHASE.
THE PHYSICAL ELEMENTS OF A PRODUCT ARE TYPICALLY ORGANIZED INTO SEVERAL
MAJOR PHYSICAL BUILDING BLOCKS, WHICH ARE CALLED “CHUNKS’.

4. DEVELOPMENT OF PRODUCT ARCHITECTURE (2) (Ulrich, 2000)
EACH CHUNK IS MADE UP OF A COLLECTION OF COMPONENTS THAT IMPLEMENT
THE FUNCTIONS OF PRODUCT.
THE ARCHITECTURE OF A PRODUCT IS THE SCHEME BY WHICH THE FUNCTIONAL
ELEMENTS OF THE PRODUCTS ARE ARRANGED INTO PHYSICAL CHUNKS AND BY
WHICH THE CHUNKS INTERACT.

5. DEVELOPMENT OF PRODUCT ARCHITECTURE (3) (Ulrich, 2000)
THE DIFFERENCES BETWEEN A MODULAR ARCHITECTURE AND INTEGRAL
ARCHITECTURE :
MODULAR ARCHITECTURE INTEGRAL ARCHITECTURE
CHUNKS IMPLEMENT ONE OR A FEW
FUNCTIONAL ELEMENTS IN THEIR
ENTIRETY
THE INTERACTIONS BETWEEN CHUNKS
ARE WELL DEFINED AND ARE GENERALLY
FUNADAMENTAL TO THE PRIMARY
FUNCTIONS OF THE PRODUCT
FUNCTIONAL ELEMENTS OF THE PRODUCT ARE
IMPLEMENTED USING MORE THAN ONE CHUNK.
A SINGLE CHUNK IMPLEMENTS MANY FUNCTI-
NAL ELEMENTS.
THE INTERACTIONS BETWEEN CHUNKS ARE ILL
DEFINED AND MAY BE INCIDENTAL TO THE
PRIMARY FUNCTIONS OF THE PRODUCTS

6. DEVELOPMENT OF PRODUCT ARCHITECTURE (4) (Ulrich, 2000)
MODULARITY IS A RELATIVE PROPERTY OF A PRODUCT ARCHITECTURE. PRODUCTS
ARE RARELY STRICTLY MODULAR OR INTEGRAL. RATHER, WE CAN SAY THAT THEY
EXHIBIT EITHER MORE OR LESS MODULARITY THAN A COMPARATIVE PRODUCT.
WHEN IS THE PRODUCT ARCHITECTURE DEFINED ?
A PRODUCT’S ARCHITECTURE BEGINS TO EMERGE DURING CONCEPT DEVELOPMENT.
GENERALLY, THE MATURITY OF THE BASIC PRODUCT TECHNOLOGY DICTATES
WHETHER THE PRODUCT ARCHITECTURE IS FULLY DEFINED DURING CONCEP DEVE-
LOPMENT OR DURING SYSTEM-LEVEL DESIGN.

7. IMPLICATIONS OF PRODUCT ARCHITECTURE (Ulrich, 2000)
DECISIONS ABOUT HOW TO DIVIDE THE PRODUCT INTO CHUNKS AND ABOUT HOW
MUCH MODULARITY TO IMPOSE ON THE ARCHITECTURE ARE TIGHTLY LINKED TO
SEVERAL ISSUES OF IMPORTANCE TO THE ENTIRE ENTERPRISE :
1. PRODUCT CHANGE
2. PRODUCT VARIETY
3. COMPONENT STANDARDIZATION
4. PRODUCT PERFORMANCE
5. MANUFACTURABILITY
6. PRODUCT DEVELOPMENT MANAGEMENT

8. ESTABLISHING THE PRODUCT ARCHITECTURE (1) (Ulrich, 2000)
STEP 1 : CREATE A SCHEMATIC OF THE PRODUCT
A SCHEMATIC IS A DIAGRAM REPRESENTING THE TEAM’S UNDERSTANDING OF THE
CONSTITUENT ELEMENTS OF THE PRODUCT. THE SCHEMATIC SHOULD REFLECT
THE TEAM’S BEST UNDERSTANDING OF THE STATE OF THE PRODUCT, BUT IT DOES
NOT HAVE TO CONTAIN EVERY IMAGINABLE DETAIL.
STEP 2 : CLUSTER THE ELEMENTS OF THE SCHEMATIC
THE CHALLENGE OF THE STEP 2 IS TO ASSIGN EACH OF THE ELEMENTS OF THE
SCHEMATIC TO A CHUNK.
STEP 3 : CREATE A ROUGH GEOMETRIC LAYOUT
CREATING A GEOMETRIC LAYOUT FORCES THE TEAM TO CONSIDER WHETHER THE
GEOMETRIC INTERFACES AMONG THE CHUNKS ARE FEASIBLE AND TO WORK OUT
THE BASIC DIMENSIONAL RELATIONSHIPS AMONG THE CHUNKS.

9. ESTABLISHING THE PRODUCT ARCHITECTURE (2) (Ulrich, 2000)
STEP 4 : IDENTIFY THE FUNDAMENTAL AND INCIDENTAL INTERACTIONS
THERE ARE TWO CATEGORIES OF INTERACTIONS BETWEEN CHUNKS.
FIRST, FUNDAMENTAL INTERACTIONS ARE THOSE CORRESPONDING TO THE
LINES ON THE SCHEMATIC THAT CONNECT THE CHUNKS TO ONE ANOTHER.
SECOND, INCIDENTAL INTERACTIONS ARE THOSE THAT ARISE BECAUSE OF
THE PARTICULAR PHYSICAL IMPLEMENTATION OF FUNCTIONAL ELEMENTS OR
BECAUSE OF THE GEOMETRIC ARRANGEMENT OF THE CHUNKS.

10. INDUSTRIAL DESIGN (1) (Ulrich, 2000)
THE PRIMARY MISSIONS OF INDUSTRIAL DESIGN IS TO DESIGN THE ASPECTS OF
A PRODUCT THAT RELATE TO THE USER : ERGONOMIC & AESTHETIC NEEDS.
ERGONOMICS NEEDS
HOW IMPORTANT IS EASE OF USE ?
HOW IMPORTANT IS EASE OF MAINTENANCE?
HOW MANY USER INTERACTIONS ARE REQUIRED FOR THE PRODUCT’S
FUNCTIONS?
HOW NOVEL ARE THE USER INTERACTION NEEDS?
WHAT ARE THE SAFETY ISSUES?.

11. INDUSTRIAL DESIGN (2) (Ulrich, 2000)
II. AESTHETIC NEEDS :
IS VISUAL PRODUCT DIFFERENTIATION REQUIRED?
HOW IMPORTANT ARE PRIDE OF OWNERSHIP, IMAGE & FASHION?
WILL AN AESTHETIC PRODUCT MOTIVATE THE TEAM ?

12. INDUSTRIAL DESIGN (3) (Ulrich, 2000)
MOST PRODUCTS CAN BENEFIT IN SOME WAY OR ANOTHER FROM INDUSTRIAL
DESIGN. THE MORE A PRODUCT IS LOOKED AT OR USED BY PEOPLE, THE MORE
IT WILL DEPEND ON GOOD INDUSTRIAL DESIGN FOR ITS SUCCES.
THE INDUSTRIAL DESIGN PROCESS CAN BE THOUGHT OF AS CONSISTING OF THE
FOLLOWING PHASES :
INVESTIGATION OF CUSTOMER NEEDS.
CONCEPTUALIZATION.
PRELIMINARY REFINEMENT.
FURTHER REFINEMENT & FINAL CONCEPT SELECTION.
CONTROL DRAWING.
COORDINATION WITH THE ENGINEERING, MANUFACTURING, & VENDORS.

13. ROLE INDUSTRIAL DESIGN ACCORDING TO THE PRODUCT TYPE (1)
TYPE OF RODUCT
PRODUCT DEVELOPMENT
ACTIVITY
TECHNOLOGY-DRIVEN USER-DRIVEN
1. IDENTIFICATION OF ID TYPICALLY HAS NO INVOLVEMENT ID WORKS CLOSELY WITH MARKETING
CUSTOMER NEEDS TO IDENTIFY CUSTOMER NEEDS.
INDUSTRIAL DESIGNERS PARTICIPATE
IN FOCUS GROUPS OR ONE-ON-ONE
CUSTOMER INTERVIEWS.
2. CONCEPT GENERATION ID WORKS WITH MARKETING & ID GENERATES MULTIPLE CONCEPTS
& SELECTION ENGINEERING TO ASSURE THAT ACCORDING TO THE INDUSTRIAL
HUMAN FACTORS & USER-INTER DESIGN PROCESS FLOW DESCRIBED
FACE ISSUES ARE ADDRESSED EARLIER.
SAFETY & MAINTENANCE ISSUES
ARE OFTEN OF PRIMARY IMPOR-
TANCE.
3. CONCEPT TESTING ID HELPS ENGINEERING TO CREATE ID LEADS IN THE CREATION OF
PROTOTYPES, WHICH ARE SHOWN MODELS TO BE TESTED WITH CUS-
TO CUSTOMERS FOR FEEDBACK TOMERS BY MARKETING.

14. ROLE INDUSTRIAL DESIGN ACCORDING TO THE PRODUCT TYPE (2)
TYPE OF RODUCT
PRODUCT DEVELOPMENT
ACTIVITY
TECHNOLOGY-DRIVEN USER-DRIVEN
SYSTEM-LEVEL ID TYPICALLY HAS LITTLE INVOL ID NARROWS DOWN THE CONCEPTS
DESIGN VEMENT & REFINES THE MOST PROMISING APPROACHES.
DETAIL DESIGN, ID IS RESPONSIBLE FOR PACKAGING ID SELECTS A FINAL CONCEPT, THEN
TESTING, THE PRODUCT ONCE MOST OF THE COORDINATES WITH ENGINEERING,
& REFINEMENT ENGINEERING DETAILS HAVE MANUFACTURING, & MARKETING TO
BEEN ADDRESSED. ID RECEIVES FINALIZE THE DESIGN
PRODUCT SPECIFICATIONS &
CONSTRAINTS FROM ENGINEERING
& MARKETING

15. DFM: DESIGN FOR MANUFACTURING (1) (Ulrich, 2000)
DFM IS AIMED AT REDUCING MANUFACTURING COSTS WHILE SIMULTANEOUSLY
IMPROVING (OR AT LEAST NOT INAPPROPRIATELY COMPROMISING) PRODUCT
QUALITY, DEVELOPMENT TIME, & DEVELOPMENT COST.
DFM BEGINS WITH THE CONCEPTS DEVELOPMENT PHASE & SYSTEM-LEVEL DESIGN
PHASE; IN THESE PHASES IMPORTANT DECISIONS MUST BE MADE WITH THE
MANUFACTURING COST IMPLICATIONS IN MIND.
DFM UTILIZES ESTIMATES OF MANUFACTURING COST TO GUIDE & PRIORITIZE
COST REDUCTION EFFORTS.

16. DFM: DESIGN FOR MANUFACTURING (2) (Ulrich, 2000)
DFM CONSISTS OF FIVE STEPS :
ESTIMATE THE MANUFACTURING COSTS.
THE MANUFACTURING COST OF A PRODUCT CONSISTS OF COSTS IN THREE
CATEGORIES :
A. COMPONENTS COSTS
B. ASSEMBLY COSTS
C. OVERHEAD COSTS

17. DFM: DESIGN FOR MANUFACTURING (3) (Ulrich, 2000)
2. REDUCE THE COSTS OF COMPONENTS
SEVERAL STRATEGIES FOR MINIMIZING THE MANUFACTURING COST :
A. UNDERSTAND THE PROCESS CONSTRAINT & COST DRIVER.
B. REDESIGN COMPONENTS TO ELIMINATE PROCESSING STEPS.
C. CHOOSE THE APPROPRIATE ECONOMIC SCALE FOR THE PART PROCESS.
D. STANDARDIZE COMPONENTS AND PROCESS
E. ADHERE TO “BLACK BOX” COMPONENT PROCUREMENT

18. DFM: DESIGN FOR MANUFACTURING (4) (Ulrich, 2000)
3. REDUCE THE COSTS OF ASSEMBLY
WE CAN A FEW PRINCIPLES USEFUL TO GUIDE DFA (DESIGN FOR ASSEMBLY)
DECISIONS IN ORDER TO REDUCE THE COSTS OF ASSEMBLY.
A. KEEPING SCORE DFA INDEX :
(THEORETICAL MINIMUM NUMBER OF PARTS) X 3 SECONDS
DFA INDEX =
ESTIMATED TOTAL ASSEMBLY TIME
B. INTEGRATE PARTS
C. MAXIMIZE EASE OF ASSEMBLY
D. CONSIDER CUSTOMER ASSEMBLY

19. DFM: DESIGN FOR MANUFACTURING (5) (Ulrich, 2000)
4. REDUCE THE COSTS OF SUPPORTING PRODUCTION
A. MINIMIZE SYSTEMIC COMPLEXITY
B. ANTICIPATE THE POSSIBLE FAILURE MODES OF THE PRODUCTION SYSTEM
& TAKE APPROPRIATE CORRECTIVE ACTION EARLY IN THE DEVELOPMENT
PROCESS
5. CONSIDER THE IMPACT OF DFM DECISIONS ON OTHER FACTORS
A. THE IMPACT OF DFM ON DEVELOPMENT TIME
B. THE IMPACT OF DFM ON DEVELOPMENT COST
C. THE IMPACT OF DFM ON PRODUCT QUALITY
D. THE IMPACT OF DFM ON EXTERNAL FACTORS

20. DFM: DESIGN FOR MANUFACTURING (6) (Ulrich, 2000)
PROPOSED DESIGN
ESTIMATE THE
MANUFACTURING COSTS
REDUCE THE COSTS
OF COMPONENTS
REDUCE THE COSTS
OF ASSEMBLY
REDUCE THE COSTS
OF SUPPORTING PRODUCTION
CONSIDER THE IMPACT
OF DFM DECISIONS ON
OTHER FACTORS
RECOMPUTE THE MANUFACTURING COSTS NO
GOOD
ENOUGH ?
YES
ACCEPTABLE DESIGN

21. PROTOTYPING (1) (ULLMAN, 1996)
Prototipe yang dibuat memenuhi persyaratan sbb:
1. Prototipe merupakan perwujudan atribut-atribut pokok dari konsep
produk.
2. Prototipe harus bekerja dengan aman dalam keadaan penggunaan
yang normal.
3. Prototipe dibuat dalam batas-batas anggaran.
4. Prototipe tidak hanya mampu menunjukkan segi kegunaannya
saja, tapi juga mampu mengkomunikasikan sisi-sisi psikologis dari
produk (isyarat-isyarat fisik).

22. PROTOTYPING (2) (Ulrich, 2000)
PRODUCT DEVELOPMENT ALMOST ALWAYS REQUIRES THE BUILDING AND TESTING
OF PROTOTYPES.
A PROTOTYPE IS AN APPROXIMATION OF THE PRODUCT ON ONE OR MORE DIMEN-
SIONS OF INTEREST.
PROTOTYPES CAN BE USEFULLY CLASSIFIED ALONG TWO DIMENSIONS : (1) THE
DEGREE TO WHICH THEY ARE PHYSICAL AS OPPOSED TO ANALYTICAL AND (2) THE
DEGREE TO WHICH THEY ARE COMPREHENSIVE AS OPPOSED TO FOCUSED.
PROTOTYPES ARE USED FOR LEARNING, COMMUNICATION, INTEGRATION, AND
MILESTONES. WHILE ALL TYPES OF PROTOTYPES CAN BE USED FOR ALL OF THESE
PURPOSES, PHYSICAL PROTOTYPES ARE USUALLY BEST FOR COMMUNICATION,
AND COMPREHENSIVE PROTOTYPES ARE BEST FOR INTEGRATION AND MILES-
TONES.

23. PROTOTYPING (3) (Ulrich, 2000)
A PROTOTYPES MAY REDUCE THE RISK OF COSTLY ITERATIONS. A PROTOTYPE
MAY EXPEDITE OTHER DEVELOPMENT STEPS. A PROTOTYPE MAY RESTRUCTURE
TASK DEPENDENCIES.
3D COMPUTER MODELING & FREE-FORM FABRICATION TECHNOLOGIES HAVE
REDUCED THE RELATIVE COST & TIME REQUIRED TO CREATE PROTOTYPES.
FOUR-STEP METHOD FOR PLANNING A PROTOTYPE IS :
DEFINE THE PURPOSE OF THE PROTOTYPE
ESTABLISH THE LEVEL OF APPROXIMATION OF THE PROTOTYPE
OUTLINE AN EXPERIMENTAL PLAN
CREATE A SCHEDULE FOR PROCUREMENT, CONSTRUCTION, AND TEST