1. Chapter 1: Introduction
EIN 6392, Summer 2012
Product Design for Manufacturability and Automation

2. Outline Importance of product development Scope of development efforts
Role of structured methods
Benefits of integration
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3. Importance of product development to firms
Successful stories
Nokia mobile phones
Ford Sport/utility vehicles
George Foremen grill
Apple computer: iPod, iPad, i…
Digital cameras
Thermo care
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4. Lessons learned from the stories
It is products like these that make companies successful
What in common is that their developers understood their customers and their competitors
They created products that met or exceeded their customers’ expectation
Without these products, none of these companies would be competitive at that time.
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5. Characteristics of successful product development
Product quality
In terms of meeting needs, robustness, and reliability.
Yardsticks: market share and price.
Product cost
Indirect cost
Direct cost
Development cost
Development lead time
Accumulation of development capability and experience of the team.
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6. Today’s business environment
Innovation
Be the first in the market
Shortened product life cycle & shortened product development cycle
concurrent engineering/operation
Frequent changes & agile operations
mass customization
Smaller lots and just-in-time production
lean manufacturing/thinking
Core business and supply network
Global economy and corporate intelligence
Internet and wireless integration
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7. Scope of development efforts
The team
Development time: 1-5 years
Development cost: US$100K-3B
Team size (internal): 3-10K
Team size (external): 3-10K
The product
Product cost: US$1-200M
Numbers of parts: 3-130K
Annual production volume: 50-50M
Sales lifetime: 1-40 years
Initial production cost: US$100K-3B
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9. Product development team – core team
Marketing function
Design function ME EE
Industrial designer
Manufacturing function
Manufacturability
Supply chain
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10. Product development team – extended team
Legal
Consulting firm
Government agencies
Universities
Environmental groups
Professional regulatory groups (such as the ASME)
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12. Benefits of integration
The best practice is to involve a team of people representing the necessary disciplines and skills (a cross-functional team)
Note:
Assemble your project team of multi-disciplinary backgrounds as required.
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13. Challenges of product development
Trade-off
Dynamics in the environment
Tremendous amount of design details
Time pressure
Satisfaction of societal and individual needs
Team diversity & spirit
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14. Organizational realities – leading to dysfunctional product development team
Lack of empowerment of the team
Functional allegiances transcending project goals
That is, allegiance to functional department vs. project success
Inadequate resources
Lack of cross-functional representation on the project team
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15. Role of structured methods
Product development process
is a creative effort
is a process of design-related activities, which can be documented, studied and improved.
Question?
Is product development an art or an science?
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16. Product development process
Planning
Concept development
Architectural (system-level) design
Detailed design
Testing and refinement
Production design and ramp-up
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17. Chapter 1: Assignments Homework assignment Project assignment
Do exercise #2 on page 10
Follow exhibit 1-3 to identify the scope of efforts for a PC (or cellphone) development project.
Project assignment
Form an integration team of 4 members
Due date: next week
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