1. Manufacturing Processes for Engineering Materials (5th Edition in SI Units)
Chapter 16:
Product Design and Manufacturing
in a Global Competitive Environment 1

2. Index
Quality
Material
Manufacturing
Cost

3. Product Design and Robust Design
Software helps designers develop products which reduced assembly and manufacture time.
Some product design considerations:
Simplified product design
Environmental considerations
Alternative designs
Unnecessary features are eliminated
Modular design

4. Product design and quantity of materials
High production rates and reduced labour made automation and computer integration possible.
Reductions in materials require selection of materials with high strength-to-weight ratios.
Robustness and robust design -
Robustness is defined as a design that functions within acceptable parameters.
Yet its difficult or impossible to control.

5. Quality as a manufacturing goal
Product quality includes well-defined technical considerations and human opinion.
High product quality includes:
High reliability
Performs, functions well and safely
Good appearance
Inexpensive
Upgradeable
Robustness

6. Quality as a manufacturing goal
Concept of continuous improvement in quality means that there should be never-ending improvement.
Concurrent engineering design is to select specific materials for components for a particular product.
Concept of return on quality (ROQ) is:
Making sure quality is an investment.
Limit on how resources should be explanded.
Having quality improvement.

7. Total quality management
Total quality management (TQM) is a system that emphasizes that quality must be designed and built into a product.
Both management and employees make an effort to manufacture high-quality products without any defects.
Quality circle
Concept consists of regular meetings.
Worker involvement, responsibility, creativity and team effort are emphasized.

8. Deming methods

9. Taguchi methods
High quality and low costs are achieved by engineering and statistical methods.
Loss of quality will result in:
customer dissatisfaction
costs are incurred
marketplace is diminished
loses its company share in the market

10. Taguchi methods
Taguchi methods of quality engineering emphasizes the importance of:
Enhancing cross-functional team interaction
Implementing experimental design
Taguchi loss function
σ = standard deviation of parts
Y = mean value from manufacturing
LSL = lower specification limitation
T = target value from design
k = constant

11. Example 16.1 Production of polymer tubing
High-quality polymer tubes are being produced for medical applications, where the
target wall thickness is 2.6 mm, with an upper specification limit of 3.2 mm and a lower specification limit of 2.0 mm (2.6±0.6mm). If the units are defective, they are replaced at a shipping-included cost of $ The current process produces parts with a mean of 2.6 mm and a standard deviation of 0.2 mm. The current volume is 10,000 pieces of tube per month. An improvement is being considered for the extruder heating system. This improvement will cut the variation in half, but it will cost $50,000. Determine the Taguchi loss function and the payback period for the original production process and incorporating the process improvement.

12. Example 16.1 Production of polymer tubing
Solution
The quantity k is given by
The loss cost is then
After improvement,
The savings are
The payback period for the investment is

13. The ISO and QS Standards
Customers always demand high-quality products and services at low prices.
The ISO 9000 standard
Quality Management and Quality Assurance Standards is a generic series of quality-system management standards.
Companies which fail to meet the requirements of the standard will not be registered.

14. Life-Cycle Engineering and Sustainable Manufacturing
Product life cycle is concerned with environmental factors, design, optimization and technical considerations of the product.
Cradle-to-grave
Consecutive and interlinked stages of a product or service system.
Sustainable manufacturing
The need for conserving these resources through maintenance and reuse.

15. General properties of materials
Mechanical properties of materials include strength, toughness, ductility, hardness and resistance to fatigue, creep and impact.
Physical properties include density, melting point, specific heat, thermal and electrical conductivity, thermal expansion and magnetic properties.
The chemical properties are oxidation and corrosion.

16. Shapes of commercially available materials
Materials are available in various forms.

17. Manufacturing characteristics of materials
Manufacturing characteristics include castability, workability, formability, machinability, grindability, weldability and hardenability through heat treatment.
Quality of a raw material influences its manufacturing characteristics.

18. Substitution of Materials in Products
Product improvements result from:
substitution of materials
implement new designs, technologies or improved processing techniques
better control of processing parameters
increased automation

19. Capabilities of Manufacturing Processes
Casting and injection molding can produce complex shapes.
Forgings have higher toughness.

20. Capabilities of Manufacturing Processes
Dimensional tolerances and surface finishing
Important for functioning of parts, machines, and instruments and assembly operations.

21. Capabilities of Manufacturing Processes
Production quantity or volume
Manufacturing discipline is to determine the optimum production quantity.
Production rate
Production rate is the number of pieces that can be produced per unit of time.
Lead time
Lead time is the length of time between receipt of order and delivery of product to customer.

22. Selection of Manufacturing Processes
Some considerations are:
Properties of the material
Geometric features
Dimensional-tolerance and surface-finish requirements
Functional requirements of the part
Production quantity required
Costs

23. Manufacturing Costs and Cost Reduction
The total cost of a product consists material, tooling, fixed, variable, direct and indirect labour costs.
Costing has the following considerations:
quality improvements and inventory reduction
life-cycle costs
machine usage
purchasing cost
financial risks

24. Manufacturing Costs and Cost Reduction
Major cost factors are:
Material costs
Tooling costs
Fixed costs
Capital costs
Labour costs

25. Cost reduction
Cost reduction requires assessment of costs that incurred and interrelated.
An approximate breakdown of costs is
Cost reductions can be achieved by:
simplifying product design
reducing the amount of materials
investigating alternative methods
using more efficient equipments