2. Product Design & Process Selection-Manufacturing
Chapter 5
Product Design & Process Selection-Manufacturing

3. OBJECTIVES Typical Phases of Product Design Development
Designing for the Customer
Design for Manufacturability
Types of Processes
Process Flow Structures
Process Flow Design
Global Product Design and Manufacturing 2

4. Typical Phases of Product Design Development
Concept Development
Product Planning
Product/Process Engineering
Pilot Production/Ramp-Up 3

5. Concurrent Engineering Defined
Concurrent engineering can be defined as the simultaneous development of project design functions, with open and interactive communication existing among all team members for the purposes of reducing time to market, decreasing cost, and improving quality and reliability 4

6. Concurrent Engineering(Continued)
Teams provide the primary integration mechanism in CE programs
There are three types of teams
Program Management Team
Technical Team
Design-Build Teams
Time savings of CE programs are created by performing activities in parallel 4

7. Designing for the Customer
House of Quality
Ideal Customer Product
Quality Function
Deployment
Value Analysis/
Value Engineering

8. Designing for the Customer: Quality Function Deployment
Interfunctional teams from marketing, design engineering, and manufacturing
Voice of the customer
House of Quality 6

9. Designing for the Customer: The House of Quality9
Designing for the Customer: The House of Quality
Customer
Requirements
Importance to Cust.
Easy to close
Stays open on a hill
Easy to open
Doesn’t leak in rain
No road noise
Importance weighting
Engineering Characteristics
Energy needed
to close door
Check force on level ground
to open door
Water resistance 10 6 9 2 3 7 5 X
Correlation:
Strong positive
Positive
Negative
Strong negative *
Competitive evaluation
X = Us
A = Comp. A
B = Comp. B
(5 is best) AB
X AB
XAB
A X B
X A B
Relationships:
Strong = 9
Medium = 3
Small = 1
Target values
Reduce energy
level to 7.5 ft/lb
Reduce force
to 9 lb.
to 7.5 ft/lb.
current level
Maintain
Technical evaluation 4 1 A BA
BXA
Door seal
resistance
Accoust. Trans.
Window
Customer requirements information forms the basis for this matrix, used to translate them into operating or engineering goals.
The McGraw-Hill Companies, Inc., 2004 7

10. Designing for the Customer: Value Analysis/Value Engineering (VA/VE)
Achieve equivalent or better performance at 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 into one?
How can we cut down the weight?
Are there nonstandard parts that can be eliminated? 8

11. Design for Manufacturability
Traditional Approach
“We design it, you build it” or “Over the wall”
Concurrent Engineering
“Let’s work together simultaneously” 9

12. Design for Manufacturing and Assembly
Greatest improvements related to DFMA arise from simplification of the product by reducing the number of separate parts:
During the operation of the product, does the part move relative to all other parts already assembled?
Must the part be of a different material or be isolated from other parts already assembled?
Must the part be separate from all other parts to allow the disassembly of the product for adjustment or maintenance? 10

13. Types of Processes Conversion (ex. Iron to steel)
Fabrication (ex. Cloth to clothes)
Assembly (ex. Parts to components)
Testing (ex. For quality of products) 11

14. Process Flow Structures
Job shop (ex. Copy center making a single copy of a student term paper)
Batch shop (ex. Copy center making 10,000 copies of an ad piece for a business)
Assembly Line (ex. Automobile manufacturer)
Continuous Flow (ex. Petroleum manufacturer) 12

15. These are the major stages of product and process life cycles
IV.
Continuous
Flow
III.
Assembly
Line
II.
Batch I.
Job
Shop
Low
Volume,
One of a
Kind
Multiple
Products,
Volume
Few
Major
Higher
High
Standard-
ization
Commercial
Printer
French Restaurant
Heavy
Equipment
Automobile
Burger King
Sugar
Refinery
Flexibility (High)
Unit Cost (High)
Flexibility (Low)
Unit Cost (Low)
Exhibit 5.10
These are the major stages of product and process life cycles 13

16. Virtual Factory Defined
A virtual factory can be defined as a manufacturing operation where activities are carried out not in one central plant, but in multiple locations by suppliers and partner firms as part of a strategic alliance 14

17. Break-Even Analysis
A standard approach to choosing among alternative processes or equipment
Model seeks to determine the point in units produced (and sold) where we will start making profit on the process or equipment
Model seeks to determine the point in units produced (and sold) where total revenue and total cost are equal 14

18. Break-Even Analysis (Continued)
Break-even Demand=
Purchase cost of process or equipment
Price per unit - Cost per unit or
Total fixed costs of process or equipment
Unit price to customer - Variable costs per unit
This formula can be used to find any of its components algebraically if the other parameters are known 14

19. Break-Even Analysis (Continued)
Example: Suppose you want to purchase a new computer that will cost $5,000. It will be used to process written orders from customers who will pay $25 each for the service. The cost of labor, electricity and the form used to place the order is $5 per customer. How many customers will we need to serve to permit the total revenue to break-even with our costs?
Break-even Demand:
= Total fixed costs of process or equip.
Unit price to customer – Variable costs
=5,000/(25-5)
=250 customers 14

20. Process Flow Design Defined
A process flow design can be defined as a mapping of the specific processes that raw materials, parts, and subassemblies follow as they move through a plant
The most common tools to conduct a process flow design include assembly drawings, assembly charts, and operation and route sheets 15

21. Example: Assembly Chart (Gozinto)
From Exhibit 5.14
A-2
SA-2 4 5 6 7
Lockring
Spacer, detent spring
Rivets (2)
Spring-detent
A-5
Component/Assy Operation
Inspection 16

22. Example: Process Flow Chart
Material Received from Supplier
No, Continue…
Inspect Material for Defects
Defects found?
Yes
Return to Supplier for Credit 4

23. Global Product Design and Manufacturing Strategies
Joint Ventures
Global Product Design Strategy 17

24. Measuring Product Development Performance
Dimension
Measures
Freq. Of new products introduced
Time to market introduction
Number stated and number completed
Actual versus plan
Percentage of sales from new products
Time-to-market
Engineering hours per project
Cost of materials and tooling per project
Actual versus plan
Productivity
Conformance-reliability in use
Design-performance and customer satisfaction
Yield-factory and field
Quality 17

25. Question Bowl
Which of the following is the first phase of the typical phases of product development?
Product/process engineering
Product planning
Concept development
Pilot production
Ramp-up
Answer: c. Concept development 7

26. Question Bowl
Which of the following has been primarily used to speed the completion of product development programs?
Concurrent engineering
Job shop
Value analysis
Break-even analysis
Value engineering
Answer: a. Concurrent engineering (The primary purpose of CE is to reduce time it takes to complete a product.) 7

27. Question Bowl
Which of the following is primarily focused on getting the voice of the customer into design specifications in product development?
Concurrent engineering
Value engineering
DFMA
Quality function deployment
None of the above
Answer: d. Quality function deployment 7

28. Question Bowl
Which of the following is the first step in building a House of Quality in product development?
Develop a list of customer requirements for the product
Concept development
Pilot production/Ramp-up
Concurrent engineering
None of the above
Answer: a. Develop a list of customer requirements for the product 7

29. Question Bowl
Of the following abbreviated concepts which derive the greatest product improvements as a result of simplification of the product by reducing the number of separate parts? CE
DFMA
QFD
VA/VE
CAD
Answer: b. DFMA (Design for Manufacturing and Assembly) 7

30. Question Bowl
Which of the following is an example of a Continuous Flow type of process flow structure?
Fast food
Grocery
Hospitals
Chemical company
None of the above
Answer: d. Chemical company 7

31. Question Bowl
What is the break-even in demand for a new process that costs $25,000 to install, will generate a service product that customers are willing to pay $500 per unit for, and whose labor and material costs for each unit is $100?
400 units
250 units
100 units
62.5 units
None of the above
Answer: d units (25,000/( )=62.5) 7

32. End of Chapter 5