1 Mc Graw-Hill Irwin 2006 The Mc Graw-Hill

1 Mc. Graw-Hill/Irwin © 2006 The Mc. Graw-Hill Companies, Inc. , All Rights Reserved.

2 Chapter 4 Product Design Mc. Graw-Hill/Irwin © 2006 The Mc. Graw-Hill Companies, Inc. , All Rights Reserved.

3 OBJECTIVES Product Development Process Economic Analysis of Development Projects Designing for the Customer Design for Manufacturability Measuring Product Development Performance Mc. Graw-Hill/Irwin © 2006 The Mc. Graw-Hill Companies, Inc. , All Rights Reserved.

Typical Phases of Product Development Planning Concept Development System-Level design Detail Testing and Refinement 4 Production Ramp-up Mc. Graw-Hill/Irwin © 2006 The Mc. Graw-Hill Companies, Inc. , All Rights Reserved.

Economic Analysis of Project Development Costs 5 Using measurable factors to help determine: – Operational design and development decisions – Go/no-go milestones Building a Base-Case Financial Model – A financial model consisting of major cash flows – Sensitivity Analysis for “what if” questions Mc. Graw-Hill/Irwin © 2006 The Mc. Graw-Hill Companies, Inc. , All Rights Reserved.

Designing for the Customer 6 House of Quality Function Deployment Mc. Graw-Hill/Irwin Ideal Customer Product Value Analysis/ Value Engineering © 2006 The Mc. Graw-Hill Companies, Inc. , All Rights Reserved.

7 Designing for the Customer: Quality Function Deployment Interfunctional teams from marketing, design engineering, and manufacturing Voice of the customer House of Quality Mc. Graw-Hill/Irwin © 2006 The Mc. Graw-Hill Companies, Inc. , All Rights Reserved.

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

Designing for the Customer: Value Analysis/Value Engineering 9 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? Mc. Graw-Hill/Irwin © 2006 The Mc. Graw-Hill Companies, Inc. , All Rights Reserved.

10 Design for Manufacturability Traditional Approach – “We design it, you build it” or “Over the wall” Concurrent Engineering – “Let’s work together simultaneously” Mc. Graw-Hill/Irwin © 2006 The Mc. Graw-Hill Companies, Inc. , All Rights Reserved.

11 Design for Manufacturing and Assembly 1. 2. 3. 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? Mc. Graw-Hill/Irwin © 2006 The Mc. Graw-Hill Companies, Inc. , All Rights Reserved.

Measuring Product Development Performance Measures Performance • Freq. Of new products introduced Dimension Time-to-market Productivity Quality Mc. Graw-Hill/Irwin 12 • Time to market introduction • Number stated and number completed • Actual versus plan • Percentage of sales from new products • Engineering hours per project • Cost of materials and tooling per project • Actual versus plan • Conformance-reliability in use • Design-performance and customer satisfaction • Yield-factory and field © 2006 The Mc. Graw-Hill Companies, Inc. , All Rights Reserved.

13 End of Chapter 4 Mc. Graw-Hill/Irwin © 2006 The Mc. Graw-Hill Companies, Inc. , All Rights Reserved.