Chapter 6 Product Design and Process Selection—Manufacturing u

Chapter 6 Product Design and Process Selection--Manufacturing u The Product Design Process – Concurrent Engineering u Designing for the Customer – QFD u Process Selection u Process Flow Design u Process Analysis u Globalization of Product Design and Development Irwin/Mc. Graw-Hill ©The Mc. Graw-Hill Companies, Inc. , 1998 2

The Product Design Process u Concept Development u Product Planning u Detailed Engineering u Engineering Irwin/Mc. Graw-Hill Release (Sign-Off) ©The Mc. Graw-Hill Companies, Inc. , 1998 3

Concurrent Engineering u 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 u reducing time to market, – decreasing cost, and – improving quality and reliability. Irwin/Mc. Graw-Hill ©The Mc. Graw-Hill Companies, Inc. , 1998 4

Designing for the Customer u Industrial Design » Aesthetics » Ergonomics Irwin/Mc. Graw-Hill ©The Mc. Graw-Hill Companies, Inc. , 1998 5

Quality Function Deployment u Interfunctional teams from marketing, design engineering, and manufacturing u Voice of the customer u House of Quality Irwin/Mc. Graw-Hill ©The Mc. Graw-Hill Companies, Inc. , 1998 6

Correlation: House of Quality Strong positive X Positive X X t. Water resistance Cu s * Accoust. Trans. Window to Energy needed to open door Customer Requirements Check force on level ground nc e Door seal resistance or ta Energy needed to close door Engineering Characteristics Im p Negative Strong negative X X X Competitive evaluation X = Us A = Comp. A B = Comp. B (5 is best) 1 2 Easy to close 7 5 3 No road noise 2 AB 3 Doesn’t leak in rain 5 X AB Easy to open 4 X Stays open on a hill 3 XAB A XB X A Importance weighting 10 6 6 9 2 3 B Relationships: Technical evaluation (5 is best) 5 4 3 2 1 B A X B B A A BXA Maintain current level Medium = 3 Small = 1 BA X X X Maintain current level Reduce energy to 7. 5 ft/lb. Reduce force to 9 lb. Target values Maintain current level Reduce energy level to 7. 5 ft/lb Strong = 9 7

Value Analysis/Value Engineering (VA/VE) u 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? Irwin/Mc. Graw-Hill ©The Mc. Graw-Hill Companies, Inc. , 1998 8

Types of Processes u Conversion u Fabrication u Assembly u Testing Irwin/Mc. Graw-Hill ©The Mc. Graw-Hill Companies, Inc. , 1998 11

Process Flow Structures u Job shop u Batch u Assembly Line u Continuous Irwin/Mc. Graw-Hill Flow ©The Mc. Graw-Hill Companies, Inc. , 1998 12

Exhibit 4. 9 Low Volume One of a Kind I. Job Shop II. Batch III. Assembly Line IV. Continuous Flow Multiple Products, Low Volume Few Major Products, Higher Volume High Volume, High Standardization Flexibility (High) Unit Cost (High) Commercial Printer French Restaurant Heavy Equipment Coffee Shop Automobile Assembly Burger King Sugar Refinery Flexibility (Low) Unit Cost (Low) Source: Modified from Robert Hayes and Steven Wheelwright, Restoring Our Competitive Edge: Competing through Manufacturing (New York: John Wiley & Sons, 1984). p. 209. 13

Global Product Design and Manufacturing u Joint Ventures u Strategic u Global Irwin/Mc. Graw-Hill Suppliers Product Design Strategy ©The Mc. Graw-Hill Companies, Inc. , 1998 17