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PERANCANGAN PRODUK Chapter 7 Gasal 2015/2016
Debrina Puspita AndrianiTeknik Industri Universitas Brawijaya
e-Mail : debrina@ub.ac.id Blog : http://debrina.lecture.ub.ac.id/
Concept Development Process
Perform Economic Analysis
Benchmark Competitive Products
Build and Test Models and Prototypes
IdentifyCustomer
Needs
EstablishTarget
Specifications
GenerateProduct
Concepts
SelectProduct
Concept(s)
Set Final
Specifications
PlanDownstreamDevelopment
MissionStatement Test
ProductConcept(s)
DevelopmentPlan
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Concept Generation
Customer Needs
Target Specifications
SET of Possible ConceptsConcept Generation
Phase
Goal: By the end of this phase, your team should feel confident that the full spectrum of
options has been explored.
"Fail Often, Fail Fast, Fail Cheap"
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• Goal: generate many concepts • Numerous techniques
• use functional decomposition, then generate concepts from function • concept combinations • analogies • related, unrelated stimuli
Product concept • A technical description of how the product will satisfy the customer’s needs
• An approximate description of • the technology, • working principles, and • form of the product
• Often expressed with a sketch or 3D model, accompanied with a brief textual description.
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Common dysfunctions during concept generation
• Consider only one or two alternatives • Fail to consider the usefulness of the concepts • Involve only one or two people in the process • Ineffectively integrate promising partial solutions • Fail to consider entire categories of solutions
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• Understand the problem • From the team’s (product) mission statement • From the customers needs • From the product specifications
• Decompose the problem into simpler sub-problems • Divide and conquer • Using function diagrams
• Decompose by sequence of user actions • Decompose by key customer’s need
• Focus initial efforts on the critical sub-problems • Focus on critical sub-problems • Defer solutions to other sub-problems
Clarify the
Problem
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Understand the Problem
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• From mission statement • It will use nails • It will be compatible with nail magazines • It will nail through roofing singles into wood • It will be hand held
• Based on assumptions • It inserts nails in rapid succession • It is light weight. • It has no nailing delays (from the user’s view)
• From specifications • Nail length ranges from 25-28 mm • Nailing rate is 1 nail per second. • Tool mass is less than 4 KG.
A. Functional Decomposition • Function: WHAT the product must do • Form (Shape, or Structure): HOW the product will do it • “Form follows function”
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• System Flow Diagram
• Energy, Material, Information (Signal) System Flow Diagram
Functional Decomposition
• Find the overall function that needs to be accomplished
Step 1:
• Create subfunction descriptions
Step 2: • Order the subfunctions
Step 3:
• Refine subfunctions
Step 4:
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Problem Decomposition: Function Diagram
Storenails
Store oraccept
externalenergy
Isolatenail
Convertenergy to
translationalenergy
Applytranslational
energy to nail
Sensetrip
Triggertool
Energy
Nails
"Trip" oftool
Drivennail
Hand-heldnailer
Energy (?)
Signal (?)
Material (nails)
Energy (?)
Signal (tool "trip")
INPUT OUTPUT
Material (driven nail)
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Step 1
Step 2
Functional Decomposition
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• Example: Refinement showing subfunctions (Hand-Held Nailer)
Store/accept external energy
Sensetrip
Storenails
Trigger tool
Isolate nail
Convert energy to
translational energy
Apply translational energy to nail
Energy
Nails
“Trip” of Tool
Driven Nail
B. The FAST Method • FAST - Function Analysis System Technique • A top-down approach • Used to display functions in a logical sequence, prioritize
them, and test their dependency
• First step - brainstorm all functions the product will serve in the eyes of the customer
• Ask “what the product does”, not “what the product is” • Use simple noun-verb / verb-noun structure
• produce torque, generate light, shape material
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The FAST Model • Construct two vertical dashed lines - one left (How → ),
one right (← Why ) • define scope of product development objective
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How → ← Why
BasicFunction
SecondaryFunction
SecondaryFunction
BasicFunctionGoal Method
Domain of Project Study
The FAST Model • Horizontal direction orientation • How → Why (left to right on diagram)
• Start with function - ask How that function is performed; develop subfunctions in moving left to right
• How ← Why (right to left on diagram) • Moving right to left abstracts the problem to a higher level
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FAST Example – Cannister Vacuum Cleaner with Power Head
How → ← Why
LoosenDirt Scrape
Surface
MoveAir
CleanSurface
Pwr HeadAttachments
ProvidePower
RemoveDirt
StoreDirt
ConveyDirt
EntrainDirt
BrushSurface
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• Essential for information gathering • Aimed at overall problem as well as
sub-problems • Continuous throughout development
process • Conventional solutions for some sub-
functions can be combined with novel solutions for others
External search
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External Search: Hints for Finding Related Solutions
Lead Users
benefit from improvement
innovation source
Benchmarking
competitive products
Experts
technical experts
experienced customers
Patents
search related
inventions
Literature
technical journals
trade literature
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Patents/Literature • US Patent and Trademark Office Web Site
• http://www.uspto.gov/ • http://www.uspto.gov/web/offices/com/iip/index.htm
• European Patent Office • http://www.european-patent-office.org/online/
• Academic Journals • Database tools such as web of science, engineering index,
compendex, science citations index, etc. • Conference Proceedings • Internet Resources
• Search engines: Google, Metacrawler, … • Government Web Site (Foreign and Domestic) • DO NOT rely exclusively on internet search resources. They are often
good, but they are also often WRONG and INCOMPLETE
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Professional Societies • Project Management Institute (PMI) • Institute of Electrical and Electronics Engineers (IEEE)
The technical objectives of the IEEE focus on advancing the theory and practice of electrical, electronics and computer engineering and computer science.
• Software Engineering Institute The SEI mission is to provide leadership in advancing the state of the practice of software engineering to improve the quality of systems that depend on software.
• The International Society for Optical Engineering (SPIE) The society's fundamental mission is to provide world-class education and information services that enhance and promote the profession and field of optical engineering and that add quality and value to the careers of the members it serves.
• Society of Automotive Engineers (SAE) SAE provides technical information and expertise used in designing, building, maintaining, and operating self-propelled vehicles for use on land or sea, in air or space.
• American Society for Testing and Materials (ASTM) The society promotes public health and safety, and the overall quality of life; contributes to the reliability of materials, products, systems and services.
• Society of Manufacturing Engineers (SME) The society is dedicated to serving its members and the manufacturing community through the advancement of professionalism, knowledge, and learning.
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Standards • Private Companies & Organizations
• Underwriter’s Laboratory • International Organization for Standards (ISO) • European Environment Agency
• Government • Occupational Safety & Health Administration • MIL standards • Codes
• Societies • Design standards • Accepted practices
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• Most open-ended and creative phase • Overlapping and Iteration: While the
concept development process appears purely sequential, in fact there are usually parts of the concept generation process beginning during customer needs analysis and the process is iterative.
Internal search
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Tips for Idea Generation Focus on generating a large QUANTITY of ideas
Do not criticize individuals, ideas, or suggestions
Do not pass judgment on the statements made
Do not evaluate the merits of an idea – welcome ideas that may first appear infeasible
Set goals – either fixed number of ideas in a session, or maximum ideas in a fixed length of time
Analogies – What other devices solve related problem?
Wish and wonder – Consider new possibilities
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More Tips for Idea Generation
• Balance Individual and Group Search • Individuals generate ideas more quickly than groups
• Analogies – What other devices solve related problem? • Wish and wonder – Consider new possibilities
• Group interaction is critical for refinement, combination, and critique of the solutions • Group sessions build team consensus that solution space has
been adequately explored • Gallery Method – Display many concepts created by various
individuals at once (via post-its, etc.) • Explain • Improve/refine • Identify related concepts
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Internal Search: Hints for Generating Many Concepts
Suspend judgment
Generate a lot of ideas
Infeasible ideas are welcome
Use graphical and physical
media
Make analogies
Wish and wonder
Solve the conflict
Use related stimuli
Use unrelated stimuli
Set quantitative
goals
Use the gallery method
Trade ideas in a group
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Intuitive Techniques
Imagery
Analogy
Brainstorming
• Relax • Ask your intuition for an image • Accept whatever images emerge • Make the image vivid • Look for qualities in the image
• Similarity between things that are otherwise dissimilar
• Makes the familiar strange and the strange familiar
• Goes hand in hand with imagery
• Define in neutral terms • Record all ideas - even wild ones • Suspend judgment • Stretch for ideas • Encourage embellishments • Select at a separate time
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• This step is particularly valuable when the problem has been successfully decomposed into sub-problems.
• However for some simple or highly integrated products, the team may find it more useful to consider entire concepts from the start, rather than combining solution fragments.
Systematic exploration
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Linear Techniques
Osborn’s Idea Spurring
Questions Interrogatory
Analysis Matrix/
Morphological Analysis
Concept combination
tree
Concept combination
table
A. Osborn’s Idea Spurring Questions • Substitute (What other process, material?) • Combine (Combine units, purposes, …?) • Adapt (What else is like this, …?) • Modify (New twist? Change form, function?) • Put to other uses (New/other ways to use?) • Magnify, Minify (Add to, subtract from,..?) • Reverse (Transpose input, output?)
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B. Interrogatory Analysis • Phrase a question about the problem using each of the 5
W’s and H
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• Why… • Where… • Who… • When… • What… • How…
C1. Function Trees • An elementary approach to developing a functional
description of a product • Decompose prime function hierarchically into subfunctions • Iterate down to functions of simple features • Fast and simple, but interconnecting links between
subfunctions not considered
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Menyimpan atau menerima enegri
Sistem bahan bakar udara
Pneumatic
Hidrolik
Listrik
Nuklir
Kimia
Sistem ledakan
Dari saluran di dinding
Batterai
Sel bahan bakar
Pohon Klasifikasi Konsep untuk Beberapa Konsep Sumber Energi Alat Pemaku
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C2. Concept Combination Table Generating Concepts From Functions • Concepts are the means of providing the function • Concepts can be represented as sketches, block
diagrams, textual descriptions, models, etc. • “Morphological technique” a widely used technique
• morphology à study of form or structure
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Generating Concepts From Functions
Step 1: Develop concepts for each function
• Goal: generate as many concepts as possible
• First: For each function, develop as many alternative functions as possible
• Second: For each subfunction, develop as many means of accomplishing the function as possible
Step 2: Combine concepts
• Method: Select one concept for each function and combine those selected into a single design
• Cautions • May generate too many ideas • Erroneously assumes that
each function is independent and each concept satisfies only one function
• results may not make sense
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• Encourage teams to reflect upon the process used and to improve upon it
• Continuous improvement is an essential part of the product development process
• Questions: • The solution space? • Alternative function diagrams? • Alternative ways to decompose the problem? • Additional external resources? • All ideas generated and integrated?
Reflect on the
process
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