Product Architecture, Industrial Design, Design for Manufacturing

Chapter 9: Product ArchitectureProduct Architecture has 2 elements:

Functional – individual operations and transformations that contribute to the overall performance of the product

Physical – parts, components, and subassemblies that implement the product function

Creating modules or building blocks can help in organization and manufacturing

Implications of the ArchitectureDecisions of architecture can affect many

issues:Product change

Upgrades, Add-ons, Adaptation, Wear, Consumption, Flexibility in use, Reuse

Product varietyComponent standardizationProduct performanceManufacturabilityProduct development management

ExamplesExhibit 9-4 pg 169 – Swatch watch

Example – F-150

Example – Sport Trac

Establishing Architecture Steps1. Create a schematic of the product

Layout of the components, their hierarchy and interactions

2. Cluster the elements of the schematicGroup the components into clusters based on: Geometric integration and precision Function sharing Capabilities of vendors Similarity of design or production technology Localization of change Accommodating variety Enabling standardization Portability of the interfaces

Establishing Architecture Steps3. Create the rough geometry

Create a rough, basic 3-D and 2-D sketches4. Identify the fundamental and incidental

interactions Likely the functional groups or clusters will be

assigned to the respective areas of expertise for further design. As a cross functional team the interaction between groups should be know

Fundamental interactions – interactions of components based on function of the product

Incidental interactions – interactions that arise from physical arangement

Delayed DifferentiationOn occasion variations in architecture will be

delayed until further in the Supply Chain.Examples – voltage components, product

variation or customer orderingDesign evolves around the customized group

to allow for the options

Chapter 11: Design for ManufacturingDetail design decisions have a substantial

impact on final product quality and costDevelopment teams face multiple and often

conflicting goalsImportant to have metrics to compare

alternative designsDramatic improvements often require

substantial creative efforts early in the processWell-defined method makes the decision-

making process much easier

DFMRequires a cross-functional team, internal to the

organization and external experts, as well as vendors

Performed throughout the processOverview:

1. Estimate the manufacturing costs2. Reduce the costs of components3. Reduce the costs of assembly4. Reduce the cost of supporting production5. Consider the impact of DFM decision on other

facors

Estimate the Manufacturing $Manufacturing $ = ∑Input costs

Raw material Purchased components Employees effort Energy Equipment

Component $Assembly $Overhead $

Estimating the Manufacturing $Fixed $ vs. Variable $

Fixed - $ spent regardless of the quantity of products sold

Variable - $ spent that changes based on the quantity of products sold

Estimate the $ of standard componentsEstimate the $ of custom componentsEstimate the $ of assemblyEstimate the $ of overhead cost

Reduce the $ of ComponentsUnderstand the process constraints and cost

driversRedesign components to eliminate processing

stepsChoose an appropriate Economic scaleStandardize components and processes

Reduce the $ of Assembly - DFAIntegrate partsMaximize ease of assembly

Parts inserted from the top of the assyPart is self-aligningPart does not need to be orientedPart requires only one hand for assyPart requires no toolsPart is assembled in a single, linear motionPart is secured imediately upon insertion

Reduce the $ of Supporting ProductionMinimize systemic complexityError proofing

Consider the impact of DFMThe impact of DFM on development timeThe impact of DFM on development costThe impact of DFM on product qualityThe impact of DFM on external factors

Component reuseLife cycle cost