PM lecture 3_FTUI.pdf

8/14/2019 PM lecture 3_FTUI.pdf

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Product Design andProduct Design and

Process SelectionProcess SelectionManufacturingManufacturing

Henky S. Nugroho

Bambang P. PriantoProduction Management Course

Manufacturing Management & System Research Groups

Mechanical Engineering

Faculty of Engineering Univ. of Indonesia


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Product Design and Process Selection--

Manufacturing

The Design of Products & Services

Concurrent Engineering Designing for the Customer

QFD Process Selection

Process Flow Design Process Analysis

Globalization of Product Design and

Development2


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Design in Operations Management

design:

has a purpose of satisfying customer needs

applies to both products and systems (processes)

influences each performance objective of an operation

of products/services and processes are interrelated

starts with a concept and turns it into a specification of something which can be

created

the design funnel

One

design

timeChoice and

evaluation

screens


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designs need to be evaluated (assessed for their worth) to choose between

alternatives, using criteria:

feasibility (can it be done?)

acceptability (do we want to do it?)

vulnerability (what about risk?)

decisions between designs can be aided by:

simulations

prototypes

computer-based models


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environmentally sensitive design needs to consider:

source of materials used

quantities and sources of energy used in processes

amounts and types of waste material

life of the product (while in use)

end-of-life of the product (disposal) through life-cycle analysis

process design is likely to be influenced by volume-variety nature of products

standardising products and processes reduces cost outputs or inputs can be standardised


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modular design involves standardised sub-components of a product, which

are put together in different ways (ie. computers)

types of manufacturing processes (in order of increasing volume, decreasing

variety)


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The Design of Products and Services

products and services have 3 aspects:

concept: set of expected benefits that customers buy

package:

component products and services that provide the benefits

eg. the package of a washing machine includes the product of the machine itself, andservices such as warranties

some components of the package are core (fundamental to the purchase), while others

are supporting

while the components of the package are ingredients of the design, the connection of thesecomponents make the final design

process:

connection and relationship between component products and services


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The Product Design Process

Concept Development

Product Planning

Detailed Engineering

Engineering Release (Sign-Off)3


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there are several stages in the product design:

concept generation:

ideas for new products

sourced from inside or outside the company

market research (external source)

focus groups listening to customers

follow activities of competitors (external source)

ideas from staff, R&D, reverse engineering (internal source)


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ideas are transformed into a concept

concept is a statement of overall form, function, purpose and benefits of the idea

concept screening:

evaluate all concepts for their feasibility, acceptability, vulnerability (risk)

preliminary design:

specifying the component products of the package

BOM

product structure

define the processes to create the package

flow of materials

activities to take place

flow charts


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design evaluation and improvement:

evaluate and improve preliminary design prior to test in market

through QFD (quality function deployment), analysing customer needs

through value engineering (VE), to reduce costs (cost-to-function)

via Taguchi methods and testing robustness

prototyping and final design:

virtual prototyping using computers (CAD)


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interactive design is the merging of design of products and processes

the benefit of interactive design is the reduction of time spent to achieve marketintroduction from concept time to market (TTM)

factors leading to reduced TTM include:

simultaneous development:

simultaneous engineering

early conflict resolution

project based organisation structures


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Overhead storage bins

make larger bins B737 idea

sourced from outside (A320)

Concept generation

Screening

Preliminary design

Evaluation and

improvement

Prototyping and final

design

The

Package

The

Process

The

Concept

2 options, one expensive and

time consuming, other not:feasibility, acceptability,

vulnerability

BOM, process flow

(outsourced to supplier)

supplier and customer work

together

CAD models and official

design approval

more storagespace

big bin, moreon board

more onboarddue to big bin


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Concurrent Engineering

Concurrent engineering can be defined as the

simultaneous development of project designfunctions, with open and interactive

communication existing among all teammembers for the purposes of

reducing time to market,

decreasing cost, and

improving quality and reliability.

4


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Designing for the Customer

Industrial Design

Aesthetics

Ergonomics

5


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Quality Function Deployment

Interfunctional teams from marketing, design

engineering, and manufacturing

Voice of the customer

House of Quality

6

Correlation:


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House of Quality

Customer

Requirements

ImportancetoCust.

Easy to close

Stays open on a hill

Easy to open

Doesnt leak in rain

No road noise

Importance weighting

Engineering

Characteristics

Energyneeded

toclosedoor

Checkforceon

levelground

Energyneeded

toopendoor

Waterresistance

10 6 6 9 2 3

7

5

3

3

2

X

X

X

X

X

Strong positive

Positive

Negative

Strong negativeX

*

Competitive evaluation

X = Us

A = Comp. A

B = Comp. B

(5 is best)

1 2 3 4 5

X AB

X AB

XAB

A X B

X A B

Relationships:

Strong = 9

Medium = 3

Small = 1Target values

Reduceenergy

levelto7.5ft/lb

Reduceforce

to9lb.

Reduceenergy

to7.5ft/lb.

Maintain

currentlevel

Technical evaluation

(5 is best)

54

3

2

1

B

A

X

BAX B

A

X

B

X

A

BXABA

X

Doorseal

resistance

Accoust.Trans.

Window

Maintain

currentlevel

Maintain

currentlevel

7


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Value Analysis/Value Engineering (VA/VE)

Achieve equivalent or better performance at a

lower cost while maintaining all functionalrequirements defined by the customer

Does the item have any design features that are notnecessary?

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


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Design for Manufacturability

Traditional Approach

Over the wall

Concurrent Engineering

9


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Design for Manufacturing and Assembly

Greatest improvements related to DFMA arise

from simplification of the product by reducingthe number of separate parts:

1. During the operation of the product, does the partmove relative to all other parts already assembled?

2. Must the part be of a different material than or be

isolated from other parts already assembled? 3. Must the part be separate from all other parts to

allow the disassembly of the product for adjustment or

maintenance?

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Types of Processes

Conversion

Fabrication

Assembly

Testing

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IV.

Continuous

Flow

III.

Assembly

Line

II.

Batch

I.

JobShop

Low

Volume

One of a

Kind

Multiple

Products,

Low

Volume

Few

Major

Products,Higher

Volume

High

Volume,

HighStandard-

ization

Commercial

PrinterFrench Restaurant

Heavy

EquipmentCoffee Shop

Automobile

Assembly

Burger King

Sugar

Refinery

Flexibility (High)

Unit Cost (High)

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


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Process Flow Structures

types of manufacturing processes (in order of increasing volume,

decreasing variety):

project processes:

highly customised

discrete products

time-scale is long

eg. ship building

jobbing processes:

similar to project process, but operation resources are shared by products

eg. specialist tool makers


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Process Flow Structures

batch processes:

reduced variety of jobbing process

eg. automobile component manufacturing

mass processes:

high volume, narrow variety eg. automobile plant

continuous processes:

one step beyond mass process

operate for longer periods of time

inflexible

eg. electricity utilities


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Virtual Factory

Shift from centralized production to ....

... an integrated network of capabilities

14


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Process Flow Design

Assembly drawing

Assembly chart

Operation and route sheet

15


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Assembly (Gozinto) Chart

A-2SA-2

4

5

6

7

Lockring

Spacer, detent spring

Rivets (2)

Spring-detent

A-5

Component/Assy Operation

Inspection

16The McGraw-Hill Companies, Inc., 1998Irwin/McGraw-Hill


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Global Product Design and Manufacturing

Joint Ventures

Strategic Suppliers

Global Product Design Strategy

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Documents

PM lecture 3_FTUI.pdf