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Product Design & Process Selection-Manufacturing. Typical Phases of Product Development. New Product. Design. Mfg. Design for Manufacturability. Traditional Approach-“We design it, you build it” or “Over the wall”. Concurrent Engineering-“Let’s work together simultaneously”. - PowerPoint PPT Presentation
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EMBA-2, BUP
EO - 702
Product Design & Process Selection-Manufacturing
EMBA-2, BUP
EO - 702Typical Phases of Product Development
EMBA-2, BUP
EO - 702
Design for Manufacturability
Traditional Approach-“We design it, you build it” or “Over the wall”
DesignMfg
New Product
Concurrent Engineering-“Let’s work together simultaneously”
EMBA-2, BUP
EO - 702
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 reducing time to market, decreasing cost, and improving quality and reliability
There are three types of teams• Program Management Team• Technical Team• Design-Build Teams
Time savings of CE programs are created by performing activities in parallel
EMBA-2, BUP
EO - 702
Designing for the Customer
Value Analysis/Value Engineering
Ideal Customer Product
House of Quality
QFD: An approach that integrates the “voice of the customer” into the product and service development process.
+
VOICE OF THECUSTOMER
QFD
= CUSTOMERSATISFACTION
EMBA-2, BUP
EO - 7026
Customer requirements information forms the basis for this matrix, used to translate them into operating or engineering goals.
Customer requirements information forms the basis for this matrix, used to translate them into operating or engineering goals.
House of Quality
EMBA-2, BUP
EO - 7027
EMBA-2, BUP
EO - 7028
House of Quality
6. Targets6. Targets
4. Inter-relationships
4. Inter-relationships
2. P
lann
ing
Ma
trix
1. C
usto
me
rR
eq
uire
me
nts
3. TechnicalRequirements
3. TechnicalRequirements
5. Roof5. Roof
EMBA-2, BUP
EO - 7029
Hou
se o
f Q
uality
EMBA-2, BUP
EO - 702
Designing for the Customer
Value Analysis/Value Engineering (VA/VE)
Main aim is to eliminate unnecessary features and functions in product design.
To 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?
EMBA-2, BUP
EO - 702Design for Manufacturing and Assembly
EMBA-2, BUP
EO - 702
Design for Manufacturing and Assembly
EMBA-2, BUP
EO - 702
Process Flow Design
A process flow design can be defined as a mapping of the specific processes that raw materials, parts, and subassemblies follow as they move through a plant
Most common tools : assembly drawings, assembly charts
Example: Plug Assembly Drawing
EMBA-2, BUP
EO - 702
Process Selection
refers to the strategic decision of selecting what kind of production process to have in the plant.
Types of Process Basing on What they do : Conversion Process Fabrication Process Assembly Process Testing Process
Just to refresh:Single, Multi stage, makes to order, …..are they types of Process? If so what’s the base for consideration?
EMBA-2, BUP
EO - 702
Process Flow Structures
It refers how a factory organizes materials flow using one or more of the process technologies listed below:
Job shop – A process structure suited for low volume production of a greatly variety of non-standard products.
Batch shop – A process structure that produces a variety of standard products relatively at low volume.
Assembly Line –A process structure designed to make discrete parts.
Continuous Flow – An often automated process that convert raw materials into finished products in one continuous process.
EMBA-2, BUP
EO - 702
IV.Continuous
Flow
III.Assembly
Line
II.Batch
I.Job
Shop
LowVolume,One of a
Kind
MultipleProducts,
LowVolume
FewMajor
Products,HigherVolume
HighVolume,
HighStandard-
ization
Machine shop
Chemical,Electronics
AutomobileAssembly
SugarRefinery
Flexibility (High)Unit Cost (High)
Flexibility (Low)Unit Cost (Low)
These are the major stages of product and process life cycles
These are the major stages of product and process life cycles
Product Process Matrix
Process Structure
Process Life Cycle Stage
Effectiveness Measures
EMBA-2, BUP
EO - 702
Virtual Factory
A virtual factory can be defined as a manufacturing operation where activities are carried out not in one central plant, but in multiple locations by suppliers and partner firms as part of a strategic alliance
