Basics of Product and Process Design Management

Dr. Pradeep Desai Basics of Product and Process Design Management

Technology and Innovation

Contents

1 Product Design

2 Objectives of Product Design

3 Features of a Good Product Design

4 Concepts of Product Design

5 Steps of Product Design

6 Product Design Management

7 4-Pillars of Design Management

8 Value & Role of Design Management

9 Process Design

10 Process Development for Process Design

11 Steps for Process Design

12 Objectives of Process Design

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Product Design

• Product design is conceptualization of an idea about a product and transformation of the idea into a reality.

• To transform the idea into reality a specification about the product is prepared. This specification is prepared by considering different constraints such as production process, customer expectation, etc.

• In product design stage every aspects of the product are analyzed. Also final decision regarding the product is taken on the basis of the analysis. This decision can be any aspect related to the product. E.g. dimension and tolerances, type of material for every components etc.


Objectives of Product Design

• To ensure growth of the organization.

• To utilize the surplus capacity of the organization, such as physical facility, man power, etc.

• To utilize the surplus fund of the organization.

• To meet new requirement of the customers.

• To increase company’s market share and to target new market segment.

• To ensure complete product range in company’s portfolio.


Features of a Good Product Design Quality: The product must satisfy customer’s stated and unstated needs.

Standardization: The product should be designed in such a fashion so that most of the components are standardized and easily available in the market.

Maintainability: The product must perform for a designated period with a minimum and defined maintenance. Adequate provision for maintenance should be kept in the product.

Cost effectiveness: The product must be cost effective. The must be manufactured in the most cost effective environment.


Concepts of Product Design Research & development:

• Basic research is a search for new knowledge. It does not have any immediate application, but based on the basic research new product can be developed in future.

• Applied research has objective of developing commercial products.

Reverse engineering:

• Reverse engineering is the process of carefully dismantling a product, understanding its design and developing a product which is better than the existing one.

CAD-CAM:

By using 3D modeling software system, designers develop a computerized model of a new product and analyze its design parameters. After computer aided design (CAD), computer aided manufacturing (CAM) system produce the product by using CNC facility.


Steps of Product Design 1. Synthesis: Try to develop different alternatives

2. Sketching: Draw sketches in exact scale for different alternatives

3. Analysis: Analysis different alternatives with respect to operability,

maintainability, inspection, assembling and dismantling issues, cost

parameters, production methods, etc.

4. Selection: Select the best alternative

5. Basic engineering: Prepare layout in exact scale, calculate strength of

components, select proper cost effective material.

6. Detail design: Prepare detail engineering drawing for each component

7. Prototype: If option is there, then prepare prototype and test it

8. Manufacturing: If prototype is not made, then follow manufacturing

steps and solve manufacturing problems and assembly problems, if any.

9. Operation: collect feedback during actual operation of the new

product. If any problem exists, try to provide design based solution.

Also, implement lessons in the future design.

10. Product development: If any modification can be done, implement

the same in the next generation product.


Product Design Management

• Product Design Management is a multidisciplinary management methodology that benefits product design and innovation for business growth, as part of the company strategy.

• Business side of design- Used to develop and maintain a business environment in which an organization can achieve its strategic goals through design.

• It includes: – Strategy and planning

– Information and communication, link to R&D and branding

– Project management


Project Management- Helps to achieve project goals within: Time, Scope, Budget and Quality.

Design- A specification of an object, intended to accomplish goals in a particular environment, satisfying a set of requirements and subject to constraints.

Strategy- A high level plan to achieve one or more goals under conditions of uncertainty.

Supply Chain Techniques-

Role of Design in the Supply Chain: – Demand Generation

– Influencing manufacturing processes, cost, quality and lead time

– Effect on transportation, quality, quantity, production schedule and production technologies

4-Pillars of Design Management


Value of Design Management-

• Innovation in internal business processes

• Learning and growing opportunity

• Customer and brand: strategic positioning

• Financial- Explicit and measurable value for company reputation and market performance

Roles of Design Management-

• Align design strategy with corporate /brand strategy

• Manage quality and consistency of design outcomes

• Enhance user experience, create new solutions,

differentiate from rivals

Value & Role of Design Management


• At the time of designing a product, preliminary consideration is given to the capacity of the firm to manufacture the product

• Process planning is concerned with planning the conversion or transformation processes needed to convert the materials into finished products

• Process and Operations design provide information on what is required to effectively utilize the existing equipment and to determine what new equipment and machinery would be required

Product Design

Process planning

Process Design

Operations Design

Process Design

Process Design

Process design is taking the product development and breaking it down into parts, which in turn helps the actual manufacturing process.

• It ensures that there is smooth and continuous relationship between required output and all the intermediate process.

• Process design is a diagram representing a sequence of activities. It typically shows events, actions and links or connection points, in the sequence from end to end.

Process Development for Process Design • Process Requirement: The 1st step is to collect and gather

information to give structure with the end objective. That is to make process requirement document highlighting various stages, risk and stakeholders for production. This will include assessment of available technology, raw material requirement, factory/plant layout and demand forecast.

• Team Building: Once the process requirements are finalized, for each objective, a team is finalized based on skill level and experience. Function of the team is to get familiarize with the whole process.

• Planning and Implementation: Process planning team will develop module; policies and procedure require for production, which are after required approval internal as well as external is implemented.

• Audit: A regular audit is carried out to ensure that process thus implemented is in line and delivering value to customers.

• End of Life: Over a course of time there may be enhancement of the product or product may get discontinued in these circumstances, process thus develop is discontinued.

Objectives of Process Design

Operations performance objectives translate directly to process design objectives. Because processes are managed at a very operational level, process design also needs to consider a more micro and detailed set of objectives. These are largely concerned with flow through the process.

Process flow performance is described by:

• Throughput rate- the rate at which units emerge from the process i.e. the number of units passing through the process per unit of time.

• Throughput time- the average elapsed time taken for inputs to move through the process and become outputs.

• Work in progress- the number of units in the process as an average over a period of time.

• Utilization- the proportion of available time that the resources within the process are performing useful work.


Leadership & Management

Basics of Product and Process Design Management