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PRODUCT DESIGN
DTM, ADTEC SHAH
ALAM
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2010 Wiley 2
CONCURRENT ENGINEERING
Old over-the-wall sequential products
design process
Each function did its work and
passed it to the next function
Improved Concurrent Engineering process
All functions form a design team
that develops specifications,
involves customers early, solves
potential problems, reduces costs,
& shortens time to market
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2010 Wiley 3
PRODUCT DESIGN & PROCESS SELECTION
1. Product design the process of defining all of the companies
product characteristics
Product design must support product manufacturability (the ease
with which a product can be made)
Product design defines a products characteristics of:
i. Appearance
ii. Materials
iii. Dimensions
iv. Tolerances
v. Performance standards
2. Process selection the development of the process
necessary to produce the designed product
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THE PRODUCT DESIGN PROCESS
1. Idea development: all products begin with an
idea whether from:i. customers
ii. competitors or
iii. suppliers
2. Reverse engineering: buying a competitors
product
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PRODUCT DESIGN PROCESS
1. Idea developments selection affects
i. Product quality
ii. Product cost
iii. Customer satisfaction
iv. Overall manufacturability the ease with which
the product can be made
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THE PRODUCT DESIGN PROCESSStep 1
Idea Development
Someone thinks of a need and a product/service design to satisfy it: customers,marketing, engineering, competitors, benchmarking, reverse engineering
Step 2
Product Screening
Every business needs a formal/structured evaluation process: fit with facility and
labor skills, size of market, contribution margin, break-even analysis, return onsales
Step 3
Preliminary Design and Testing
Technical specifications are developed, prototypes built, testing starts
Step 4Final Design
Final design based on test results, facility, equipment, material, & labor skills
defined, suppliers identified
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DESIGN FOR MANUFACTURING (DFM)
Guidelines to produce a product easily and profitably
i. Simplification - Minimize parts
ii. Standardization - Design parts for multiply applications
iii. Use modular design - subdivides a system into smaller parts (modules) that can beindependently created and then used in different systems to drive multiple functionalities
ex : cars, computer, building
i. Simplify operations
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PROCESS SELECTION
Product design considerations must include the processi. Intermittent processes:
Processes used to produce a variety of products withdifferent processing requirements in lower volumes.(such as healthcare facility)
ii. Repetitive processes:
Processes used to produce one or a few standardizedproducts in high volume. (such as a cafeteria, or carwash)
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PRODUCT PROCESS GRID
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PROCESS TYPES
Process types can be: Project process make a one-at-a-time product exactly
to customer specifications
Batch process small quantities of product in groupsor batches based on customer orders or specifications
Line process large quantities of a standard product
Continuous process very high volumes of a fullystandard product
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Intermittent VS. Repetitive Facility Layouts
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Process Selection Considerations
Process selection is based on five principal
considerations
1. Product-Process Grid
2. Degree of vertical integration
3. Flexibility of resources
4. Mix between capital & human resources
5. Degree of customer contact
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Process Decisions-Vertical Integration & Make or Buy
Vertical integration refers to the degree a firm chooses to do processes itself-raw material to sales
Backward Integration means moving closer to primary operations
Forward Integration means moving closer to customers
A firms Make-or-Buychoices should be based on the followingconsiderations:
Strategic impact
Available capacity
Expertise
Quality considerations
Speed
Cost (fixed cost + variable cost)make = Cost (fixed cost + Variable cost)buy
Business are trending toward less backward integration, more outsourcing
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Product Life Cycle also affects decisions
Product life cycle series ofchanging product demand
Consider product
life cycle stages
Introduction
Growth
Maturity
Decline
Facility & processinvestment depends on life
cycle