Chapter 6 Product Design and Process Selection--Manufacturing

1. Chapter 6Product Design and Process Selection--Manufacturing • The Product Design Process • Concurrent Engineering • Designing for the Customer • QFD • Process Selection • Process Flow Design • Process Analysis • Globalization of Product Design and Development 2

2. The Product Design Process • Concept Development • Product Planning • Detailed Engineering • Engineering Release (Sign-Off) 3

3. Concurrent Engineering • 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. 4

4. Designing for the Customer • Industrial Design • Aesthetics • Ergonomics 5

5. Quality Function Deployment • Interfunctional teams from marketing, design engineering, and manufacturing • Voice of the customer • House of Quality 6

6. Correlation: Strong positive X Positive X X Negative X X X Strong negative * Engineering Characteristics Competitive evaluation X = Us Check force on level ground Energy needed to close door Energy needed to open door Accoust. Trans. Window Door seal resistance Water resistance A = Comp. A Importance to Cust. B = Comp. B Customer Requirements (5 is best) 1 2 3 4 5 AB X Easy to close 7 X AB Stays open on a hill 5 Easy to open 3 XAB A X B Doesn’t leak in rain 3 No road noise 2 X A B Relationships: Importance weighting 10 6 6 9 2 3 Strong = 9 Medium = 3 Target values Reduce energy level to 7.5 ft/lb Small = 1 Reduce energy to 7.5 ft/lb. Reduce force to 9 lb. Maintain current level Maintain current level Maintain current level 5 BA BA B B BXA X Technical evaluation (5 is best) B 4 X A X A 3 A X 2 X 1 House of Quality 7

7. Value Analysis/Value Engineering (VA/VE) • 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? 8

8. Types of Processes • Conversion • Fabrication • Assembly • Testing 11

9. Process Flow Structures • Job shop • Batch • Assembly Line • Continuous Flow 12

10. Few Major Products, Higher Volume High Volume, High Standard- ization Low Volume One of a Kind Multiple Products, Low Volume Flexibility (High) Unit Cost (High) I. Job Shop Commercial Printer French Restaurant II. Batch Heavy Equipment Coffee Shop III. Assembly Line Automobile Assembly Burger King IV. Continuous Flow Sugar Refinery Flexibility (Low) Unit Cost (Low) Exhibit 4.9 Source: Modified from Robert Hayes and Steven Wheelwright, Restoring Our Competitive Edge: Competing through Manufacturing (New York: John Wiley & Sons, 1984). p. 209. 13

11. Global Product Design and Manufacturing • Joint Ventures • Strategic Suppliers • Global Product Design Strategy 17