Académique Documents
Professionnel Documents
Culture Documents
Introduction of
Production Design
Outline
1. Product Life Cycle
2. Product Development
5-2
Outline - Continued
Generating New Products
New Product Opportunities
Importance of New Products
Product Development
Product Development System
Quality Function Deployment (QFD)
Organizing for Product Development
Manufacturability and Value Engineering
5-3
Regal Marine
Global market
3-dimensional CAD system
Reduced product development time
Reduced problems with tooling
Reduced problems in production
5-4
4
Product Decision
The objective of the product decision
is to develop and implement a
product strategy that meets the
demands of the marketplace with a
competitive advantage.
5-5
Product Decision
The good or service the organization
provides society
Top organizations typically focus on core
products
Customers buy satisfaction, not just a
physical good or particular service
Fundamental to an organization's strategy
with implications throughout the operations
function
5-6
Low cost
Taco Bell, Walmart
Rapid response
Toyota (product development under
2 years. Industry standard is over 2
years)
57
-7
5-8
Cash
flow
Negative
cash flow
Introduction
Loss
Growth
Maturity
Decline
5-9
10
5 - 10
5 11
- 11
513
- 13
Costs committed
80
60
Costs incurred
40
20
0
Concept
design
Ease of change
Detailed Manufacturing
design
prototype
Distribution,
service,
and disposal
14
5 - 14
Product-by-Value Analysis
15
5 - 15
Product-by-Value Analysis
Sams Furniture Factory
Individual
Contribution ($)
Total Annual
Contribution ($)
Love Seat
$102
$36,720
Arm Chair
$87
$51,765
Foot Stool
$12
$6,240
Recliner
$136
$51,000
16
5 - 16
g
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i
m
r
o
t
s
n
i
l
o
Bra
o
t
l
fu
e
s
u
is a
2.
Product Development
Ideas
Ability
Customer Requirements
Functional Specifications
Product Specifications Scope for
design and
Design Review
engineering
teams
Test Market
Introduction
Evaluation
5 18
- 18
Quality Function
Deployment
1. Identify customer wants
2. Identify how the good/service will satisfy
3.
4.
5.
6.
7.
customer wants
Relate customer wants to product hows
Identify relationships between the firms
hows
Develop importance ratings
Evaluate competing products
Compare performance to desirable technical
attributes
19
5 - 19
What the
customer
wants
Target values
How to satisfy
customer wants
Relationship
matrix
Competitive
assessment
Customer
importance
ratings
Interrelationships
Weighted
rating
Technical
evaluation
20
21
5 - 21
5 - 22
Interrelationships
HOQ
What the
Customer
Wants
Technical
Attributes and
Evaluation
What the
customer
wants
Lightweight
Easy to use
Reliable
Easy to hold steady
Color correction
Relationship
Matrix
Analysis of
Competitors
How to Satisfy
Customer Wants
Customer
importance
rating
(5 = highest)
3
4
5
2
1
5 - 23
Interrelationships
HOQ
Relationship
Matrix
Ergonomic design
Paint pallet
Auto exposure
Auto focus
Technical
Attributes and
Evaluation
Aluminum components
What the
Customer
Wants
Analysis of
Competitors
How to Satisfy
Customer Wants
How to Satisfy
Customer Wants
5 - 24
Interrelationships
HOQ
What the
Customer
Wants
5 = High relationship
3 = Medium relationship
1 = Low relationship
Lightweight
Easy to use
Reliable
Easy to hold steady
Color corrections
Relationship
Matrix
Analysis of
Competitors
How to Satisfy
Customer Wants
Technical
Attributes and
Evaluation
3
4
5
2
1
Relationship matrix
5 - 25
Interrelationships
HOQ
What the
Customer
Wants
Relationship
Matrix
Analysis of
Competitors
How to Satisfy
Customer Wants
Ergonomic design
Paint pallet
Auto exposure
Auto focus
Aluminum components
Relationships
between the
things we can do
Technical
Attributes and
Evaluation
5 - 26
Interrelationships
HOQ
What the
Customer
Wants
Relationship
Matrix
Analysis of
Competitors
How to Satisfy
Customer Wants
Technical
Attributes and
Evaluation
Lightweight
3
Easy to use
4
Reliable
5
Easy to hold steady
2
Color corrections
1
Our importance ratings
22
27 27
32
25
Weighted
rating
5 - 27
Interrelationships
Relationship
Matrix
Company A
Technical
Attributes and
Evaluation
How well do
competing products
meet customer wants
Lightweight
3
Easy to use
4
Reliable
5
Easy to hold steady
2
Color corrections
1
Our importance ratings
Company B
What the
Customer
Wants
Analysis of
Competitors
HOQ
How to Satisfy
Customer Wants
G
G
F
G
P
22
P
P
G
P
P
5
5 - 28
Interrelationships
2 circuits
2 to
75%
Target
values
(Technical
attributes)
0.5 A
Technical
Attributes and
Evaluation
Panel ranking
Relationship
Matrix
What the
Customer
Wants
Analysis of
Competitors
HOQ
How to Satisfy
Customer Wants
ok G
ok F
ok G
5 - 29
Company B
Company A
Ergonomic design
Paint pallet
Auto exposure
Auto focus
Aluminum components
Lightweight
G P
Easy to use
G P
Reliable
F G
G P
Color correction
Panel ranking
2 to
75%
Target values
(Technical
attributes)
2 circuits
0.5 A
Completed
House of
Quality
HOQ
Company A
ok
Technical Company B
evaluation Us
ok
ok
5 - 30
HOQ
Deploying resources through the
organization in response to
customer requirements
Customer
requirements
Design
characteristics
House
1
Design
characteristics
Specific
components
House
2
Specific
components
Production
process
House
3
Production
process
Quality
plan
House
4
31
5 - 31
(Advantage)
Difficult to foster forward thinking (Disadvantage)
2
A Champion
3 Team approach
Cross functional representatives from
32
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Benefits:
1. Reduced complexity of products
2. Reduction of environmental impact
3. Additional standardization of products
4. Improved functional aspects of
product
5. Improved job design and job safety
6. Improved maintainability
(serviceability) of the product
7. Robust design
33
5 - 33
5 34
- 34
(CAM)
Virtual reality technology
Value analysis
Environmentally friendly design
35
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1. Robust Design
Product is designed so that small
variations in production or
assembly do not adversely affect
the product
Typically results in lower cost
and higher quality
36
5 - 36
2. Modular Design
Products designed in easily
segmented components
Adds flexibility to both production
and marketing
Improved ability to satisfy customer
requirements
37
5 - 37
38
5 - 38
Extensions of CAD
3-D Object Modeling
Small prototype
development
CAD through the
internet
International data
exchange through STEP
39
5 - 39
4. Computer-Aided
Manufacturing (CAM)
Utilizing specialized computers
and program to control
manufacturing equipment
Often driven by the CAD system
(CAD/CAM)
CNC Machines
540
- 40
Benefits of CAD/CAM
1. Better Product quality
2. Shorter design time
3. Production cost
reductions
4. Database availability
541
- 41
6. Value Analysis
While Value Engineering focuses on
5 - 43
7. Ethics, Environmentally
Friendly Designs, and
Sustainability
44
5 - 44
545
- 45
5 - 46
47
5 - 47
Product Documents
Engineering drawing
Shows dimensions, tolerances, and
materials
Shows codes for Group Technology
Bill of Material
Lists components, quantities and where
used
Shows product structure
48
5 - 48
Engineering Drawings
49
5 - 49
Bills of Material
BOM for Panel Weldment
NUMBER
DESCRIPTION
QTY
A 60-71
PANEL WELDMT
A 60-7
R 60-17
R 60-428
P 60-2
1
1
1
1
A 60-72
R 60-57-1
A 60-4
02-50-1150
1
1
1
1
A 60-73
A 60-74
R 60-99
02-50-1150
1
1
1
1
550
- 50
Bills of Material
Hard Rock
Cafes Hickory
BBQ Bacon
Cheeseburger
DESCRIPTION
QTY
Bun
Hamburger patty
Cheddar cheese
Bacon
BBQ onions
Hickory BBQ sauce
Burger set
Lettuce
Tomato
Red onion
Pickle
French fries
Seasoned salt
11-inch plate
HRC flag
1
8 oz.
2 slices
2 strips
1/2 cup
1 oz.
1 leaf
1 slice
4 rings
1 slice
5 oz.
1 tsp.
1
1
551
- 51
similar characteristics
Coding system describes processing
and physical characteristics
Part families can be produced
in dedicated manufacturing cells
52
5 - 52
Slotted
Threaded
Drilled
Machined
53
5 - 53
loading
5. Reduced tooling setup time, work-inprocess, and production time
54
5 - 54
55
5 - 55
Assembly Drawing
Shows
exploded view
of product
Details relative
locations to
show how to
assemble the
product
556
- 56
Assembly Chart
1
2
3
4
5
6
7
8
9
10
R 209 Angle
R 207 Angle
Bolts w/nuts (2)
Left
bracket
SA
A1
1 assembly
R 209 Angle
R 207 Angle
Bolts w/nuts (2)
Right
SA bracket A2
2 assembly
Bolt w/nut
R 404 Roller
A3
Lock washer
Part number tag
Poka-yoke
inspection
A4
A5
5 57
- 57
Route Sheet
Lists the operations and times required
to produce a component
Process
Machine
Operations
Auto Insert 2
2
3
Manual
Insert 1
Wave Solder
Test 4
Insert Component
Set 56
Insert Component
Set 12C
Solder all
components
to board
Circuit integrity
test 4GY
Setup
Time
Operation
Time/Unit
1.5
.4
.5
2.3
1.5
4.1
.25
.5
558
- 58
Work Order
Instructions to produce a given quantity
of a particular item, usually to a schedule
Work Order
Item
Quantity
Start Date
Due Date
157C
125
5/2/08
5/4/08
Production
Dept
Delivery
Location
F32
Dept K11
559
- 59
Product Life-Cycle
Management (PLM)
Integrated software that brings
together most, if not all, elements of
product design and manufacture
Product design
CAD/CAM, DFMA
Product routing
Materials
Assembly
Environmental
61
5 - 61
Transition to Production
Know when to move to production
Product development can be viewed as
evolutionary and never complete
Product must move from design to
production in a timely manner
Most products have a trial production
62
5 - 62
Transition to Production
Responsibility must also transition as
managing transition
Project managers
Product development teams
Integrate product development and
manufacturing organizations
63
5 - 63
End of Chap. 1
64
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