Product Design and Process Selection

1. Product Design and Process Selection Manufacturing Operations

2. Product Design and Development • Sources • Developing New Products • Getting Them to Market • Improving Current Products • Design Considerations

3. Possible Sources ofProduct Innovation • Customers • Managers • Marketing • Operations • Engineering • Research and Development (R&D) • Basic research • Applied research

4. A Model for DevelopingNew Products • Technical and Economic Feasibility Studies • Prototype Design • Market Sensing and Evaluation • Economic Evaluation of the Product Design • Production Design

5. A Model for Developing New Products Ideas Market requirements Functional specifications Product specifications Design review Test market Introduction Success? 8

6. Getting Them to Market Quickly • Speed Creates Competitive Advantages • Speed Saves Money • Tools To Improve Speed • Autonomous design and development teams • Computer-aided design/computer-aided manufacturing (CAD/CAM) • Design Procedures To Improve Speed • Simultaneous (Concurrent) Engineering

7. Research Development Manufacturing Process Design Manufacturing Product Product Design:American and Japanese Philosophies Compared American Japanese Research, Development, and Manufacturing Process Design Manufacturing Product http://www.ecrc.uofs.edu/ce.html

9. Air Bags

10. Passenger-Side Air Bags Air Bags

11. Side Impact Air Bags Passenger-Side Air Bags Air Bags

13. Building theHouse of Quality (1 of 2) 1. Identify customer requirements 2. Identify technical requirements 3. Relate the customer requirements to the technical requirements 4. Conduct an evaluation of competing products

14. Building theHouse of Quality (2 of 2) 5. Evaluate technical requirements and develop targets 6 Determine which technical requirements to deploy to the remainder of the production process

15. Interrelationships Customer requirement priorities Technical requirements Voice of the customer Relationship matrix Technical requirement priorities Competitive evaluation House of Quality http://dfca.larc.nasa.gov/dfc/qfd.html

16. Some Methods of Improving the Design of Existing Products • Value Analysis/Value Engineering • Continuous Improvement • Failure Analysis

17. Considerations During the Product Design Phase • Ease of Production (Manufacturability) • Specifications - A communication link between the designer and the operations personnel • Tolerances - Minimum and maximum limits on a dimension that allows the item to function as designed • Standardization - Reduce variety among a group of products or parts • Simplification - Reduce or eliminate the complexity of a part or product • Quality

18. Process Planningand Design What Process Technology Is the Correct Technology?

19. Major Factors to be Considered • Nature of demand • volume • variability • Type and degree of flexibility required by the market • Degree of vertical integration • Degree of automation • Quality

20. Some Basic Types of Process Technology Alternatives • Product-Focused • Process-Focused • Group Technology/Cellular Manufacturing

21. Product-Focused Process Technology (Production Line) • Processes (Transformations) are arranged based on the sequence of operations required to produce a product • Two general forms • Discrete unit • Process (Continuous) • Examples

22. Process-Focused Process Technology (Job Shop) • Processes (Transformations) are arranged based on the type of process, i.e., like processes are grouped together • Products (Jobs) move from department (process group) to department based on that particular job’s processing requirements • Examples

23. Group Technology/CellsProcess Technology • Group technologyforms parts with similar processing requirements into families or groups • A cellis an arrangement of the processes required to make the parts that make up the group

24. Group Technology/Cells (continued) • Advantages (relative to a job shop) • Process changeovers simplified • Variability of tasks reduced • More direct routes through the system • Quality control is improved • Production planning and control simpler • Automation simpler

25. Group Technology/Cells (continued) • Disadvantages • Duplication of equipment • Under-utilization of facilities • Processing of items that do not fit into a family may be inefficient

26. Product-Process Matrix Poor Strategy (High variable costs) Good Match Poor Strategy (Fixed costs and cost changing to other products are high)

27. Factors to Consider When Selecting Among Processing Alternatives • Batch Size and Product Variety • Capital Requirements • Economic Analysis • Cost functions of alternatives • Operating leverage - relationship between a firm’s annual costs and its annual sales • Break-even analysis • Financial analysis

28. Defining and Documentingthe Product • Engineering drawings • Bills of material (BOM) • Computer-aided design (CAD) • Product quality • Shorter design time • Production cost reductions • Database availability • New range of capabilities

29. Preparing for Production • Assembly drawing • Assembly (Gozinto) chart • Route/Process sheet • Process flow charts • Job instructions • Standards manuals • Engineering change notice Page 227