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Introduction of
Production Design
Outline
Product Life Cycle
2. Product Development
1.
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
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
Rapid response
Toyota
57
-7
5-8
Cash
flow
Negative
cash flow
Introduction
Loss
Growth
Maturity
Decline
5-9
5 - 10
5 13
- 13
Costs committed
80
60
Costs incurred
40
20
Ease of change
0
Concept
design
Detailed Manufacturing
design
prototype
Distribution,
service,
and disposal
14
5 - 14
Product-by-Value Analysis
Lists products in descending order of their
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
30%
20%
10%
Industry
leader
Top
third
Middle
third
Bottom
third
2.
Product Development
Ideas
Ability
Customer Requirements
Functional Specifications
Scope of
product
development
team
5.
6.
7.
5 - 20
What the
customer
wants
Target values
Interrelationships
How to satisfy
customer wants
Relationship
matrix
Competitive
assessment
Customer
importance
ratings
Weighted
rating
Technical
evaluation
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
Easy to use
Reliable
Easy to hold steady
Color corrections
3
4
5
2
1
22
27 27
32
25
Weighted
rating
5 - 27
Interrelationships
Technical
Attributes and
Evaluation
How well do
competing products
meet customer wants
Lightweight
Easy to use
Reliable
Easy to hold steady
Color corrections
Our importance ratings
3
4
5
2
1
22
Company B
Relationship
Matrix
Company A
What the
Customer
Wants
Analysis of
Competitors
HOQ
How to Satisfy
Customer Wants
G
G
F
G
P
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
Technical
evaluation Company B 0.6 50% yes 2
Us
0.5 75% yes 2
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
ok
ok
Us
5 - 30
HOQ
Deploying resources through the
organization in response to
customer requirements
Quality
plan
Customer
requirements
House
1
House
2
House
3
Production
process
Design
characteristics
Design
characteristics
Specific
components
Specific
components
Production
process
House
4
31
5 - 31
A Champion
Product manager drives the product through
32
5 - 32
disciplines or functions
Product development teams, design for
manufacturability teams, value engineering
teams
Japanese whole organization approach
No organizational divisions
33
5 - 33
Manufacturability and
Value Engineering
Benefits:
1. Reduced complexity of products
2. Reduction of environmental impact
3. Additional standardization of products
4. Improved functional aspects of product
product
7. Robust design
34
5 - 34
5 35
- 35
Modular design
Computer-aided design (CAD)
Computer-aided manufacturing (CAM)
Virtual reality technology
Value analysis
Environmentally friendly design
36
5 - 36
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
37
5 - 37
Modular Design
Products designed in easily segmented
components
Adds flexibility to both production and marketing
Improved ability to satisfy customer
requirements
38
5 - 38
5 - 39
Extensions of CAD
Design for Manufacturing and Assembly
(DFMA)
Solve manufacturing problems during the
design stage
3-D Object Modeling
Small prototype
development
CAD through the
internet
International data
exchange through STEP
40
5 - 40
Computer-Aided Manufacturing
(CAM)
Utilizing specialized computers
and program to control
manufacturing equipment
Often driven by the CAD system
(CAD/CAM)
5 41
- 41
Benefits of CAD/CAM
1.
2.
3.
4.
5.
Product quality
Shorter design time
Production cost reductions
Database availability
New range of capabilities
5 42
- 42
543
- 43
Value Analysis
Focuses on design improvement during
production
Seeks improvements leading either to a better
product or a product which can be produced
more economically with less environmental
impact
44
5 - 44
45
5 - 45
546
- 46
5 - 47
3.
4.
5.
6.
48
5 - 48
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
49
5 - 49
Engineering Drawings
50
5 - 50
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
551
- 51
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
552
- 52
characteristics
Coding system describes processing and
physical characteristics
Part families can be produced
in dedicated manufacturing cells
53
5 - 53
Slotted
Threaded
Drilled
Machined
54
5 - 54
Improved design
Reduced raw material and purchases
Simplified production planning and control
Improved layout, routing, and machine loading
Reduced tooling setup time, work-in-process, and
production time
55
5 - 55
Route sheet
Work order
Engineering change notices (ECNs)
56
5 - 56
Assembly Drawing
Shows exploded
view of product
Details relative
locations to
show how to
assemble the
product
57
5 - 57
Assembly Chart
1
2
3
4
5
6
7
8
9
R 209 Angle
R 207 Angle
Bolts w/nuts (2)
Left
SA bracket A1
1 assembly
R 209 Angle
R 207 Angle
Bolts w/nuts (2)
Right
bracket
SA
A2
2 assembly
Bolt w/nut
R 404 Roller
A3
Lock washer
Part number tag
10
Poka-yoke
inspection
A4
A5
5 58
- 58
Route Sheet
Lists the operations and times required
to produce a component
Process
Machine
Operations
Auto Insert 2
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
5 59
- 59
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
5 60
- 60
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
to insure producibility
Develop tooling, quality control, training
Ensures successful production
63
5 - 63
Transition to Production
Responsibility must also transition as the
transition
Project managers
Product development teams
Integrate product development and
manufacturing organizations
64
5 - 64
End of Chap. 1
65
5 - 65