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Chapter 4

Chapter 4. Product Design. Product Development Process Economic Analysis of Development Projects Designing for the Customer Design for Manufacturability Measuring Product Development Performance. OBJECTIVES. Typical Phases of Product Development. Planning Concept Development

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Chapter 4

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  1. Chapter 4 Product Design

  2. Product Development Process • Economic Analysis of Development Projects • Designing for the Customer • Design for Manufacturability • Measuring Product Development Performance OBJECTIVES

  3. Typical Phases of Product Development • Planning • Concept Development • System-Level design • Design Detail • Testing and Refinement • Production Ramp-up

  4. Economic Analysis of Project Development Costs • Using measurable factors to help determine: • Operational design and development decisions • Go/no-go milestones • Building a Base-Case Financial Model • A financial model consisting of major cash flows • Sensitivity Analysis for “what if” questions

  5. Value Analysis/ Value Engineering Quality Function Deployment Designing for the Customer House of Quality Ideal Customer Product

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

  7. 8 Correlation: Strong positive X Positive X X Negative X X X Strong negative * Engineering Characteristics Check force on level ground Competitive evaluation Energy needed to close door Energy needed to open door Accoust. Trans. Window Door seal resistance Water resistance X = Us Importance to Cust. A = Comp. A 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 Importance weighting Relationships: 10 6 6 9 2 3 Strong = 9 Reduce energy level to 7.5 ft/lb Medium = 3 Reduce energy to 7.5 ft/lb. Reduce force to 9 lb. Target values Maintain current level Maintain current level Maintain current level Small = 1 5 BA BA B B BXA X Technical evaluation (5 is best) B 4 X A X A 3 A X 2 X 1 Designing for the Customer: The House of Quality Customer requirements information forms the basis for this matrix, used to translate them into operating or engineering goals. • The McGraw-Hill Companies, Inc., 2004

  8. Designing for the Customer: Value Analysis/Value Engineering • 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?

  9. Design for Manufacturability • Traditional Approach • “We design it, you build it” or “Over the wall” • Concurrent Engineering • “Let’s work together simultaneously”

  10. Design for Manufacturing and Assembly • Greatest improvements related to DFMA arise from simplification of the product by reducing the number of separate parts: • During the operation of the product, does the part move relative to all other parts already assembled? • Must the part be of a different material or be isolated from other parts already assembled? • Must the part be separate from all other parts to allow the disassembly of the product for adjustment or maintenance?

  11. Measuring Product Development Performance Measures Performance Dimension • Freq. Of new products introduced • Time to market introduction • Number stated and number completed • Actual versus plan • Percentage of sales from new products Time-to-market • Engineering hours per project • Cost of materials and tooling per project • Actual versus plan Productivity • Conformance-reliability in use • Design-performance and customer satisfaction • Yield-factory and field Quality

  12. End of Chapter 4

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