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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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