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Irwin/McGraw-Hill

PART THREE. DESIGN OF PRODUCTION SYSTEMS. Chapter Four Product and Service Design Chapter Five Process Selection and Capacity Planning Chapter Six Facilities Layout Chapter Seven Design of Work Systems Chapter Eight Location Analysis. Irwin/McGraw-Hill.

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Irwin/McGraw-Hill

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  1. PART THREE DESIGN OF PRODUCTION SYSTEMS • Chapter Four • Product and Service Design • Chapter Five • Process Selection and Capacity Planning • Chapter Six • Facilities Layout • Chapter Seven • Design of Work Systems • Chapter Eight • Location Analysis Irwin/McGraw-Hill • The McGraw-Hill Companies, Inc., 1999

  2. Chapter 4 Product and Service Design

  3. Reasons for Product or Service Design • Be competitive • Increase business growth & profits • Avoid downsizing with development of new products • Improve product quality • Achieve cost reductions in labor or materials

  4. Trends in Product & Service Design • Increased emphasis on or attention to: • Customer satisfaction • Reducing time to introduce new product or service • Reducing time to produce product

  5. Trends in Product & Service Design (Cont’d) • Increased emphasis on or attention to: • The organization’s capabilities to produce or deliver the item • Environmental concerns • Designing products & services that are “user friendly” • Designing products that use less material

  6. Objects of Product & Service Design Beyond the overall objective to achieve customer satisfaction while making a reasonable profit is: Design for Manufacturing(DFM) The designers’ consideration of the organization’s manufacturing capabilities when designing a product. The more general term design for operationsencompasses services as well as manufacturing

  7. The Design Process • Motivation • Customer • Marketing • Competitors • Forecasts

  8. Reverse Engineering Reverse engineering is the dismantling and inspecting of a competitor’s product to discover product improvements.

  9. Manufacturability • Manufacturability is the ease of fabrication and/or assembly which is important for: • Cost • Productivity • Quality

  10. Regulations & Legal Considerations • Product Liability - A manufacturer is liable for any injuries or damages caused by a faulty product. • Uniform Commercial Code - Products carry an implication of merchantability and fitness.

  11. Research & Development (R&D) • Organized efforts to increase scientific knowledge or product innovation & may involve: • Basic Research advances knowledge about a subject without near-term expectations of commercial applications. • Applied Research achieves commercial applications. • Development converts results of applied research into commercial applications.

  12. Product Design • Product Life Cycles • Robust Design • Concurrent Engineering • Computer-Aided Design • Modular Design

  13. Advantages of Standardization • Fewer parts to deal with in inventory & manufacturing • Reduced training costs and time • More routine purchasing, handling, and inspection procedures

  14. Advantages of Standardization (Cont’d) • Orders fillable from inventory • Opportunities for long production runs and automation • Need for fewer parts justifies increased expenditures on perfecting designs and improving quality control procedures.

  15. Disadvantages of Standardization • Designs may be frozen with too many imperfections remaining. • High cost of design changes increases resistance to improvements. • Decreased variety results in less consumer appeal.

  16. Time Life Cycles of Products or Services Figure 4-2 Saturation Maturity Decline Demand Growth Incubation

  17. Product design • Design for manufacturing (DFM) • Design for assembly (DFA) • Design for recycling (DFR) • Remanufacturing • Design for disassembly (DFD) • Robust design

  18. Taguchi Approach Robust Design • Design a robust product • Insensitive to environmental factors either in manufacturing or in use. • Central feature is Parameter Design. • Determines: • factors that are controllable and those not controllable • their optimal levels relative to major product advances

  19. Concurrent Engineering Concurrent engineering is the bringing together of engineering design and manufacturing personnel early in the design phase.

  20. New Product Design Mfg “Over the Wall” Approach

  21. Computer-Aided Design • Computer-Aided Design (CAD) is product design using computer graphics. • increases productivity of designers, 3 to 10 times • creates a database for manufacturing information on product specifications • provides possibility of engineering and cost analysis on proposed designs

  22. Modular Design Modular design is a form of standardization in which component parts are subdivided into modules that are easily replaced or interchanged. It allows: • easier diagnosis and remedy of failures • easier repair and replacement • simplification of manufacturing and assembly

  23. Goods-service spectrum Steel productionAutomobile fabrication House buildingRoad construction Low service content High goods content Dressmaking Farming Auto Repair Appliance repair Maid Service Manual car wash Increasing goods content Increasing service content Teaching Lawn mowing High service content Low goods content Figure 4-3

  24. High CustomizedClothing Moderate Dept. StorePurchase Low TelephonePurchase None InternetPurchase Low None Moderate High Service Variability & Customer Influence Service Design Figure 4-4 Variability in Service Requirements Degree of Contact with Customer

  25. The House of Quality Figure 4-7 Correlation matrix Design requirements Customer require- ments Relationship matrix Competitive assessment Specifications or target values

  26. Correlation: Strong positive X Positive X X Negative X X X Strong negative * Engineering Characteristics Competitive evaluation Energy needed to close door Check force on level ground Energy needed to open door Accoust. Trans. Window Door seal resistance Water resistance X = Us A = Comp. A Importance to Cust. 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 10 6 6 9 2 3 X A B Importance weighting Relationships: Strong = 9 Medium = 3 Reduce energy level to 7.5 ft/lb Reduce energy to 7.5 ft/lb. Target values Reduce force to 9 lb. 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 House of Quality Example

  27. Improving Reliability • Component design • Production/assembly techniques • Testing • Redundancy • Preventive maintenance procedures • User education • System design

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