MINGGU KE 10: PENGEMBANGAN DESAIN RINCI

1. MINGGU KE 10: PENGEMBANGAN DESAIN RINCI

2. INTRODUCTION(Ulrich, 2000) • TO DEVELOP DETAILED DESIGN, THERE ARE SEVERAL ACTIVITIES REQUIRED : • DEVELOPMENT OF PRODUCT ARCHITECTURE. • DEVELOPMENT DETAILED DESIGN CONSIDERING THE PRINCIPLES OF • INDUSTRIAL DESIGN. • DFM (DESIGN FOR MANUFACTURING) • PROTOTYPING

3. DEVELOPMENT OF PRODUCT ARCHITECTURE (1)(Ulrich, 2000) A PRODUCT CAN BE THOUGHT OF IN BOTH FUNCTIONAL AND PHYSICAL TERMS. THE FUNCTIONAL ELEMENTS OF A PRODUCT ARE THE INDIVIDUAL OPERATIONS AND TRANSFORMATIONS THAT CONTRIBUTE TO THE OVERALL PERFORMANCE OF THE PRODUCT. FOR EXAMP : A PRINTER, SOME OF THE FUNCTIONAL ELEMENTS ARE “STORE PAPER” AND “COMMUNICATE WITH THE HOST COMPUTER”. THE PHYSICAL ELEMENTS OF A PRODUCT ARE THE PARTS, COMPONENTS, AND SUB- ASSEMBLIES THAT ULTIMATELY IMPLEMENT THE PRODUCT’S FUNCTIONS. SOME PHYSICAL ELEMENTS ARE DICTATED BY THE PRODUCT CONCEPT AND OTHER BECOME DEFINED DURING THE DETAIL DESIGN PHASE. THE PHYSICAL ELEMENTS OF A PRODUCT ARE TYPICALLY ORGANIZED INTO SEVERAL MAJOR PHYSICAL BUILDING BLOCKS, WHICH ARE CALLED “CHUNKS’.

4. DEVELOPMENT OF PRODUCT ARCHITECTURE (2)(Ulrich, 2000) EACH CHUNK IS MADE UP OF A COLLECTION OF COMPONENTS THAT IMPLEMENT THE FUNCTIONS OF PRODUCT. THE ARCHITECTURE OF A PRODUCT IS THE SCHEME BY WHICH THE FUNCTIONAL ELEMENTS OF THE PRODUCTS ARE ARRANGED INTO PHYSICAL CHUNKS AND BY WHICH THE CHUNKS INTERACT.

5. DEVELOPMENT OF PRODUCT ARCHITECTURE (3)(Ulrich, 2000) THE DIFFERENCES BETWEEN A MODULAR ARCHITECTURE AND INTEGRAL ARCHITECTURE : MODULAR ARCHITECTURE INTEGRAL ARCHITECTURE • CHUNKS IMPLEMENT ONE OR A FEW • FUNCTIONAL ELEMENTS IN THEIR • ENTIRETY • THE INTERACTIONS BETWEEN CHUNKS • ARE WELL DEFINED AND ARE GENERALLY • FUNADAMENTAL TO THE PRIMARY • FUNCTIONS OF THE PRODUCT • FUNCTIONAL ELEMENTS OF THE PRODUCT ARE • IMPLEMENTED USING MORE THAN ONE CHUNK. • A SINGLE CHUNK IMPLEMENTS MANY FUNCTI- • NAL ELEMENTS. • THE INTERACTIONS BETWEEN CHUNKS ARE ILL • DEFINED AND MAY BE INCIDENTAL TO THE • PRIMARY FUNCTIONS OF THE PRODUCTS

6. DEVELOPMENT OF PRODUCT ARCHITECTURE (4)(Ulrich, 2000) MODULARITY IS A RELATIVE PROPERTY OF A PRODUCT ARCHITECTURE. PRODUCTS ARE RARELY STRICTLY MODULAR OR INTEGRAL. RATHER, WE CAN SAY THAT THEY EXHIBIT EITHER MORE OR LESS MODULARITY THAN A COMPARATIVE PRODUCT. WHEN IS THE PRODUCT ARCHITECTURE DEFINED ? A PRODUCT’S ARCHITECTURE BEGINS TO EMERGE DURING CONCEPT DEVELOPMENT. GENERALLY, THE MATURITY OF THE BASIC PRODUCT TECHNOLOGY DICTATES WHETHER THE PRODUCT ARCHITECTURE IS FULLY DEFINED DURING CONCEP DEVE- LOPMENT OR DURING SYSTEM-LEVEL DESIGN.

7. IMPLICATIONS OF PRODUCT ARCHITECTURE(Ulrich, 2000) DECISIONS ABOUT HOW TO DIVIDE THE PRODUCT INTO CHUNKS AND ABOUT HOW MUCH MODULARITY TO IMPOSE ON THE ARCHITECTURE ARE TIGHTLY LINKED TO SEVERAL ISSUES OF IMPORTANCE TO THE ENTIRE ENTERPRISE : 1. PRODUCT CHANGE 2. PRODUCT VARIETY 3. COMPONENT STANDARDIZATION 4. PRODUCT PERFORMANCE 5. MANUFACTURABILITY 6. PRODUCT DEVELOPMENT MANAGEMENT

8. ESTABLISHING THE PRODUCT ARCHITECTURE (1)(Ulrich, 2000) STEP 1 : CREATE A SCHEMATIC OF THE PRODUCT A SCHEMATIC IS A DIAGRAM REPRESENTING THE TEAM’S UNDERSTANDING OF THE CONSTITUENT ELEMENTS OF THE PRODUCT. THE SCHEMATIC SHOULD REFLECT THE TEAM’S BEST UNDERSTANDING OF THE STATE OF THE PRODUCT, BUT IT DOES NOT HAVE TO CONTAIN EVERY IMAGINABLE DETAIL. STEP 2 : CLUSTER THE ELEMENTS OF THE SCHEMATIC THE CHALLENGE OF THE STEP 2 IS TO ASSIGN EACH OF THE ELEMENTS OF THE SCHEMATIC TO A CHUNK. STEP 3 : CREATE A ROUGH GEOMETRIC LAYOUT CREATING A GEOMETRIC LAYOUT FORCES THE TEAM TO CONSIDER WHETHER THE GEOMETRIC INTERFACES AMONG THE CHUNKS ARE FEASIBLE AND TO WORK OUT THE BASIC DIMENSIONAL RELATIONSHIPS AMONG THE CHUNKS.

9. ESTABLISHING THE PRODUCT ARCHITECTURE (2)(Ulrich, 2000) STEP 4 : IDENTIFY THE FUNDAMENTAL AND INCIDENTAL INTERACTIONS THERE ARE TWO CATEGORIES OF INTERACTIONS BETWEEN CHUNKS. FIRST, FUNDAMENTAL INTERACTIONS ARE THOSE CORRESPONDING TO THE LINES ON THE SCHEMATIC THAT CONNECT THE CHUNKS TO ONE ANOTHER. SECOND, INCIDENTAL INTERACTIONS ARE THOSE THAT ARISE BECAUSE OF THE PARTICULAR PHYSICAL IMPLEMENTATION OF FUNCTIONAL ELEMENTS OR BECAUSE OF THE GEOMETRIC ARRANGEMENT OF THE CHUNKS.

10. INDUSTRIAL DESIGN (1)(Ulrich, 2000) • THE PRIMARY MISSIONS OF INDUSTRIAL DESIGN IS TO DESIGN THE ASPECTS OF • A PRODUCT THAT RELATE TO THE USER : ERGONOMIC & AESTHETIC NEEDS. • ERGONOMICS NEEDS • HOW IMPORTANT IS EASE OF USE ? • HOW IMPORTANT IS EASE OF MAINTENANCE? • HOW MANY USER INTERACTIONS ARE REQUIRED FOR THE PRODUCT’S • FUNCTIONS? • HOW NOVEL ARE THE USER INTERACTION NEEDS? • WHAT ARE THE SAFETY ISSUES?.

11. INDUSTRIAL DESIGN (2)(Ulrich, 2000) • II. AESTHETIC NEEDS : • IS VISUAL PRODUCT DIFFERENTIATION REQUIRED? • HOW IMPORTANT ARE PRIDE OF OWNERSHIP, IMAGE & FASHION? • WILL AN AESTHETIC PRODUCT MOTIVATE THE TEAM ?

12. INDUSTRIAL DESIGN (3)(Ulrich, 2000) • MOST PRODUCTS CAN BENEFIT IN SOME WAY OR ANOTHER FROM INDUSTRIAL • DESIGN. THE MORE A PRODUCT IS LOOKED AT OR USED BY PEOPLE, THE MORE • IT WILL DEPEND ON GOOD INDUSTRIAL DESIGN FOR ITS SUCCES. • THE INDUSTRIAL DESIGN PROCESS CAN BE THOUGHT OF AS CONSISTING OF THE • FOLLOWING PHASES : • INVESTIGATION OF CUSTOMER NEEDS. • CONCEPTUALIZATION. • PRELIMINARY REFINEMENT. • FURTHER REFINEMENT & FINAL CONCEPT SELECTION. • CONTROL DRAWING. • COORDINATION WITH THE ENGINEERING, MANUFACTURING, & VENDORS.

13. ROLE INDUSTRIAL DESIGN ACCORDING TO THE PRODUCT TYPE (1) TYPE OF RODUCT PRODUCT DEVELOPMENT ACTIVITY TECHNOLOGY-DRIVEN USER-DRIVEN • 1. IDENTIFICATION OF ID TYPICALLY HAS NO INVOLVEMENT ID WORKS CLOSELY WITH MARKETING • CUSTOMER NEEDS TO IDENTIFY CUSTOMER NEEDS. • INDUSTRIAL DESIGNERS PARTICIPATE • IN FOCUS GROUPS OR ONE-ON-ONE • CUSTOMER INTERVIEWS. • 2. CONCEPT GENERATION ID WORKS WITH MARKETING & ID GENERATES MULTIPLE CONCEPTS • & SELECTION ENGINEERING TO ASSURE THAT ACCORDING TO THE INDUSTRIAL • HUMAN FACTORS & USER-INTER- DESIGN PROCESS FLOW DESCRIBED • FACE ISSUES ARE ADDRESSED. EARLIER. • SAFETY & MAINTENANCE ISSUES • ARE OFTEN OF PRIMARY IMPOR- • TANCE. • 3. CONCEPT TESTING ID HELPS ENGINEERING TO CREATE ID LEADS IN THE CREATION OF • PROTOTYPES, WHICH ARE SHOWN MODELS TO BE TESTED WITH CUS- • TO CUSTOMERS FOR FEEDBACK. TOMERS BY MARKETING.

14. ROLE INDUSTRIAL DESIGN ACCORDING TO THE PRODUCT TYPE (2) TYPE OF RODUCT PRODUCT DEVELOPMENT ACTIVITY TECHNOLOGY-DRIVEN USER-DRIVEN • SYSTEM-LEVEL ID TYPICALLY HAS LITTLE INVOL- ID NARROWS DOWN THE CONCEPTS • DESIGN VEMENT & REFINES THE MOST PROMISING APPROACHES. • DETAIL DESIGN, ID IS RESPONSIBLE FOR PACKAGING ID SELECTS A FINAL CONCEPT, THEN • TESTING, THE PRODUCT ONCE MOST OF THE COORDINATES WITH ENGINEERING, • & REFINEMENT ENGINEERING DETAILS HAVE MANUFACTURING, & MARKETING TO • BEEN ADDRESSED. ID RECEIVES FINALIZE THE DESIGN • PRODUCT SPECIFICATIONS & • CONSTRAINTS FROM ENGINEERING • & MARKETING

15. DFM: DESIGN FOR MANUFACTURING (1)(Ulrich, 2000) DFM IS AIMED AT REDUCING MANUFACTURING COSTS WHILE SIMULTANEOUSLY IMPROVING (OR AT LEAST NOT INAPPROPRIATELY COMPROMISING) PRODUCT QUALITY, DEVELOPMENT TIME, & DEVELOPMENT COST. DFM BEGINS WITH THE CONCEPTS DEVELOPMENT PHASE & SYSTEM-LEVEL DESIGN PHASE; IN THESE PHASES IMPORTANT DECISIONS MUST BE MADE WITH THE MANUFACTURING COST IMPLICATIONS IN MIND. DFM UTILIZES ESTIMATES OF MANUFACTURING COST TO GUIDE & PRIORITIZE COST REDUCTION EFFORTS.

16. DFM: DESIGN FOR MANUFACTURING (2)(Ulrich, 2000) • DFM CONSISTS OF FIVE STEPS : • ESTIMATE THE MANUFACTURING COSTS. • THE MANUFACTURING COST OF A PRODUCT CONSISTS OF COSTS IN THREE • CATEGORIES : • A. COMPONENTS COSTS • B. ASSEMBLY COSTS • C. OVERHEAD COSTS

17. DFM: DESIGN FOR MANUFACTURING (3)(Ulrich, 2000) 2. REDUCE THE COSTS OF COMPONENTS SEVERAL STRATEGIES FOR MINIMIZING THE MANUFACTURING COST : A. UNDERSTAND THE PROCESS CONSTRAINT & COST DRIVER. B. REDESIGN COMPONENTS TO ELIMINATE PROCESSING STEPS. C. CHOOSE THE APPROPRIATE ECONOMIC SCALE FOR THE PART PROCESS. D. STANDARDIZE COMPONENTS AND PROCESS E. ADHERE TO “BLACK BOX” COMPONENT PROCUREMENT

18. DFM: DESIGN FOR MANUFACTURING (4)(Ulrich, 2000) 3. REDUCE THE COSTS OF ASSEMBLY WE CAN A FEW PRINCIPLES USEFUL TO GUIDE DFA (DESIGN FOR ASSEMBLY) DECISIONS IN ORDER TO REDUCE THE COSTS OF ASSEMBLY. A. KEEPING SCORE DFA INDEX : (THEORETICAL MINIMUM NUMBER OF PARTS) X 3 SECONDS DFA INDEX = ESTIMATED TOTAL ASSEMBLY TIME B. INTEGRATE PARTS C. MAXIMIZE EASE OF ASSEMBLY D. CONSIDER CUSTOMER ASSEMBLY

19. DFM: DESIGN FOR MANUFACTURING (5)(Ulrich, 2000) 4. REDUCE THE COSTS OF SUPPORTING PRODUCTION A. MINIMIZE SYSTEMIC COMPLEXITY B. ANTICIPATE THE POSSIBLE FAILURE MODES OF THE PRODUCTION SYSTEM & TAKE APPROPRIATE CORRECTIVE ACTION EARLY IN THE DEVELOPMENT PROCESS 5. CONSIDER THE IMPACT OF DFM DECISIONS ON OTHER FACTORS A. THE IMPACT OF DFM ON DEVELOPMENT TIME B. THE IMPACT OF DFM ON DEVELOPMENT COST C. THE IMPACT OF DFM ON PRODUCT QUALITY D. THE IMPACT OF DFM ON EXTERNAL FACTORS

20. DFM: DESIGN FOR MANUFACTURING (6)(Ulrich, 2000) PROPOSED DESIGN ESTIMATE THE MANUFACTURING COSTS REDUCE THE COSTS OF COMPONENTS REDUCE THE COSTS OF ASSEMBLY REDUCE THE COSTS OF SUPPORTING PRODUCTION CONSIDER THE IMPACT OF DFM DECISIONS ON OTHER FACTORS RECOMPUTE THE MANUFACTURING COSTS GOOD ENOUGH ? NO YES ACCEPTABLE DESIGN

21. PROTOTYPING (1)(ULLMAN, 1996) • Prototipe yang dibuat memenuhi persyaratan sbb: • 1. Prototipe merupakan perwujudan atribut-atribut pokok dari konsep • produk. • 2. Prototipe harus bekerja dengan aman dalam keadaan penggunaan • yang normal. • 3. Prototipe dibuat dalam batas-batas anggaran. • 4. Prototipe tidak hanya mampu menunjukkan segi kegunaannya • saja, tapi juga mampu mengkomunikasikan sisi-sisi psikologis dari • produk (isyarat-isyarat fisik).

22. PROTOTYPING (2) (Ulrich, 2000) PRODUCT DEVELOPMENT ALMOST ALWAYS REQUIRES THE BUILDING AND TESTING OF PROTOTYPES. A PROTOTYPE IS AN APPROXIMATION OF THE PRODUCT ON ONE OR MORE DIMEN- SIONS OF INTEREST. PROTOTYPES CAN BE USEFULLY CLASSIFIED ALONG TWO DIMENSIONS : (1) THE DEGREE TO WHICH THEY ARE PHYSICAL AS OPPOSED TO ANALYTICAL AND (2) THE DEGREE TO WHICH THEY ARE COMPREHENSIVE AS OPPOSED TO FOCUSED. PROTOTYPES ARE USED FOR LEARNING, COMMUNICATION, INTEGRATION, AND MILESTONES. WHILE ALL TYPES OF PROTOTYPES CAN BE USED FOR ALL OF THESE PURPOSES, PHYSICAL PROTOTYPES ARE USUALLY BEST FOR COMMUNICATION, AND COMPREHENSIVE PROTOTYPES ARE BEST FOR INTEGRATION AND MILES- TONES.

23. PROTOTYPING (3) (Ulrich, 2000) • A PROTOTYPES MAY REDUCE THE RISK OF COSTLY ITERATIONS. A PROTOTYPE • MAY EXPEDITE OTHER DEVELOPMENT STEPS. A PROTOTYPE MAY RESTRUCTURE • TASK DEPENDENCIES. • 3D COMPUTER MODELING & FREE-FORM FABRICATION TECHNOLOGIES HAVE • REDUCED THE RELATIVE COST & TIME REQUIRED TO CREATE PROTOTYPES. • FOUR-STEP METHOD FOR PLANNING A PROTOTYPE IS : • DEFINE THE PURPOSE OF THE PROTOTYPE • ESTABLISH THE LEVEL OF APPROXIMATION OF THE PROTOTYPE • OUTLINE AN EXPERIMENTAL PLAN • CREATE A SCHEDULE FOR PROCUREMENT, CONSTRUCTION, AND TEST