Chapter 9, 10, 11

1. Chapter 9, 10, 11 ProductArchitecture, Industrial Design, Design for Manufacturing

2. Chapter 9: Product Architecture • Product Architecture has 2 elements: • Functional – individual operations and transformations that contribute to the overall performance of the product • Physical – parts, components, and subassemblies that implement the product function • Creating modules or building blocks can help in organization and manufacturing

3. Implications of the Architecture • Decisions of architecture can affect many issues: • Product change • Upgrades, Add-ons, Adaptation, Wear, Consumption, Flexibility in use, Reuse • Product variety • Component standardization • Product performance • Manufacturability • Product development management

4. Examples • Exhibit 9-4 pg 169 – Swatch watch

5. Example – F-150

6. Example – Sport Trac

7. Establishing Architecture Steps • Create a schematic of the product • Layout of the components, their hierarchy and interactions • Cluster the elements of the schematic Group the components into clusters based on: • Geometric integration and precision • Function sharing • Capabilities of vendors • Similarity of design or production technology • Localization of change • Accommodating variety • Enabling standardization • Portability of the interfaces

8. Establishing Architecture Steps • Create the rough geometry • Create a rough, basic 3-D and 2-D sketches • Identify the fundamental and incidental interactions • Likely the functional groups or clusters will be assigned to the respective areas of expertise for further design. As a cross functional team the interaction between groups should be know • Fundamental interactions – interactions of components based on function of the product • Incidental interactions – interactions that arise from physical arangement

9. Delayed Differentiation • On occasion variations in architecture will be delayed until further in the Supply Chain. • Examples – voltage components, product variation or customer ordering • Design evolves around the customized group to allow for the options

10. Chapter 11: Design for Manufacturing • Detail design decisions have a substantial impact on final product quality and cost • Development teams face multiple and often conflicting goals • Important to have metrics to compare alternative designs • Dramatic improvements often require substantial creative efforts early in the process • Well-defined method makes the decision-making process much easier

11. DFM • Requires a cross-functional team, internal to the organization and external experts, as well as vendors • Performed throughout the process • Overview: • Estimate the manufacturing costs • Reduce the costs of components • Reduce the costs of assembly • Reduce the cost of supporting production • Consider the impact of DFM decision on other facors

12. Estimate the Manufacturing $ • Manufacturing $ = ∑Input costs • Raw material • Purchased components • Employees effort • Energy • Equipment • Component $ • Assembly $ • Overhead $

13. Estimating the Manufacturing $ • Fixed $ vs. Variable $ • Fixed - $ spent regardless of the quantity of products sold • Variable - $ spent that changes based on the quantity of products sold • Estimate the $ of standard components • Estimate the $ of custom components • Estimate the $ of assembly • Estimate the $ of overhead cost

14. Reduce the $ of Components • Understand the process constraints and cost drivers • Redesign components to eliminate processing steps • Choose an appropriate Economic scale • Standardize components and processes

15. Reduce the $ of Assembly - DFA • Integrate parts • Maximize ease of assembly • Parts inserted from the top of the assy • Part is self-aligning • Part does not need to be oriented • Part requires only one hand for assy • Part requires no tools • Part is assembled in a single, linear motion • Part is secured imediately upon insertion

16. Reduce the $ of Supporting Production • Minimize systemic complexity • Error proofing

17. Consider the impact of DFM • The impact of DFM on development time • The impact of DFM on development cost • The impact of DFM on product quality • The impact of DFM on external factors • Component reuse • Life cycle cost