Professor Ken Pickar

1. “Product Design” (E105)(Robert)Millikan said . . .that that he had observed that a good many Caltech graduates were going into Industry and he said they ought to know something about that.Oral history of Prof. Horace Gilbert recounting conversation in 1929- from the Caltech Archives

2. Professor Ken Pickar E-mail Pickar@caltech.edu Snail mail 104-44 Thomas Office Thomas 101 Classroom Thomas 306 Phone X 4185 Website http://www.cco.caltech.edu/~kpickar/ Sec’y Maria Koerper X3385 Office Hours 1:00-5:30 PM Afternoons (please call or e-mail first)

3. My background • PhD Low Temperature Physics • Bell Labs • GE Corporate R&D • AlliedSignal

4. E105 Name e-mail phone Class Concentration or Research Area

5. Purpose of Course • To Learn how Product development is carried out in a modern company • through learning about tools • through examples of how these tools are used • To apply this knowledge to a design • To learn Team and Communications skills as applied to Product Design • To do research in Product Design methodologies

6. Not the Purpose • To teach you CAD tools • Formal Methods • Product optimization Algorithms • To learn how to manage technology • A course in Management of Technology will be taught in Q3

7. What is available at Caltech in Technology Management and Entrepreneurship? • Technology Management Courses at Caltech • E105 Product design (Q1) • Pickar • E102 Entrepreneurship (Q2) • Baldeschwieler • E103 Management of Technology (Q3) • Pickar • Other Resources • Industrial Relations Center Short courses (http://www.irc.caltech.edu) • Caltech/MIT Enterprise Forum • Caltech Entrepreneur’s Club (http://www.its.caltech.edu/~eclub) • Caltech Women’s Center (wcenter@caltech.edu)

8. E 105 Review of subjects covered Introduction Process Teams Cycle Time Program Management Engineering Economics QFD Marketing TRIZ and Creativity Systems Engineering DF Assembly Factory Operations Design of Experiments Six Sigma Reliability (FMEA) Design for Environment Baldridge and Quality Ethics of Product design

9. Team Project Early Milestones Term Product Design assignment 1. Form a team Thursday 9/30 2. Take Team Course Saturday, 10/2 3. Choose a project 10/7 4. Get problem accepted 10/12

10. Form a Team • Suggest teams of 3-4 (tops) • Some bases for choice • Compatibility • Challenge • Dependability • Choose carefully- but decisions are reversible • Each member of the team has at least one Leadership Role plus each assists the other in their roles. Roles can rotate. • Leadership Role examples • Program Manager • Marketing • Systems Engineering • Component Design • Producability

11. Examples of Team Projects Examples: • A security project e.g. an electronic lock which is controllable remotely • A laser projection patterning system for home or rock concerts • A digital instant camera • A light emission diode display • A mass spectrograph accessory • A simple computer animation system • An auto body dent removal system • A design based on business plan of E102 • A Research Project you are involved in which has productization potential • Other ideas arising from brainstorming

12. Team Problem • Use tools described in Class including the following tools • PM • ROI • Market Research • QFD • TRIZ • Systems Engineering • DOE • DFA • FMEA • Six Sigma • DFE Grade or P/F (but whole team must be the same status) 40% HW, 40% Term Assignment, 20% class participation All grades are designed to assess knowledge of the design process, creativity in application

13. A word on teams • Feedback show that this is an area that needs improvement • Schedule engineering • Running a meeting- too much wheel spinning • Equality of Effort • Occasional blow-up • To help in resolving some of these concerns, we are requiring that all class participants attend a one-day course on Teams

16. Class Attendance Expectations • Lectures will be posted on web-site but. . . . . • Cannot significantly benefit from the course without class attendance. Don’t depend on web-posted Vugraphs! • Powerpoint bullets don’t contain • Background • Discussion • Q and A • Demos • Decide whether you want to make commitment

17. Other HW • One team will present the results at the beginning of the class. Vugraphs may be e-mailed in advance or presented at class • All teams must do all Homework • 8-10 assignments- due one week from hand-out • 20% for every class day late • Drop the lowest grade

18. Other • Field trips • TBD • To see how designs and factories interact • To see how Internet products are created

19. Books on Reserve

20. Times • Tuesday, Thursday evenings • 7:00-8:30 OK • Open reception when speakers attend • Potential Saturday morning visits • Company A • Company B

21. Introduction to the Product Design Process

22. Why is this important to Caltech students? (WIIFM?) • For people going into industry • What kind of company will you work in? Results are applicable to • Established corporation or new start-up • All industries • All technologies • e.g. Applicable to systems, software/hardware • Why now? • Product design has changed significantly over the last 20 years • Not well-documented • Changing rapidly due to the Internet • Why me? • To understand how Industry really works. • To help decide whether this is for you? • To decrease shock when starting with company • to provide a more sophisticated understanding of how products are made

23. Product Design Research Why is this important to Caltech students? (WIIFM?) • For people going into academic research • Research is the input parameter into product design and/or uses the output of product design

24. Some Characteristics of Product Design • Affects all people in the world • Changes and improves people’s lives • A strong determinant in national standards of living • Fundamentally drives our economic system by • Providing the link between what people need and want (marketing) and what an enterprise can make (production). • Providing the link between new knowledge on what is possible (research) and new useful objects • Is highly creative • The output never existed before • Is highly complex • Involves the linked contributions of many different skills • Is highly evolving • learns from the past • anticipates (and sometimes brings about) the future • subject to rapid change • highly timing dependant • Can be esthetically beautiful • the product • sometimes the process

25. Change Opportunity What has changed in the last 10 years? • In the World • Geo-politically • Economically • In Technology • In Business

26. What’s changed?

27. How has this affected the way we develop products?

28. How has this affected the way we develop products? • Customer focus • Death of Long Range Planning • Rise of new start-ups • De-bureaucratization of older businesses • Fast Manufacturing • Higher Quality • Process-centered Question: What is the effect of the Internet on these characteristics?

29. A Process • What is a Process? • A set of actions with decision points which describe a flow of activities • Why a Process? • Repetition allows for continuous learning • Don’t need to reinvent the wheel • Can tell where you are • Can tell where you are going • Can tell how you are doing • Forces clear roles and responsibilities • for smooth handoffs • Can import ideas from other domains • Is a common language, extensible to other domains

30. What are some examples?

31. What are some examples? • Performing an experiment • Synthesizing a new material • Building a MEM device • Writing a grant proposal Or. . . • Waking up and arriving at work • Writing bills at the end of the month • Mowing the lawn • Planning a vacation • Caltech education!

32. Start, Stop Action, Decision Continuation Process Mapping • A process has. . . • - A Beginning • - An end • - A Duration (C/T) • - Entitlement • - Theoretical • - Actual • Sequential Actions (flow) • Decision Points • Quality • Performance • Efficiency

33. What Characterizes all processes? • Cycle time • average time for products to be designed • Quality • defects in process • Cost • development cost per product in dollars, people • Performance • Are products competitive? Are these co-variant? How would you measure these characteristics?

34. Work Example of a process • Getting a job

35. Another example

36. Three Fundamental Business Processes 1. Make/Market To take an order To manufacture the product To ship the product To collect the payment for the product 2. Design Develop To conceive the product To design the product To transfer the product to steady-state manufacturing 3. Strategic To write and execute the strategic plan of the company All business activity is contained in these processes or directly support them

37. Product Definition Pre- Concept Concept Integration and test Detailed Design Transition to Manufacture The Integrated Product Delivery Process (Design/Develop)

38. Integrated Product Development Process 1 Pre-Concept • Determine marketable product • Write outline of business plan 2 Concept • At least one viable approach determined • Systems simulation 3 Product Definition • Demonstrate viable approach (prototype, model) 4 Detailed Design • Create the data package that enables the design to be built 5 Integration and Test • Validate that the product meets requirements 6 Transition to manufacturing

39. NBD A Sub-process

40. Questions • Which of these step takes the longest? • Which should take the longest? • Which costs the most? • Where is it hardest to correct mistakes?

42. Phase Exit Reviews • To put discipline in process, DFX tools must be used at their appropriate phase in the process • Outside reviewers are employed to assure that the process is followed

43. Concurrent Engineering • Design/Build Team • Early Problem discovery • Early Decision making • Cross Functional team optimized designs

44. Old Way

45. Linear to Concurrent

46. Cross Functional Teams

47. Quality How well the product satisfies specifications Measured in DPU Cost Meets specs Competitive Profitable Speed How long did the product take to get to market? Performance Did the product perform to specifications Were specs sufficiently aggressive? Product Metrics

48. Manufacturing Process • Quality • Yield, redo rate (First pass yield) • Product DPU (Defects per Unit) • Cost • per unit • standard parts use (inventory) • capital avoidance • Speed • Cycle Time (Order Entry to Delivery) • Performance • Productivity • Management of Variation • fill rate • Capacity • Max Product per unit time

49. Product Development Process Metrics • Cycle time • Average time for products to be designed • Do products consistently get to market on time? • Quality • defects in process • First pass success • Manufacturing hiccoughs due to design • Measured in DPU • Cost • Development cost per product in dollars, people • Performance • Use of Resource V Plan • Competitive Development Costs • Did the products perform to specifications?

50. Superior Vs Average Company