Beruflich Dokumente
Kultur Dokumente
Product Design
Operations Management - 6th Edition
Roberta Russell & Bernard W. Taylor, III
Lecture Outline
Design Process Concurrent Design Technology in Design Design Reviews Design for Environment Design for Robustness Quality Function Deployment
Copyright 2009 John Wiley & Sons, Inc. 4-2
Design Process
Effective design can provide a competitive edge
matches product or service characteristics with customer requirements ensures that customer requirements are met in the simplest and least costly manner reduces time required to design a new product or service minimizes revisions necessary to make a design workable
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defines appearance of product sets standards for performance specifies which materials are to be used determines dimensions and tolerances
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Idea Generation
Companys own R&D department Customer complaints or suggestions Marketing research Suppliers Salespersons in the field Factory workers New technological developments Competitors
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Benchmarking
Comparing product/process against best-in-class best-in-
Reverse engineering
Dismantling competitors product to improve your own product
Copyright 2009 John Wiley & Sons, Inc. 4-7
Feasibility Study
Market analysis Economic analysis Technical/strategic analyses Performance specifications
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Rapid Prototyping
testing and revising a preliminary design model Build a prototype
Functional Design
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Computing Reliability
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0.95
R1
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System Reliability
0.90
0.98
0.92
0.98
0.98
0.92+(1-0.92)(0.90)=0.99
0.98
SA =
where: MTBF = mean time between failures MTTR = mean time to repair
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SAA = 60 / (60 + 4) = .9375 or 94% SAB = 36 / (36 + 2) = .9473 or 95% SAC = 24 / (24 + 1) = .96 or 96%
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Usability
Ease of use of a product or service
ease of learning ease of use ease of remembering how to use frequency and severity of errors user satisfaction with experience
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Production Design
How the product will be made
Simplification
reducing number of parts, assemblies, or options in a product using commonly available and interchangeable parts combining standardized building blocks, or modules, to create unique finished products
Standardization
Modular Design
Design for Manufacture (DFM) Designing a product so that it can be produced easily and economically
Copyright 2009 John Wiley & Sons, Inc. 4-17
Design Simplification
(a) Original design (b) Revised design
Source: Adapted from G. Boothroyd and P. Dewhurst, Product Design. Key to Successful Robotic Assembly. Assembly Engineering (September 1986), pp. 90-93.
Process plans
workable instructions
necessary equipment and tooling component sourcing recommendations job descriptions and procedures computer programs for automated machines
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Design Team
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Concurrent Design
A new approach to design that involves simultaneous design of products and processes by design teams Improves quality of early design decisions Involves suppliers Incorporates production process Uses a price-minus system price Scheduling and management can be complex as tasks are done in parallel Uses technology to aid design
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Technology in Design
Computer Aided Design (CAD)
tests and analyzes designs on computer screen ultimate design-to-manufacture connection design-tomanaging entire lifecycle of a product
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conduct virtual review sessions test what if scenarios assign and track design issues communicate with multiple tiers of suppliers create, store, and manage project documents
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Design Review
Review designs to prevent failures and ensure value
a systematic method of analyzing product failures a visual method for analyzing interrelationships among failures helps eliminate unnecessary features and functions
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Cause of Failure
low moisture content expired shelf life poor packaging too thin too brittle rough handling rough use poor packaging outdated receipt process not in control uneven distribution of salt
Effect of Failure
tastes bad wont crunch thrown out lost sales cant dip poor display injures mouth chocking perceived as old lost sales eat less drink more health hazard lost sales
Corrective Action
add moisture cure longer better package seal shorter shelf life change recipe change process change packaging
Broken
Too Salty
experiment with recipe experiment with process introduce low salt version
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a less costly method? with less costly tooling? with less costly material?
Is it recyclable or biodegradable? Is the process sustainable? Will it use more energy than it is worth? Does the item or its by-product harm the byenvironment?
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designing a product from material that can be recycled design from recycled material design for ease of repair minimize packaging minimize material and energy used during manufacture, consumption and disposal holds companies responsible for their product even after its useful life
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Sustainability
Ability to meet present needs without compromising those of future generations Green product design
Use fewer materials Use recycled materials or recovered components Dont assume natural materials are always better Dont forget energy consumption Extend useful life of product Involve entire supply chain Change paradigm of design
Source: Adapted from the Business Social Responsibility Web site, www.bsr.org, accessed April 1, 2007.
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House of Quality
Importance 5 Trade-off matrix 3 Design characteristics 4 Relationship matrix 2 Competitive assessment
1 Customer requirements
Target values
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A ABX X
Thickness of soleplate
Irons well
Customer Requirements Presses quickly Removes wrinkles Doesnt stick to fabric Provides enough steam Doesnt spot fabric Doesnt scorch fabric Heats quickly Automatic shut-off Quick cool-down Doesnt break when dropped Doesnt burn when touched Not too heavy
- + + + + + + + + + + + + + + + + + - - + + + - + - + + + + + + + 4-35
- - + + + + + + - - - +
Automatic shutoff
Number of holes
Size of soleplate
Weight of iron
Size of holes
Tradeoff Matrix
-
Size of soleplate Thickness of soleplate Material used in soleplate Number of holes Size of holes Flow of water from holes Time required to reach 450 Time to go from 450 to 100 Protective cover for soleplate
+ + +
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Automatic shutoff
Units of measure Iron A Iron B Our Iron (X) Estimated impact Estimated cost Targets Design changes
Objective measures
ft-lb 3 4 2 3 3
cm 2 1 4 4 3 3 *
ty SS MG T 5 4 SS *
ea 27 27 35 4 3 30 *
mm oz/s sec sec Y/N Y/N 15 15 15 3 3 0.5 0.3 0.7 2 3 45 35 50 5 4 30 * 500 350 600 5 4 500 * Y Y Y 0 2
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Automatic shutoff
Number of holes
Size of holes
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A-1
Product characteristics
Part characteristics
Process characteristics
Parts deployment
Part characteristics
House of quality
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Process characteristics
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Process planning
Operations
A-4
Operating requirements Copyright 2009 John Wiley & Sons, Inc. 4-39
Benefits of QFD
Promotes better understanding of customer demands Promotes better understanding of design interactions Involves manufacturing in design process Provides documentation of design process
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designed to withstand variations in environmental and operating conditions yields a product or service designed to withstand variations design parameters such as material used, dimensions, and form of processing users control (length of use, maintenance, settings, etc.)
Robust design
Controllable factors
Uncontrollable factors
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allowable ranges of variation in the dimension of a part consistent errors are easier to correct than random errors parts within tolerances may yield assemblies that are not within limits consumers prefer product characteristics near their ideal values
Consistency
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Quality Loss
Target
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Copyright 2009 John Wiley & Sons, Inc. All rights reserved. Reproduction or translation of this work beyond that permitted in section 117 of the 1976 United States Copyright Act without express permission of the copyright owner is unlawful. Request for further information should be addressed to the Permission Department, John Wiley & Sons, Inc. The purchaser may make back-up copies for his/her own use only and backnot for distribution or resale. The Publisher assumes no responsibility for errors, omissions, or damages caused by the use of these programs or from the use of the information herein.
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