Topic 5 Product Development

04/07/23Product Development: Topic 5Page 1

Topic 5

Product Development


Manufacturing Techniques

5.1


Manufacturing Processes Designers need to understand a

wide range of manufacturing processes and techniques to match their knowledge of materials. This topic does not try to encompass all known techniques but outlines and exemplifies the main manufacturing processes and techniques.


Manufacturing Processes• It is important to understand how the

different processes link together in the manufacture of a product. During manufacture material is usually first shaped crudely and then more precisely into finished parts or components and finally assembled. Some products or components are made by a single process although most require a mixture of processes.


Manufacturing Technique

• manufacturing technique - A specific manufacturing term, sometimes relating to one material group only.


Different Techniques• Moulding• Casting• Weaving• Fusing• Stitching

• Cutting• Machining• abrading • using adhesives • using fasteners.


Different techniques for different materials• casting relates to metals, plastics,

food, ceramics and some composites, but not to timber or textiles.

• Technique often relates to the viewpoint of the manufacturer and the user.


Craft Production

5.2


Small scale production methods • craft production - A small-scale

production process centered on manual skills

• one-off production - An individual (often craft-produced) article or a prototype for larger-scale production.


Prior to the Industrial Revolution• most products were manufactured

by craft techniques • This required: • development of skills• sources of materials and energy• sales and distribution• relationship of craftsman or

designer with client or consumer.


Craft Production• Works if • Small economies of scale • High value of the product• Area of lower labor costs (relative)• High flexibility in manufacture

(specialized individual orders)


Craft Production• May be an option in developing

countries when Economic development, infrastructure and market needs are considered,

• In developed countries it gives rise to the "master craftsman"


Mechanization

5.3


Mechanization• mechanization – A volume

production process involving machines controlled by humans

• the availability of new sources of power like water and steam power during the Industrial Revolution led to the introduction of mechanization.


Assembly-line Production • assembly-line production – The mass

production of a product via a flow line based on the interchangeability of parts, pre-processing of materials, standardization and work division.

• What is the relevance of assembly-line production to mechanization in regards to

• Economics?• design of products?• effect on the workforce?• consumer choice?


Trade-offs of mechanizing a production process. • Cost• quality of product• social conditions • labour


Production scales• batch production - Limited volume production (a

set number of items to be produced • mass production – The production of large amounts

of standardized products on production lines, permitting very high rates of production per worker

• Compare batch production and mass production in a mechanized production system based on:

• market needs• consumer choice• product differentiation • economies of scale.


Automation

5.4


Automation• automation – A volume production

process involving machines controlled by computers

• The development of computer and information technology in the "technological revolution" led to the introduction of automation

• This transformation requires electricity to be reasily available


Computer applications• computer-aided manufacture (CAM) - The use of

computers to aid manufacturing • computer numerical control (CNC) – Refers

specifically to the computer control of machines for the purpose of manufacturing complex parts in metals and other materials. Machines are controlled by a program commonly called a "G code". Each code is assigned to a particular operation or process. The codes control X,Y,Z movements and feed speeds.

• How does CAD, CAM and CNC contribute to an automated production system?


Production Rationales• just-in-time (JIT) - A situation where a firm

does not allocate space to the storage of components or completed items, but instead orders them (or manufactures them) when required. Large storage areas are not needed and items that are not ordered are not made.

• just-in case (JIC) – A situation where a company keeps a small stock of components (or complete items) or ones that take a long time to make, just in case of a rush order.


Mass Customization• mass customization -A sophisticated CIM system

that manufactures products to individual customer orders. The benefits of economy of scale are gained whether the order is for a single item or for thousands

• changing the relationship between the manufacturer and the consumer

• The relationship is akin to craft production, where the individual requirements of the consumer dominate


The impact of automation on working conditions • nature and type of employment• health and safety issues• social interaction• job satisfaction.


The impact of automation on product quality

• Many products require such precision in their manufacture that, without automation, it would not be possible to produce them at an affordable price

• For many years, foreign import automobiles had much higher quality control than American automobiles


Economic Considerations

5.5


Production Costs• scale of production• complexity of

product• Resources• Skills• quality control• size and weight of

product for storage and distribution,

• type of advertising and marketing,

• taxes.

• costs relating to availability and procurement of materials

• R&D• Labour• manufacturing costs• capital costs• overheads• Distribution• sales


Types of Costs• fixed costs - The costs that must be paid

out before production starts, for example, machinery. These costs do not change with the level of production.

• variable costs – Costs that vary with output, for example, fuel or raw materials.

• Return to the list on the previous slide and identify the type of cost for each


Cost based on production process• raw materials and labour costs will

be significant for an individually crafted mahogany table, but for an injection-moulded plastic component these costs would be low and the capital cost of machinery high.


Break-even Point• Once "break-even" point is

reached, profits can be made, because fixed costs have been covered. Variable costs will continue to rise with increased production.


Clean Manufacturing

5.6


The introduction of mass production increased damage to the natural environment. • A historical perspective is

important. Environmental considerations were not an issue in the 18th and 19th centuries. Little quantitative data was available, and all governments encouraged the growth of industry


Why clean our manufacturing processes?

• promoting positive impacts• ensuring neutral impact or minimizing

negative impacts through conserving natural resources

• reducing pollution and use of energy, • reducing wastage of energy and

resources.


The "end-of-pipe" approach. • The initial response to reducing

emission of pollutants is usually adding clean-up technologies to the end of the manufacturing process.

• legislation provides an impetus to manufacturers to clean up manufacturing processes.


Strategies for cleaning up manufacturing are mainly reactive

• Many companies react to legislation or impending legislation by doing the minimum required. More radical approaches, for example, life cycle analysis, are proactive

• more radical approaches require a rethink of the whole system and may result in significant product and/or process modification or radically new technologies.


Reducing pollution • targets for reducing pollution and

waste from industry are agreed internationally, but not all industrial nations agree to the targets

• What are the difficulties of stating targets against the background of ever-changing social, political and economic changes?


End of Topic 5

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Topic 5 Product Development