Ch04 Designing Products

Designing ProductsChapter 4

Copyright 2011 John Wiley & Sons, Inc.

Lecture OutlineDesign ProcessRapid Prototyping and Concurrent DesignTechnology in DesignDesign Quality ReviewsDesign for EnvironmentQuality Function DeploymentDesign for RobustnessCopyright 2011 John Wiley & Sons, Inc.4-*


Design ProcessEffective design can provide a competitive edgematches product or service characteristics with customer requirementsensures that customer requirements are met in the simplest and least costly mannerreduces time required to design a new product or serviceminimizes revisions necessary to make a design workable

Copyright 2011 John Wiley & Sons, Inc.4-*


Design ProcessProduct designdefines appearance of productsets standards for performancespecifies which materials are to be useddetermines dimensions and tolerancesCopyright 2011 John Wiley & Sons, Inc.4-*


Idea GenerationCompanys own R&D departmentCustomer complaints or suggestionsMarketing researchSuppliersSalespersons in the fieldFactory workersNew technological developmentsCompetitorsCopyright 2011 John Wiley & Sons, Inc.4-*


Idea GenerationPerceptual Mapsvisual comparison of customer perceptionsBenchmarkingcomparing product/process against best-in-classReverse engineeringdismantling competitors product to improve your own productCopyright 2011 John Wiley & Sons, Inc.4-*


Feasibility StudyMarket analysisEconomic analysisTechnical/strategic analysesPerformance specifications



Rapid Prototyping and Concurrent DesignTesting and revising a preliminary design modelBuild a prototypeform designfunctional designproduction designTest prototypeRevise designRetest



System Availability (SA)where:MTBF = mean time between failures MTTR = mean time to repair



UsabilityEase of use of a product or serviceease of learningease of useease of remembering how to usefrequency and severity of errorsuser satisfaction with experienceCopyright 2011 John Wiley & Sons, Inc.4-*


Production DesignHow the product will be madeSimplificationreducing number of parts, assemblies, or options in a productStandardizationusing commonly available and interchangeable partsModular Designcombining standardized building blocks, or modules, to create unique finished productsDesign for Manufacture (DFM)Designing a product so that it can be produced easily and economically



Final Design and Process PlansFinal designdetailed drawings and specifications for new product or serviceProcess plansworkable instructionsnecessary equipment and toolingcomponent sourcing recommendationsjob descriptions and procedures computer programs for automated machines



Technology in DesignComputer Aided Design (CAD)assists in creation, modification, and analysis of a designcomputer-aided engineering (CAE)tests and analyzes designs on computer screencomputer-aided manufacturing (CAD/CAM)ultimate design-to-manufacture connectionproduct life cycle management (PLM)managing entire lifecycle of a productcollaborative product design (CPD)Copyright 2011 John Wiley & Sons, Inc.4-*


Collaborative Product Design (CPD)A software system for collaborative design and development among trading partnersWith PML, manages product data, sets up project workspaces, and follows life cycle of the productAccelerates product development, helps to resolve product launch issues, and improves quality of designDesigners canconduct virtual review sessionstest what if scenariosassign and track design issuescommunicate with multiple tiers of supplierscreate, store, and manage project documentsCopyright 2011 John Wiley & Sons, Inc.4-*


Design Quality ReviewReview designs to prevent failures and ensure valueFailure mode and effects analysis (FMEA)a systematic method of analyzing product failuresFault tree analysis (FTA)a visual method for analyzing interrelationships among failuresValue analysis (VA)helps eliminate unnecessary features and functions



Copyright 2011 John Wiley & Sons, Inc.4-*FMEA for Potato Chips

FailureModeCause of FailureEffect ofFailureCorrectiveActionStalelow moisture contentexpired shelf lifepoor packagingtastes badwont crunchthrown outlost salesadd moisture cure longerbetter package sealshorter shelf lifeBrokentoo thintoo brittlerough handlingrough usepoor packagingcant dippoor displayinjures mouthchockingperceived as oldlost saleschange recipechange processchange packagingToo Saltyoutdated receiptprocess not in controluneven distribution of salteat lessdrink morehealth hazardlost salesexperiment with recipeexperiment with processintroduce low salt version


Value Analysis (VA)Eliminate unnecessary features and functionsUsed by multifunctional design teamsDefine essential functions of an itemDetermine the value of the functionsDetermine the cost of providing the functionsCompute Value/Cost ratioDesign team works to increase the ratioCopyright 2011 John Wiley & Sons, Inc.4-*


Design for Environment andExtended Producer ResponsibilityDesign for environmentdesigning a product from material that can be recycled design from recycled materialdesign for ease of repairminimize packagingminimize material and energy used during manufacture, consumption and disposalExtended producer responsibilityholds companies responsible for their product even after its useful lifeCopyright 2011 John Wiley & Sons, Inc.4-*


Green AreasGreen Sourcinguse less materialuse recycled if possibleGreen Manufactureis energy from renewable sourcesamount of waste producedGreen Consumptionproducts use of energyis product recyclable and maintainableRecycling and Re-Usedesign products to be recycled or re-usedsave energy and moneyCopyright 2011 John Wiley & Sons, Inc.4-*


Quality Function Deployment (QFD)Translates voice of customer into technical design requirementsDisplays requirements in matrix diagramsfirst matrix called house of qualityseries of connected housesCopyright 2011 John Wiley & Sons, Inc.4-*


Competitive Assessment of Customer RequirementsCopyright 2011 John Wiley & Sons, Inc.4-*Irons wellEasy and safe to useCompetitive AssessmentCustomer Requirements12345Presses quickly9BAXRemoves wrinkles8ABXDoesnt stick to fabric6XBAProvides enough steam8ABXDoesnt spot fabric6XABDoesnt scorch fabric9AXBHeats quickly6XBAAutomatic shut-off3ABXQuick cool-down3XABDoesnt break when dropped5ABXDoesnt burn when touched5ABXNot too heavy8XAB


Benefits of QFDPromotes better understanding of customer demandsPromotes better understanding of design interactionsInvolves manufacturing in design processProvides documentation of design process



Design for RobustnessRobust productdesigned to withstand variations in environmental and operating conditionsRobust designyields a product or service designed to withstand variationsControllable factorsdesign parameters such as material used, dimensions, and form of processingUncontrollable factorsusers control (length of use, maintenance, settings, etc.)



Design for RobustnessToleranceallowable ranges of variation in the dimension of a partConsistencyconsistent errors are easier to correct than random errorsparts within tolerances may yield assemblies that are not within limitsconsumers prefer product characteristics near their ideal valuesCopyright 2011 John Wiley & Sons, Inc.4-*



Taguchis Quality Loss FunctionQuantifies customer preferences toward qualityEmphasizes that customer preferences are strongly oriented toward consistentlyDesign for Six Sigma (DFSS)

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Copyright 2011 John Wiley & Sons, Inc.4-*Copyright 2011 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 not 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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Ch04 Designing Products