PERANCANGAN PRODUK - Universitas Brawijayadebrina.lecture.ub.ac.id/files/2015/09/PerPro-05.pdf · PERANCANGAN PRODUK Chapter 5 Gasal 2015/2016 Debrina Puspita Andriani Teknik Industri

PERANCANGAN PRODUK Chapter 5 Gasal 2015/2016

Debrina Puspita AndrianiTeknik Industri Universitas Brawijaya

e-Mail : [email protected] Blog : http://debrina.lecture.ub.ac.id/

PRODUCT SPECIFICATIONS

13/10/2014 Perancangan Produk - Gasal 2014 2

Needs and Specifications •  Customer Needs describe What the end product or service

does for the user. •  They are expressed in the “language of the customer”. •  The “product__________”

•  Product Specifications allow quantification of the customer needs. •  A spec consists of a metric, a unit, and a value •  Specs has a set of specs.

•  The Product Metrics describe the measures used to determine IF the product meets the customer requirements.

•  The Value is the actual numeric specification that the designers use to determine when the product meets the customer requirements.


Needs and Specifications


Tools for transforming Needs into Specifications


A Product Spec for each Need

•  It is important to identify the critical factors for success and make sure you have a way of quantifying these factors.

Prioritize the Needs.

Develop a measure and value for each need.

Some needs may have more than one specification.


•  Basic control and reference document for the design and manufacture

•  Specific, measurable, testable criteria •  “Unambiguous, Understandable, Correct, Concise,

Traceable, Traced, Design Independent, Verifiable, Unique, Complete, Consistent, Comparable, Modifiable, Attainable”

•  Functional decomposition •  Performance targets •  Constraints (Demands, Musts) •  Goals (Wishes, Wants) •  Features

Product Design Specifications (PDS)


Our Approach to PDS • Process recommended for high-risk new product design. • PDS development will be modified based on your product

or process.


Importance of Clear Specifications •  Product Specifications are the “blue prints” of a project.

•  They will guide the project throughout the development.

•  Developing product specifications is a two step process.

•  Step 1 establish target specs to help channel the thinking during the product concept generation process.

•  Target specs: the hope and aspiration of the design (ideal and marginal (Usually requires making assumptions as to what the final product configuration will be.)

•  Step 2 is the refinement of the specifications once the team has picked a product concept and is ready to go into system level design. Refined specs: trade-offs among different desired characteristics.

•  Completed after concept selection.

•  Step 3 is determine Final Specs. It is in the project’s contract book.


The Product Specs Process

• Based on customer needs and benchmarks

• Develop metrics for each need

• Set ideal and acceptable values

Set Target Specifications

• Based on selected concept and feasibility testing

• Technical and economic modeling

• Trade-offs are critical

Refine Specifications • Critical for ongoing

improvement

Reflect on the Results and the

Process


What department in most companies is most concerned with Product Specifications?

•  The QA department.

• What does a QA department do? •  Works with design engineers to develop comprehensive

specifications for all critical customer requirements. •  Develops test procedures to allow designers to test their designs

against the specifications. •  Test products and processes to ensure the end product complies

with those design specifications.


Example: Specialized mountain bike design • Customer need: The Customer expresses the need in

terms of What the product must do. •  The Suspension enables high-speed descents on bumpy roads.

•  The Product Specification sets metrics and values that allow quantification of the user need. •  Attenuation from dropout to handlebar at 10 Hz. •  Maximum value from the Monster (suspension test by Mountain Bike

Magazine.) •  Minimum descent time on test track.

•  Note: the metric does not yet have an actual value assigned at this point. •  Why not? Product Specifications usually require a preliminary product definition.


Product Specifications Example: Mountain Bike Suspension Fork

Start with the Customer Needs: Kebutuhan pelanggan untuk tiang suspensi dan derajat kepentingan The process of developing product specifications begins with your completed matrix of interpreted customer needs. *Again note that there are no values.


# NEED Imp ST

Tritr

ack

Maniray 2

Rox T

ahx Q

uadra

Rox T

ahx T

i 21

Tonka P

ro

Gunhill H

ead S

hox

1 The suspension reduces vibration to the hands. 3 • •••• •• ••••• •• •••2 The suspension allows easy traversal of slow, difficult terrain. 2 •• •••• ••• ••••• ••• •••••

3 The suspension enables high speed descents on bumpy trails. 5 • ••••• •• ••••• •• •••4 The suspension allows sensitivity adjustment. 3 • •••• •• ••••• •• •••5 The suspension preserves the steering characteristics of the bike. 4 •••• •• • •• ••• •••••

6 The suspension remains rigid during hard cornering. 4 • ••• • ••••• • •••••7 The suspension is lightweight. 4 • ••• • ••• •••• •••••

8 The suspension provides stiff mounting points for the brakes. 2 • •••• ••• ••• •• •••••9 The suspension fits a wide variety of bikes, wheels, and tires. 5 •••• ••••• ••• ••••• ••• •

10 The suspension is easy to install. 1 •••• ••••• •••• •••• ••••• •11 The suspension works with fenders. 1 ••• • • • • •••••12 The suspension instills pride. 5 • •••• ••• ••••• ••• •••••

13 The suspension is affordable for an amateur enthusiast. 5 ••••• • ••• • ••• ••14 The suspension is not contaminated by water. 5 • ••• •••• •••• •• •••••

15 The suspension is not contaminated by grunge. 5 • ••• • •••• •• •••••16 The suspension can be easily accessed for maintenance. 3 •••• ••••• •••• •••• ••••• •

17 The suspension allows easy replacement of worn parts. 1 •••• ••••• •••• •••• ••••• •18 The suspension can be maintained with readily available tools. 3 ••••• ••••• ••••• ••••• •• •19 The suspension lasts a long time. 5 ••••• ••••• ••••• ••• ••••• •

20 The suspension is safe in a crash. 5 ••••• ••••• ••••• ••••• ••••• •••••

Interpretaion of Needs

Concept Development Process


Perform Economic Analysis

Benchmark Competitive Products

Build and Test Models and Prototypes

Identify Customer

Needs

Establish Target

Specifications

Generate Product

Concepts

Select Product

Concept(s)

Set Final

Specifications

Plan Downstream Development

Mission Statement Test

Product Concept(s)

Development Plan

Target Specs

Based on customer needs and benchmarking

Final Specs

Based on selected concept, feasibility, models, testing, and trade-offs

TARGET SPECIFICATIONS


Process for Establishing Target Specifications

1 Prepare the list of Metrics and measurement units based on your customer needs. 2 Collect the competitive benchmarking information. Establish what “best in class” products would require. 3 Set ideal and marginally acceptable target values for each metric (using at least, at most, between, exactly, etc.) 4 Reflect on the results.


Membuat Daftar Metrik

Metrik harus komplit Beberapa metrik

merupakan variabel dependen, beberapa variabel independen

Metrik harus praktis

Beberapa kebutuhan tidak dapat dengan

mudah diterjemahkan menjadi metrik yang

terukur

Metrik harus merupakan kriteria yang populer untuk

perbandingan di pasar


! Perhatikan:

Metrik harus komplit • Setiap kebutuhan harus berhubungan dengan sebuah/

beberapa metrik yang merefleksikan secara lengkap 1 kebutuhan pelanggan

• Nilai dari metrik harus dapat memuaskan kebutuhan terkait


Metrik harus praktis • Metrik dapat langsung diteliti dan dianalisis dengan

mudah oleh tim.

Beberapa metrik merupakan variabel dependen, beberapa variabel independen

• Metrik independen dapat di-set oleh desainer. •  misal “panjang pipa kemudi”, “ukuran roda”

• Metrik dependen adalah hasil dari keputusan desain. •  misal “massa total sepeda”

• Sangat penting untuk mengidentifikasi variabel dependen untuk memastikan bahwa desain yang dipilih tidak mengecewakan pelanggan.


Beberapa kebutuhan tidak dengan mudah diterjemahkan menjadi metrik yang terukur

• Misal Kebutuhan “menanamkan kebanggaan” •  à hal yang penting dalam menentukan keberhasilan segmen

pasar akan pentingnya gaya dan penampilan.

• Bagaimana kebanggaan diukur? •  à Pada kolom unit ditulis “subyektif” dan metrik ini akan dievaluasi

oleh sekumpulan pelanggan.


Metrik harus merupakan kriteria yang populer untuk perbandingan di pasar

• Kebanyakan pelanggan di pasar membeli produk berdasarkan evaluasi publikasi yang diterbitkan secara bebas.

• Kinerja tinggi yang diinginkan (yang tercantum dalam media) à cerminan keinginan pelanggan à tim pengembang menggunakan metrik yang digunakan media.


Establish Metrics and Units STEP 1 ESTABLISHING TARGET SPECIFICATION

Metr

ic #

Ne

ed

#s

Metric Imp Units1 1,3 Attenuation from dropout to handlebar at 10hz 3 dB2 2,6 Spring pre-load 3 N3 1,3 Maximum value from the Monster 5 g4 1,3 Minimum descent time on test track 5 s5 4 Damping coefficient adjustment range 3 N-s/m6 5 Maximum travel (26in wheel) 3 mm7 5 Rake offset 3 mm8 6 Lateral stiffness at the tip 3 kN/m9 7 Total mass 4 kg

10 8 Lateral stiffness at brake pivots 2 kN/m11 9 Headset sizes 5 in12 9 Steertube length 5 mm13 9 Wheel sizes 5 list14 9 Maximum tire width 5 in15 10 Time to assemble to frame 1 s16 11 Fender compatibility 1 list17 12 Instills pride 5 subj18 13 Unit manufacturing cost 5 US$19 14 Time in spray chamber w/o water entry 5 s20 15 Cycles in mud chamber w/o contamination 5 k-cycles21 16,17 Time to disassemble/assemble for maintenance 3 s22 17,18 Special tools required for maintenance 3 list23 19 UV test duration to degrade rubber parts 5 hours24 19 Monster cycles to failure 5 cycles25 20 Japan Industrial Standards test 5 binary26 20 Bending strength (frontal loading) 5 MN

Link Metrics to Needs: Quality Function Deployment, or a Needs-Metrics Matrix

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

Need

Metric

Atte

nuat

ion

from

dro

pout

to

hand

leba

r at

10h

z

Spr

ing

pre-

load

Max

imum

val

ue fr

om th

e M

onst

er

Min

imum

des

cent

tim

e on

test

trac

k

Dam

ping

coe

ffici

ent

adju

stm

ent

rang

e

Max

imum

trav

el (

26in

whe

el)

Rak

e of

fset

Late

ral s

tiffn

ess

at th

e tip

Tot

al m

ass

Late

ral s

tiffn

ess

at b

rake

piv

ots

Hea

dset

siz

es

Ste

ert

ub

e l

en

gth

Whe

el s

izes

Max

imum

tire

wid

th

Tim

e to

ass

embl

e to

fram

e

Fen

der

com

patib

ility

Inst

ills

prid

e

Uni

t man

ufac

turin

g co

st

Tim

e in

spr

ay c

ham

ber

w/o

wat

er e

ntry

Cyc

les

in m

ud c

ham

ber

w/o

con

tam

inat

ion

Tim

e to

dis

asse

mbl

e/as

sem

ble

for

mai

nten

ance

Spe

cial

tool

s re

quire

d fo

r m

aint

enan

ce

UV

test

dur

atio

n to

deg

rade

rub

ber

part

s

Mon

ster

cyc

les

to fa

ilure

Japa

n In

dust

rial S

tand

ards

test

Ben

ding

str

engt

h (f

ront

al lo

adin

g)

1 reduces vibration to the hands. • • •2 allows easy traversal of slow, difficult terrain. •3 enables high speed descents on bumpy trails. • • •

4 allows sensitivity adjustment. •5 preserves the steering characteristics of the bike. • •

6 remains rigid during hard cornering. • •7 is lightweight. •8 provides stiff mounting points for the brakes. •

9 fits a wide variety of bikes, wheels, and tires. • • • •10 is easy to install. •

11 works with fenders. •12 instills pride. •13 is affordable for an amateur enthusiast. •

14 is not contaminated by water. •15 is not contaminated by grunge. •

16 can be easily accessed for maintenance. •17 allows easy replacement of worn parts. • •18 can be maintained with readily available tools. •

19 lasts a long time. • •20 is safe in a crash. • •

Benchmark on Customer Needs STEP 2 ESTABLISHING TARGET SPECIFICATION

# NEED Imp ST

Tritr

ack

Maniray 2

Rox T

ahx Q

uadra

Rox T

ahx T

i 21

Tonka P

ro

Gunhill

Head S

hox

1 The suspension reduces vibration to the hands. 3 • •••• •• ••••• •• •••2 The suspension allows easy traversal of slow, difficult terrain. 2 •• •••• ••• ••••• ••• •••••

3 The suspension enables high speed descents on bumpy trails. 5 • ••••• •• ••••• •• •••4 The suspension allows sensitivity adjustment. 3 • •••• •• ••••• •• •••5 The suspension preserves the steering characteristics of the bike. 4 •••• •• • •• ••• •••••

6 The suspension remains rigid during hard cornering. 4 • ••• • ••••• • •••••7 The suspension is lightweight. 4 • ••• • ••• •••• •••••

8 The suspension provides stiff mounting points for the brakes. 2 • •••• ••• ••• •• •••••9 The suspension fits a wide variety of bikes, wheels, and tires. 5 •••• ••••• ••• ••••• ••• •

10 The suspension is easy to install. 1 •••• ••••• •••• •••• ••••• •11 The suspension works with fenders. 1 ••• • • • • •••••12 The suspension instills pride. 5 • •••• ••• ••••• ••• •••••

13 The suspension is affordable for an amateur enthusiast. 5 ••••• • ••• • ••• ••14 The suspension is not contaminated by water. 5 • ••• •••• •••• •• •••••

15 The suspension is not contaminated by grunge. 5 • ••• • •••• •• •••••16 The suspension can be easily accessed for maintenance. 3 •••• ••••• •••• •••• ••••• •

17 The suspension allows easy replacement of worn parts. 1 •••• ••••• •••• •••• ••••• •18 The suspension can be maintained with readily available tools. 3 ••••• ••••• ••••• ••••• •• •19 The suspension lasts a long time. 5 ••••• ••••• ••••• ••• ••••• •

20 The suspension is safe in a crash. 5 ••••• ••••• ••••• ••••• ••••• •••••

Benchmarking on Metrics

13/10/2014 Perancangan Produk - Gasal 2014 28 M

etr

ic #

Ne

ed

#s

Metric Imp Units ST

Trit

rack

Manira

y 2

Rox

Tahx

Quadra

Rox

Tahx

Ti 2

1

Tonka

Pro

Gunhill

Head S

hox

1 1,3 Attenuation from dropout to handlebar at 10hz 3 dB 8 15 10 15 9 132 2,6 Spring pre-load 3 N 550 760 500 710 480 680

3 1,3 Maximum value from the Monster 5 g 3.6 3.2 3.7 3.3 3.7 3.44 1,3 Minimum descent time on test track 5 s 13 11.3 12.6 11.2 13.2 115 4 Damping coefficient adjustment range 3 N-s/m 0 0 0 200 0 0

6 5 Maximum travel (26in wheel) 3 mm 28 48 43 46 33 387 5 Rake offset 3 mm 41.5 39 38 38 43.2 39

8 6 Lateral stiffness at the tip 3 kN/m 59 110 85 85 65 1309 7 Total mass 4 kg 1.409 1.385 1.409 1.364 1.222 1.1

10 8 Lateral stiffness at brake pivots 2 kN/m 295 550 425 425 325 650

11 9 Headset sizes 5 in1.0001.125

1.000

1.1251.250

1.0001.125

1.000

1.1251.250

1.0001.125 NA

12 9 Steertube length 5 mm

150180

210230255

140

165190215

150

170190210

150170

190210230

150

190210220 NA

13 9 Wheel sizes 5 list 26in 26in 26in26in

700C 26in 26in

14 9 Maximum tire width 5 in 1.5 1.75 1.5 1.75 1.5 1.515 10 Time to assemble to frame 1 s 35 35 45 45 35 85

16 11 Fender compatibility 1 list Zefal none none none none all17 12 Instills pride 5 subj 1 4 3 5 3 518 13 Unit manufacturing cost 5 US$ 65 105 85 115 80 100

19 14 Time in spray chamber w/o water entry 5 s 1300 2900 >3600 >3600 2300 >360020 15 Cycles in mud chamber w/o contamination 5 k-cycles 15 19 15 25 18 35

21 16,17 Time to disassemble/assemble for maintenance 3 s 160 245 215 245 200 425

22 17,18 Special tools required for maintenance 3 list hex hex hex hexlonghex

hex,

pinwrnch

23 19 UV test duration to degrade rubber parts 5 hours 400+ 250 400+ 400+ 400+ 250

24 19 Monster cycles to failure 5 cycles 500k+ 500k+ 500k+ 480k 500k+ 330k25 20 Japan Industrial Standards test 5 binary pass pass pass pass pass pass

26 20 Bending strength (frontal loading) 5 MN 55 89 75 75 62 102

Assign Marginal and Ideal Values STEP 3 ESTABLISHING TARGET SPECIFICATION


Metric Units Marg

inal V

alu

e

Ideal V

alu

e

1 Attenuation from dropout to handlebar at 10hz dB >10 >152 Spring pre-load N 480 - 800 650 - 7003 Maximum value from the Monster g 1.5 >1.7515 Time to assemble to frame s 518 Unit manufacturing cost US$ 360020 Cycles in mud chamber w/o contamination k-cycles >15 >3521 Time to disassemble/assemble for maintenance s 45024 Monster cycles to failure cycles >300k >500k25 Japan Industrial Standards test binary pass pass26 Bending strength (frontal loading) MN >70 >100

Values of Metrics

At least X – set a minimum amount

At most X – set a maximum

Between X and Y – set a range

Exactly X – set a fixed value

Discrete values – beberapa metrik mempunyai nilai beberapa pilihan

diskret.


Reflect on the results. STEP 4 - ESTABLISHING TARGET SPECIFICATION •  Tim memerlukan beberapa

kali pengulangan sampai target disetujui.

•  Melakukan pertimbangan (refleksi) di tiap kali pengulangan à meyakinkan bahwa hasil yang diperoleh sudah konsisten dengan tujuan proyek.

Beberapa pertimbangan: Apa anggota tim “bertaruh”? – apa wakil bagian pemasaran

menyatakan bahwa nilai yang agresif diperlukan untuk metrik tertentu? Jika ditetapkan target tinggi, apa anggota tim mampu?

Haruskah tim mempertimbangkan untuk menawarkan berbagai produk/pilihan produk agar memenuhi lebih dari satu segmen pasar atau cukup satu produk saja?

Apakah ada spesifikasi yang hilang? Apakah spesifikasi merefleksikan karakteristik dalam kesuksesan komersial?


FINAL SPECIFICATIONS


Process for setting the final specifications


Develop technical models to assess technical feasibility. The input is design variable and the output is a measurement using a metric.

Develop a cost model of the product.

Refine the specifications, making tradeoffs, where necessary to form a competitive map.

“Flow down” the final overall specs to specs for each subsystem (component and part).

Reflect on the results to see •  Whether the product is a winner, and/or •  How much uncertainty there is in the technical and cost model, or •  Whether there is a need to develop a better technical model.

Develop technical models to assess technical feasibility STEP 1 – PROCESS FOR SETTING THE FINAL SPECIFICATIONS


Misal Konsep terpilih: kumparan pegas yang dilumuri minyak untuk produk tiang suspensi

Develop a cost model of the product

•  Produk yang dihasilkan sesuai dengan “target biaya/target cost” yang ditetapkan.

•  Biaya à biaya manufaktur dimana perusahaan memperoleh cukup keuntungan dan mampu menawarkan produk ke pelanggan dengan harga yang bersaing.

•  Perkiraan biaya berdasarkan daftar bahan & komponen sesuai BOM Tree.

STEP 2 – PROCESS FOR SETTING THE FINAL SPECIFICATIONS


No Bahan/Komponen Jumlah

Harga Tertinggi

Harga Terendah

Total Tinggi

Total Rendah

1

2

:

n

Total

Profit Margin & Target Cost


Where: M: profit margin P: price C: cost

Where: C = target cost P = price to the end user Mi = the margin at the ith stage.

Dengan à Markup = P/C - 1

Gross Margin - Industry


Contoh


Diketahui P=$250. Jika produk langsung dijual ke pelanggan oleh pabrik dan

keuntungan kotor yang ingin diperoleh pabrik, MM, adalah sebesar 40%, maka harga produk tersebut adalah: C = P (1 – MM) = $250 (1 – 0,40) = $150

Jika produk dijual ke pengecer dan keuntungan pengecer, MR,

adalah sebesar 45%, maka: C = P (1 – MM) (1 – MR) = $82.50

Jika produk dijual ke distributor dan pengecer, kemudian

keuntungan kotor yang ingin diperoleh distributor, MD, sekitar 20%, maka?

Refine the specifications, making tradeoffs, where necessary STEP 3 – PROCESS FOR SETTING THE FINAL SPECIFICATIONS

Peta Persaingan

Dibuat berdasarkan bagan analisis pesaing (competitive benchmarking chart)

Specification Trade-offs

07/10/15 40

Score on Monster (Gs)

Trade-off Curves  for Three Concepts

Estim

ated

Man

ufac

turin

g C

ost (

$)

Set Final Specifications


METRIC Units Value

1 Attenuation from dropout to handlebar at 10hz dB >122 Spring pre-load N 6503 Maximum value from the Monster g 759 Total mass kg 425

11 Headset sizes in1.0001.125

12 Steertube length mm

150170190210230

13 Wheel sizes list 26in14 Maximum tire width in >1.7515 Time to assemble to frame s 418 Unit manufacturing cost US$ 360020 Cycles in mud chamber w/o contamination k-cycles >2521 Time to disassemble/assemble for maintenance s 45024 Monster cycles to failure cycles >500k25 Japan Industrial Standards test binary pass26 Bending strength (frontal loading) MN >100

Flow down” the final overall specs to specs for each subsystem

• Masalah yang dihadapi: • Memastikan spesifikasi subsistem

dapat mencerminkan spesifikasi produk secara keseluruhan.

• Meyakini bahwa spesifikasi tertentu untuk subsistem yang berbeda mempunyai tingkat kesulitan yang sama untuk dipenuhi.

• Contoh: •  Fungsi efisiensi bahan bakar mesin

tersusun dari bahan bakar mesin, daya tahan putaran mesin, koefisien putaran mesin,koefisien tarikan, aero dinamis, dll.

STEP 4 – PROCESS FOR SETTING THE FINAL SPECIFICATIONS


Reflect on the results to see STEP 5 – PROCESS FOR SETTING THE FINAL SPECIFICATIONS


Quality Function Deployment (House of Quality)

BACA: CONTOH 2 Soccer Robot


Interpreted Customer Needs The process of developing product specifications begins with your completed matrix of interpreted customer needs. Again note that there are no values.


Example of a customer needs table


From 2nd & 3rd of needs

Needs-Metrics Tables


Quality Function Deployment, or a Needs-Metrics Matrix


Competitive Benchmarking – Evaluate the competition


Example of a Product Specification table


Documents

PERANCANGAN PRODUK - Universitas Brawijayadebrina.lecture.ub.ac.id/files/2015/09/PerPro-05.pdf · PERANCANGAN PRODUK Chapter 5 Gasal 2015/2016 Debrina Puspita Andriani Teknik Industri