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4.Rising development costs 5.Increased dependence on external organization For many industries ,product design and development capability aimed at producing a continuous stream of new innovative products is turning out to be a very powerful competitive weapon
Each phase includes Tasks ,Responsibilities for each of the key functions- Marketing , Design , Other functions Approach most suited for market pull products
Identification of a specific Target Market Phase 0 - Idea Validation: Identification ,screening and initial refinement of an idea for a new product Gate 0 : Launch the project Phase 1 Conceptual Design :Exploration of feasibility Gate 1 : Approve project implementation Phase 2: Specification and design - Detailed specifications for the product and production process are worked out Gate 2 : Release the design
Phase 3: Prototype production and testing - An opportunity to learn whether the product under realistic conditions of use is apt to achieve the quality specifications set for it and whether this indeed meets the competitive needs Gate 3 : Begin volume manufacturing Phase4 :Manufacturing ramp up -Task here is to gradually achieve the manufacturing capacity necessary to meet the projected sales volume , while successfully meeting the new product targets for unit costs , conformance to performance specifications and other measures of quality including customer satisfaction Phase 5 : Cost reduction - A common follow up phase
This approach involves starting certain engineering tasks related to the manufacturing process at the same time that details of the product design are being worked out . The result is a more efficient and a more effective process. Shorter development cycle times Early Problem identification &resolution of risks
Robust design : Products should be designed to be robust in the face of changes in environmental conditions Modular design : Makes it possible to have relatively high variety with limited number of components .The basic idea is to develop a series of basic product components ( modules) which can be assembled in to large number of products Environmental design Product life cycle design
House of Quality
Engineering Characteristics
Correlation:
6
X X
Strong positive
Positive
X X
*
Water resistance Accoust. Trans. Window
Competitive evaluation
X = Us A = Comp. A B = Comp. B (5 is best) 1 2 3 4 5
3
7 5 3 3 2
X X AB
AB
2
XAB A XB
X A
10
Reduce energy level to 7.5 ft/lb
9
Reduce energy to 7.5 ft/lb.
Relationships:
Strong = 9
Target values
7
5
Medium = 3 Small = 1
4 3 2 1
B A X
BA X B A X
B X A
BXA
BA X
Helps translate the requirements as seen by the customer in to technical specifications that can be used by production and design House Of Quality : A matrix with Customer Requirements on the left side and Technical Specifications on the top of the matrix Customer Attributes ( WHATS) Relative Importance : CAs are rated in terms of relative Importance The relative importance are weights are scaled to a total of 100 points
Customers Perception(right hand side of the matrix: Customer compares each CA to competition to determine if the current product design is behind , even or ahead of competition. Engineering Characteristics ( HOW,s)These are listed on top of the matrix and shows how these CA s can be met.
Each EC is assigned a measureable qty(eg kgs,/ sq cm) Objectives (targets) for the EC are listed on the bottom of the matrix Relation ships : The CAs relation ships with ECs are shown in the matrix Strong positive , Medium positive , Medium negative , Strong negative Each EC is evaluated on at a time to for its effect on CA through engineering experiments
Roof of the House : The inter EC relation ships ( correlation )are listed in the Triangular matrix. (+ high , medium +, Medium - ,High Used to determine the influence of one EC on the others.
Value analysis is also an organized approach for analyzing products and services in which several steps and techniques are routinely used. Value / Cost : Cost : is an absolute term expressed in monetary units-which measures the resources used for creating a product or service- Labor + Material + Overhead
Value is the customers perception of the usefulness of the product or service to its cost. Usefulness includes Quality, reliability, and performance of the product for its intended use Value is what the customer is looking for meeting his needs at the lowest cost
Value = Usefulness / Cost Increase value : Increase Usefulness Decrease cost Achieved by eliminating unnecessary or costly functions that do not contribute to value.
Value analysis
State the objective , and identifying primary (Basic)function and Secondary function
Objective : The purpose or reason that the product exists Basic Function If eliminated would render the product useless in terms of its stated objectives Secondary function : Exists to support a basic function , because of the way the product was designed
Developing creative alternatives to reduce the cost or to improve the value of the product Done by consolidating , revising or eliminating the secondary function which improves the value ratio
Design for Assembly (DFA) concerned only with reducing product assembly cost
minimizes number of assembly operations
Design for Manufacturing (DFM) concerned with reducing overall part production cost
minimizes complexity of manufacturing operations
Both DFM and DFA seek to reduce material, overhead, and labor cost. They both shorten the product development cycle time. Both DFM and DFA seek to utilize standards to reduce cost
DFA Principles
Minimize part count Design parts with self-locating features Design parts with self-fastening features Minimize reorientation of parts during assembly Design parts for retrieval, handling, & insertion Emphasize Top-Down assemblies Standardize partsminimum use of fasteners. Encourage modular design Design for a base part to locate other components Design for component symmetry for insertion
DFA guidelines
Reduce part count & types Ensure parts cannot be installed incorrectly Strive to eliminate adjustments Ensure parts self-align & self-locate Ensure adequate access & unrestricted vision Ensure parts are easily handled from bulk Minimize reorientation (assemble in Z axis) & secondary operations during assembly Make parts symmetrical or obviously asymmetrical
Service experience fit : New service should fit into the current service experience of the customer Operational fit : Operational skills and the capabilities to execute the service Financial Impact: