Types of Processes

Single stage or multiple stage

Multiple stage process must be buffered internally. Buffering refers to storage area between stages. It allows the stages to operate independently Common problems are blocking and starving. Blocking means activities must stop because there is no place to deposit. Starving occurs when the activities in a stage must stop because there is no work Bottleneck : inventory buffer is placed; it limits the capacity of Product the process Chapter Design and Process 1
Selection

Types of Processes continued

Make-to-order: A process that is activated only in response to an actual order. Inventory is kept minimum. Services by nature often use make-to-order process Make-to-stock: A process that produces standard products that are stored in finished goods inventory.

Chapter Product Design and Process Selection

Types of Processes continued

Hybrid: combines the features of both make-to-order and make-to-stock. A generic product is made and stocked at some point in the process. These generic units are customized in a final process to meet actual order. Burger King- Have it your way Pacing: movements of items through a process is coordinated through a timing mechanism. Most processes are not paced but assembly lines are usually
Chapter Product Design and Process Selection

Designing for the Customer

Look at the design from users standpoint Customers must not be forgotten Many products have too many technological features- far more than necessary sometimes confusing. Where is the voice of customer?

Chapter Product Design and Process Selection

Designing for the Customer

House of Quality House of Quality

Quality Function Deployment

Ideal Customer Product

Value Analysis/ Value Engineering

Chapter Product Design and Process Selection

Quality Function Deployment

A process of determining customer requirements and translating them into the attributes that each functional area can understand and act on. Determines what will satisfy the customer Translates those desires into specific product characteristics Product design process using crossfunctional teams Chapter Product Design and Process
Selection

Value Analysis/Value Engineering Achieve equivalent or better performance

at a lower cost while maintaining all functional requirements defined by the customer Does the item have any design features that are not necessary? Can two or more parts be combined into one? How can we cut down the weight? Are there nonstandard parts that can be
Chapter Product Design and Process Selection

House of Quality
Customer requirement information forms the basis for a matrix called the house of quality Customer feedback is used to make engineering , marketing and design decisions Important characteristics and goals are jointly agreed This process encourages different department to work closely together and results in better understanding. Customer requirements and product characteristics are put in column and row. Customers are asked to compare the product to Design and Process 8 the competition Chapter Product Selection

House of Quality
Customer requirements information forms the basis for this matrix, used to translate them into operating or engineering goal
The McGraw-Hill Companies, Inc., 2004
X X X X X

Correlation:
X Strong positive Positive Negative Strong negative
X = Us A = Comp. A B = Comp. B (5 is best) 1 2 3 4

Water resistance

Energy needed to close door Door seal resistance Check force on level needed Energy ground open door to Accoust. Trans. Window

Engineering Characteris tics

Competitive evaluation

Customer Requirement s Easy to close

Easy to open

7 3

X X AB

AB

Stays open on a hill 5 Doesnt leak in rain 3 No road noise 2 Importance weighting Target values
5 4 3 2 1

XAB A XB X A B

Reduce energy level to 7.5 ft/lb Maintain current level

Reduce force to 9 lb. Reduce energy to 7.5 ft/lb. Maintain current level Maintain current level

10

Relationships:
Strong = 9 Medium = 3 Small = 1

Technical evaluation (5 is best)

B A X

BA X

B A X

B X A

BXA

BA X

Chapter Product Design and Process Selection

House of Quality Example

What the customer desires

Customer Customer Aluminum Requirements Importance Parts

Auto Focus

Auto Exposure

Light weight Easy to use Reliable

Target Values

High relationship (5) Medium relationship (3) Low Relationship (1)

10

Chapter Product Design and Process Selection

House of Quality
Target values for engineering characteristics (basement); key output
Customer Importance

Customer Requirements

Light weight Easy to use Reliable

Target Values

3 4 5

Aluminum Parts

Auto Focus

Auto Exposure

27

27

High relationship (5) Medium relationship (3) Low Relationship (1)

11

Chapter Product Design and Process Selection

Designing Products for Manufacture and Assembly

Traditional Approach
We design it, you build it or Over the wall

Concurrent Engineering
Lets work together simultaneously

Chapter Product Design and Process Selection

12

Designing for Manufacturing

Minimize parts Design parts for multiple applications Use modular design

Avoid tools
Simpler to assemble

Chapter Product Design and Process Selection

13

Process Selection
It refers to strategic decision of selecting which kind of production process to have in manufacturing plant Types:
Conversion Fabrication Assembly Testing

Chapter Product Design and Process Selection

14

Process Flow Design

This refers to organization of material flow using one or more process technologies Types of Major Process Flow structure: Job shop: Production process of small batches of large number of products Such as plants that make customdesigned product Batch shop: Standardized job shop such as Medicine Assembly Line: Automobile manufacturer Continuous Flow: Conversion or further processing of Chapter Product Design and Process undifferentiated materials such as Chemical manufacturer Selection

15

Service-System Design Matrix

Degree of customer/server contact High
Buffered core (none) Permeable system (some) Reactive system (much)

Exhibit 7.6

Low

Sales Opportunity
Phone Internet & Contact on-site technology Mail contact

Face-to-face total customization Face-to-face loose specs Face-to-face tight specs

Production Efficiency

Low
Chapter Product Design and Process Selection

High

16

Service-System Design Matrix

Buffered core: physically separated from customers Permeable system: penetrable by customer Reactive system: penetrable and reactive to customer requirements The greater the amount of contact the greater the chance of sales opportunity Production efficiency decreases as customer has more contact on the system
Chapter Product Design and Process Selection

17

1. 2. 3. 4. 5. 6. 7.

Emerging Issues in Products Design

Robust Design Modular Design Computer-Aided Design (CAD) Computer-Aided Manufacturing (CAM) Virtual Reality Technology Value Analysis Environmentally Friendly Designs

Chapter Product Design and Process Selection

18

Robust Design and Modular Design

Robust Design: The product is designed in such a way that small variations in production or assembly do not adversely affect the product Modular Design: A design in which parts or components of a product are subdivided into modules that are easily interchanged or replaced. It is helpful because it makes product development, production, and subsequent change easier. The customization provided by modularity allows customers to mix and match to their own taste. Chapter Product Design and Process
Selection

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Computer-Aided Design
CAD: It is the use of computers to interactively design products and prepare engineering documentation. CAD software allows designers to use three-dimensional drawings to save time and money by shortening development cycles Faster development, better products, accurate flow of information to other departments- all contribute to tremendous
Chapter Product Design and Process Selection 20

Computer-Aided Manufacturing
CAM refers to the use of specialized computer programs to direct and control manufacturing equipment Benefits of CAD and CAM:
Product quality Shorter design time Production cost reduction Database availability New range of capabilities
Chapter Product Design and Process Selection 21

Virtual Reality Technology and Value Analysis

Virtual reality is a visual form of communication in which images substitute for the real thing but still allow the user to respond interactively It has made drafting tables and modeling clay a thing of the past Value Analysis seeks improvements that lead to either a better product or a product made more economically
Chapter Product Design and Process Selection 22

Environmentally Friendly Designs

Goals:
Developing safe and more environmentally sound products Minimizing waste of raw materials and energy Reducing environmental liabilities Increasing cost effectiveness of complying with environmental regulations Being recognized as good corporate citizens
Chapter Product Design and Process Selection 23

Environmentally Friendly Designs

Guidelines
Make product recyclable Use recycled materials Use less harmful ingredients Use lighter components Use less energy Use less material

Chapter Product Design and Process Selection

24

Application of Decision Trees to Product Design Sarah King, president of King Electronics, Inc., has two design options for her new line of high resolution cathode-ray tubes (CRTs) for CAD work stations. The life cycle sales forecast for the CRT is 100,000 units. Design option A has 0.9 probability of yielding 59 good CRTs per 100 and 0.1 probability of yielding 64 good CRTs per 100. This design will cost $1000,000. Design option B has a 0.8 probability of yielding 64 good units per 100 and a 0.2 probability of yielding 59 good units per 100. This design will cost $1,350,000. Good or bad each CRT will cost $75. Each good CRT will sell for $150. Bad CRTs are destroyed and have no Chapter Product Design and Process 25 Selection salvage value. We ignore any disposal cost.