Designing Products and Services

•Product Design describes the process of imagining, creating and iterating products that solve
users problems or address specific needs in a given market.

To achieve the desired To reduce the cost of the

product quality product

To generate profits in the To implement the idea of

long run a new product

Objective of a good design

To ensure the availability

To reduce the cost of the
 Designing Products and Services

Characteristics of a good product design Factors influencing product design

 Concept in Product Design

Research and
Manufacturability Reverse Engineering
Development

Concurrent
Standardization Product Life Cycle
Engineering

Computer Aided
Modular Design Robust Design
Design

Further reading is suggested

 Sequential Vs Concurrent Design
Sequential design is the term used to
explain the method of production in a
linear system. The various steps are done
one after another, with all attention and
resources focused on that task
Concurrent design is a method by which
several groups within an organizational
work simultaneously to create new
products and services. Here, various tasks
are handled at the same time, and not
essentially in the standard order
Sequential Vs Concurrent Design
 Product Development and Product Life Cycle

Product life cycle

Stages of a product development Further reading is suggested

Process Design
 Process Types

Types of Process

Semi-
Continuou Intermitte
Continuou Project
s nt
s

Mass Flow Batch Job

Continuous Process
Flow Production
Mass Production
Intermittent Production
Continuous Vs Intermittent Production
Job Production
Batch production
Job vs Batch production
Examples of Job, Batch and Flow Production
Process Related Terminologies
Layout
 Objective of Layout

The objectives of facility layout are:

1. Streamline the flow of materials through the plant.
2. Facilitate the manufacturing process.
3. Maintain high turnover of in-process inventory.
4. Minimise materials handling and cost.
5. Effective utilisation of men, equipment and space.
6. Make effective utilisation of cubic space.
7. Flexibility of manufacturing operations and arrangements.
8. Provide for employee convenience, safety and comfort.
9. Minimize investment in equipment.
10. Minimize overall production time.
11. Maintain flexibility of arrangement and operation.
12. Facilitate the organizational structure.
 Principle of Facility Layout
1. Principle of integration: A good layout is one that integrates men, materials, machines and
supporting services and others in order to get the optimum utilisation of resources and maximum
effectiveness.
2. Principle of minimum distance: This principle is concerned with the minimum travel (or
movement) of man and materials. The facilities should be arranged such that, the total distance
travelled by the men and materials should be minimum and as far as possible straight line
movement should be preferred.
3. Principle of cubic space utilisation: The good layout is one that utilise both horizontal and
vertical space. It is not only enough if only the floor space is utilised optimally but the third
dimension, i.e., the height is also to be utilised effectively.
4. Principle of flow: A good layout is one that makes the materials to move in forward direction
towards the completion stage.
5. Principle of maximum flexibility: The good layout is one that can be altered without much cost
and time, i.e., future requirements should be taken into account while designing the present layout.
6. Principle of safety, security and satisfaction: A good layout is one that gives due consideration
to workers safety and satisfaction and safeguards the plant and machinery against fire, theft, etc.
7. Principle of minimum handling: A good layout is one that reduces the material handling to the
minimum.
Process Layout
Product Layout
Group Technology Layout (Cellular Manufacturing
Fixed Position Layout
Flexible Manufacturing System (FMS)
 Solution for Assignment 2
Question:-
A toy manufacturer receives crafted toys from local carpenters and performs the final operations
before stocking it for sale. The process consists of five steps. The first step is to arrange a set
of four toys in a pallet (a tray or a platform for goods being lifted or stored). After this, the
pallet moves to the next station where the toys are pre-treated. This is to increase the toy’s
life, prevent them from attacks of pests in the future, and also to improve the effectiveness
of the painting operation. The next step is to send it to the spray-painting chamber, where it
is painted as per the specifications. At present, there is one spray-painting machine. After
painting, it is left in an open area for drying. The painting process and the pre-treatment
process are specialized so the paint dries quickly. Finally, the toys are inspected and packed.
The steps in the process, along with the relevant details, are as follows:
– Step 1 (Preparation of toys) : 8 minutes
– Step 2 (Pre-treatment): 12 minutes
– Step 3 (Painting): 20 minutes
– Step 4 (Drying): 10 minutes
– Step 5 (Inspection & Packing): 5 minutes
 Process Analysis
Toy Manufacturing (Problem -I)
Develop a process flow diagram for these steps and answer
the following questions:
– What is the throughput time for this manufacturing
process?
– Identify the bottleneck for this process.
– What is the cycle time for this process?
– What is the productive capacity of the process?
– What are the assumptions behind this computation?

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A graphical representation with start and end times
 Production Capacity of the system

Inspect &
Prepare Pre-treat Paint
Dry Pack
7.5 pallets/hr 5 pallets/hr 3 pallets/hr
12 pallets/hr

Productive capacity = Number of toys produced per hour (1 hr = 60 minutes)

Example: Stage 2 has processing time of 12 minutes. It means that the productive
capacity is 5 pallets per hour (60 minutes/12 minutes = 5 pallets)

• The system can produce at the rate of 3 pallets per hour (12 toys) ( 4 toys/pallet)
• For a 8 hour operation the daily production is 24 pallets (72 toys)
• Capacity is unbalanced across different stages of the process
 Assumptions behind
• The process is continuous operation (that is , at a steady
state with no start-up and shutdown issues).
• An adequate amount of resources (including material,
men, machines, and other resources available).
• Once the operation starts, there are no delays and
breakdowns in the system.
• There are no variations and statistical fluctuations (so
that the time estimates are fixed and constant).
• The process produces a standard set of items.
Therefore, there are no additional time losses due to
set-up and changeover other than those already
factored into the time estimates.