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Chapter 6
Product Design and Process Selection--Manufacturing
The Product Design Process– Concurrent Engineering
Designing for the Customer– QFD
Process Selection Process Flow Design Process Analysis Globalization of Product Design and Development
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The Product Design Process
Concept Development
Product Planning
Detailed Engineering
Engineering Release (Sign-Off)
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Concurrent Engineering
Concurrent engineering can be defined as the simultaneous development of project design functions, with open and interactive communication existing among all team members for the purposes of
reducing time to market,– decreasing cost, and– improving quality and reliability.
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Designing for the Customer
Industrial Design
» Aesthetics
» Ergonomics
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Quality Function Deployment
Interfunctional teams from marketing, design engineering, and manufacturing
Voice of the customer
House of Quality
House of Quality
Customer Requirements
Importance to Cust.
Easy to close
Stays open on a hill
Easy to open
Doesn’t leak in rain
No road noise
Importance weighting
Engineering Characteristics
Ene
rgy
need
ed
to c
lose
doo
r
Che
ck f
orce
on
leve
l gro
und
Ene
rgy
need
ed
to o
pen
door
Wat
er r
esis
tanc
e
10 6 6 9 2 3
7
5
3
3
2
X
X
X
X
X
Correlation:
Strong positive
Positive
NegativeStrong negative
X*
Competitive evaluation
X = UsA = Comp. AB = Comp. B(5 is best)
1 2 3 4 5
X AB
X AB
XAB
A X B
X A B
Relationships:
Strong = 9
Medium = 3
Small = 1Target values
Red
uce
ener
gy
leve
l to
7.5
ft/l
b
Red
uce
forc
eto
9 lb
.
Red
uce
ener
gy to
7.5
ft/
lb.
Mai
ntai
ncu
rren
t lev
elTechnical evaluation(5 is best)
5
4321
B
A
X
BA
X B
A
X
B
X
A
BXABA
X
Doo
r se
al
resi
stan
ce
Acc
oust
. Tra
ns.
Win
dow
Mai
ntai
ncu
rren
t lev
el
Mai
ntai
ncu
rren
t lev
el
7
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Value Analysis/Value Engineering (VA/VE)
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 eliminated?
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Types of Processes
Conversion
Fabrication
Assembly
Testing
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Process Flow Structures
Job shop
Batch
Assembly Line
Continuous Flow
IV.Continuous
Flow
III.Assembly
Line
II.Batch
I.Job
Shop
LowVolumeOne of a
Kind
MultipleProducts,
LowVolume
FewMajor
Products,HigherVolume
HighVolume,
HighStandard-
ization
CommercialPrinter
French Restaurant
HeavyEquipment
Coffee Shop
AutomobileAssembly
Burger King
SugarRefinery
Flexibility (High)Unit Cost (High)
Flexibility (Low)Unit Cost (Low)
Source: Modified from Robert Hayes and Steven Wheelwright, Restoring Our Competitive Edge: Competing through Manufacturing (New York: John Wiley & Sons, 1984). p. 209.
Exhibit 4.9Exhibit 4.9
13
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Global Product Design and Manufacturing
Joint Ventures
Strategic Suppliers
Global Product Design Strategy
