product development summer 2013. increasing importance of product development 1.customers demand...
TRANSCRIPT
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Product Development
Summer 2013
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Increasing Importance of
Product Development Increasing Importance of
Product Development 1. Customers demand greater product variety.
2. Customers are causing shorter product life cycles.
3. Improving technology is causing new products to be introduced
4. The impact of increasing product variety and shortening product life cycles is having a multiplicative effect on the need for product development.
5. Today, in order to be competitive, the firm may have to produce many different products with a life cycle of only five years or less. End of Life issues
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Product Design
Specifies materialsDetermines dimensions &
tolerancesDefines appearanceSets performance standards
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Service DesignSpecifies what the customer is to
experience Physical items Sensual benefits Psychological benefits
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An Effective Design Process
Matches product/service characteristics with customer needs
Meets customer requirements in simplest, most cost-effective manner
Reduces time to market - haste vs. speed to market
Minimizes revisions - quality designed into the product
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Stages in the Design Process Idea Generation — Product Concept - can you
create your own market? What role does the voice of the customer play in idea generation?
Feasibility Study — Performance Specifications Preliminary Design — Prototype - testing and
redesign Final Design — Final Design Specifications Process Planning — Manufacturing
Specifications - make to order/stock – assembly line?
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Idea Generation
Suppliers, distributors, salespersons Trade journals and other published material Warranty claims, customer complaints,
failures Customer surveys, focus groups, interviews Field testing, trial users Research and development
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More Idea Generators Perceptual Maps
Visual comparison of customer perceptions
BenchmarkingComparing product/service
against best-in-class Reverse engineering
Dismantling competitor’s product to improve your own product
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Perceptual Map of Breakfast Cereals
HIGH HIGH NUTRITIONNUTRITION
LOW LOW NUTRITIONNUTRITION
GOOD GOOD TASTETASTE
BAD BAD TASTETASTE
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© Russell and Taylor, Prentice Hall, 2004
Perceptual Map of Breakfast Cereals
HIGH HIGH NUTRITIONNUTRITION
LOW LOW NUTRITIONNUTRITION
GOOD GOOD TASTETASTE
Cocoa PuffsCocoa Puffs
BAD BAD TASTETASTE
Rice Rice KrispiesKrispies
WheatiesWheaties
CheeriosCheerios
Shredded Shredded WheatWheat
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© Russell and Taylor, Prentice Hall, 2004
Perceptual Map of Breakfast Cereals
HIGH HIGH NUTRITIONNUTRITION
LOW LOW NUTRITIONNUTRITION
GOOD GOOD TASTETASTE
Cocoa PuffsCocoa Puffs
BAD BAD TASTETASTE
Rice Rice KrispiesKrispies
WheatiesWheaties
CheeriosCheerios
Shredded Shredded WheatWheat
How do I get here?
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Feasibility Study
Market Analysis - Market Segmentation
Economic Analysis Technical / Strategic Analysis Performance Specifications Risk Analysis
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Economic Analysis
• Can we produce it at a volume to make a profit?
• If not, why produce?• How many do we have to make to break
even?
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Break Even AnalysisTotal Costs = Total Revenues
(Volume x Price) = (Fixed Costs + Variable Costs)
Profit = (Total Revenue – Total Costs)
Fixed Costs
Sales Price – Variable CostsB/E Point =
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Example
Fixed Costs = $2000
Variable Costs = $5/item
Sales Price = $10/item
Fixed Costs ($2000)
Sales Price ($10) – Variable Costs ($5)
B/E PT =
B/E point = ($2000/$5) 400 items
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Risk Analysis
1. Identify the Hazards2.Assess hazards to determine risks.3.Develop controls and make risk decisions.4.Implement controls.5.Supervise and evaluate.
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Preliminary Design
Create form & functional designBuild prototypeTest prototypeRevise prototypeRetest
How will it look?
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Functional Design(How the Product Performs)
Reliability Probability product performs intended
function for specified length of time
Maintainability Ease and/or cost or maintaining/repairing
product
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System Availability
System Availability, SA = MTBFMTBFMTBF + MTTRMTBF + MTTR
PROVIDERPROVIDER MTBF (HR)MTBF (HR) MTTR (HR)MTTR (HR)
AA 6060 4.04.0BB 3636 2.02.0CC 2424 1.01.0
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System AvailabilityPROVIDER MTBF (HR) MTTR (HR)
A 60 4.0B 36 2.0C 24 1.0
SASAAA = 60 / (60 + 4) = .9375 or 93.75% = 60 / (60 + 4) = .9375 or 93.75%
SASABB = 36 / (36 + 2) = .9473 or 94.73% = 36 / (36 + 2) = .9473 or 94.73%
SASACC = 24 / (24 + 1) = .96 or 96% = 24 / (24 + 1) = .96 or 96%
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Production Design
Part of the preliminary design phase
Simplification Standardization Modularity
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Final Design & Process Plans
Produce detailed drawings & specificationsCreate workable instructions for
manufactureSelect tooling & equipmentPrepare job descriptionsDetermine operation & assembly orderProgram automated machines
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Improving the Design Process Design teams Concurrent design Design for manufacture & assembly Design to prevent failures and ensure value Design for environment Measure design quality Utilize quality function deployment Design for robustness Engage in collaborative design
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Design Teams
Marketing, manufacturing, engineeringSuppliers, dealers, customersLawyers, accountants, insurance
companies
Preferred solution = cross functional teams
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Concurrent Design
Improves quality of early design decisionsDecentralized - suppliers complete
detailed design Incorporates production processScheduling and management can be
complex as tasks are done in parallel include the customer in the process!!
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Design for Manufacture and Assembly
Design a product for easy& economical production
Incorporate production design early in the design phase
Improves quality and reduces costs Shortens time to design and manufacturealso known as Design for Six Sigma
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Design for Six Sigma• Define – the goals of the design activity• Measure – customer input to determine what is
critical to quality from the customers’ perspective – what are customer delighters? What aspects are critical to quality?
• Analyze – innovative concepts for products and services to create value for the customer
• Design – new processes, products, and services to deliver customer value
• Verify – new systems perform as expected
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DFM Guidelines
1. Minimize the number of parts, tools, fasteners, and assemblies
2. Use standard parts and repeatable processes
3. Modular design4. Design for ease of assembly, minimal
handling5. Allow for efficient testing and parts
replacement
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Design for Assembly (DFA)Procedure for reducing number of partsEvaluate methods for assemblyDetermine assembly sequence
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Design Review
Failure Mode and Effects Analysis (FMEA)A systematic approach for analyzing causes
& effects of failuresPrioritizes failuresAttempts to eliminate causes
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Value Analysis (Value Engineering)
Ratio of value / cost Assessment of value :
1. Can we do without it?2. Does it do more than is required?3. Does it cost more than it is worth?4. Can something else do a better job5. Can it be made by less costly method, tools,
material?6. Can it be made cheaper, better or faster by
someone else? Should we contract it out?
Is there value added?
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Design for EnvironmentDesign from recycled materialUse materials which can be recycledDesign for ease of repairMinimize packagingMinimize material & energy
used during manufacture, consumption & disposal
green laws in Europe -
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Design for Robustness
Product can fail due to poor design quality Products subjected to many conditions Robust design studies
Controllable factors - under designer’s control
Uncontrollable factors - from user or environment
Designs products for consistent performance
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A Well-Designed Service System is
Consistent with firm’s strategic focusCustomer friendlyEasy to sustainEffectively linked between front & back
officeCost effectiveVisible to customer
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Process Design Process Design
Process Selection affects the outcome – in production or sports:
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What is Process Selection?
• Series of decisions that includes technical/engineering issues and volume/scale issues
• Technical/engineering: basic methods that produce a good or service
• Scale: how many or how much to produce; how many to serve at a time
• Trade off analysis between capacity and costs
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Why process selection is critical
• Dell – from make/assemble to order in Texas to make/assemble to stock off shore
• Does this work?• Break even analysis may depend on process
costs• Which process gives the lowest costs –
assumption?
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Trade off analysis
• Customer demanded quantity drives the trade off analysis and decision process
• Example:→ retail stocks at Christmas 2008 and 2009 season - goal save money by stocking less→ At what point do you lose sales due to lower stockage levels?
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Process Design/Selection/Capacity
• Have to be simultaneous operations – some texts suggest sequential steps
• Decision process has to be customer based → what should it be? → how many should be produced/how many
are we capable of producing? → how should it be produced?
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Process Strategy - Defines
• Capital intensity• Process flexibility• Vertical integration• Customer involvement
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Goal of Process Design
• Reduce lead time for product to the customer• Is it best to be the first to market and establish
the market?• Or, be the follower and let someone else do
the R&D/design/risk?
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Process Planning
Make-or-buy decisions Process selection Specific equipment selection Process plans Process analysis
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Make-or-Buy Decisions
1. Cost2. Capacity3. Quality4. Speed5. Reliability6. Expertise
What about
Proprietary Information?
Barrier to Make-or-Buy?
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Process Plans Blueprints Bill of material Flat or multiple layers -
part or assembly Assembly chart /
product structure diagram Operations process chart - list of
operations involved in assembly Routing sheet - sequence of events
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Process Analysis
The systematic examination of all aspects The systematic examination of all aspects of a process to improve its operationof a process to improve its operation FasterFaster More efficientMore efficient Less costlyLess costly More responsiveMore responsive
Basic toolsBasic tools Process flowchartProcess flowchart Process diagramsProcess diagrams Process mapsProcess maps
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Operations Process Chart
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Process Analysis – What processes feed other processes?
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Process Flowchart
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Principles for Redesigning Processes
• Walk the Process!• Remove waste, simplify, consolidate• Link processes to create value• Let the swiftest and most capable
execute• Capture information digitally, data mine,
and use information to improve operations
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Principles for Redesigning Processes
• Provide visibility through information about process status
• Fit the process with sensors and feedback loops
• Add analytic capabilities• Connect, collect and create knowledge
around the process• Personalize the process
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Techniques for Generating Innovative Ideas
Vary entry point to a problem Draw analogies Change your perspective Use attribute brainstorming
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RFID
• Active Tags• Always on • Battery powered• Can be read from up to
300 ft• US Army • Savi Tags
• Passive Tags• Small• Must be activated• May be turned off• England• California• Rolex
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Robotics Programmable manipulators Follow specified path Better than humans with respect to
Hostile environments Long hoursConsistency
Adoption has been slowed by ineffective integration and adaptation of systems
Welding at Harley Davidson Plant
Questions?