5

• Design Process


  • Effective design can provide a competitive edge
  • Matches product or service characteristics with customer requirements
  • Ensures that customer requirements are met in the simplest and least costly manner
  • Reduces time required to design a new product or service
  • Minimizes revisions necessary to make a design workable
• Product design


  • Defines appearance of product
  • Sets standards for performance
  • Specified which materials are to be used
  • Determines dimensions and tolerances
• Idea Generation


  • Company's own R&D department
  • Customer complaints or suggestions
  • Marketing research
  • Suppliers
  • Salespersons in the field
  • Factory workers
  • New technological developments
  • Competitors
• Idea Generation: Competitors


  • Perceptual maps
  • Visual comparisons of customer perceptions
  • Benchmarking
  • Comparing product/process against best-in-class
  • Reverse engineering
• Perceptual Map of Breakfast Cereals


  Visual comparison of customer perceptions
• Feasibility Study


  • Market analysis
  • Economic analysis
  • Technical/strategic analyses
  • Performance specifications
• Rapid Prototyping


  1. Build a prototype

  2. Test the prototype

  3. Revise the design

  4. Retest
• Rapid Prototyping


  • Creates preliminary design models that are quickly tested and either discarded (as fast failures) or further refined
  • Models can be physical or electronic, rough facsimiles or full-scale working models
  • Involves form, functional and production designs
  • Involves concurrent design
• Concurrent Design


  • Process of jointly and iteratively developing designs
  • Breaks down walls between functional areas and involves people from different backgrounds and areas of expertise
• Concurrent Design


  • Improves quality of early design decisions
  • Involves suppliers
  • Incorporates production process
• Types of Concurrent Design


  • Form design
  • Functional design
  • Production design
• Form Design


  How product will look
• Functional Design


  • How product will perform
  • Reliability
  • Maintainability
  • Usability
• Reliability


  Probability that a given part or product will perform its intended function for a specified length of time under normal conditions
• Mean Time Between Failures (MTBF)


  Reciprocal of the failure rate (MTBF= 1/failure rate)
• Maintainability


  • Refers to the ease and/or cost with which a product or service is maintained or repaired
  • The location of critical parts or parts subject to failure affects the ease of disassembly and, thus, repair
  • One quantitative measure of maintainability is mean time to repair (MTTR)
• Usability


  • Ease of use of a product or service
  • Ease of learning
  • Ease of use
  • Ease of remembering how to use
  • Frequency and severity of errors
  • User satisfaction with experience
• Production Design


  • Is concerned with how the product will be made
  • Is considered in the preliminary design phase
  • Includes simplification, standardization, modularity, design for manufacture, and design for supply chain
• Design Simplification


  • Attempts to reduce the number of parts, subassemblies, and options in a product
  • Avoids tools, separate fasteners, and adjustments
• Standardization


  • Makes possible the interchangeability of parts among products
  • Results in higher-production and purchasing, lower investment in inventory, easier purchasing and material handling, fewer quality inspections, and fewer difficulties in production
• Modular Design


  • Combines standardized building blocks, or modules, in a variety of ways to create unique finished products
  • Is common in the electronics and automobile industry
• Design for Manufacture (DFM)


  • Process of designing a product so that it can be produced easily and economically
  • Emphasizes the importance of incorporating production design early in the design process
  • When successful, it improves the quality of product design and reduces both the time and cost of product design and manufacture
• DFM Practices


  • Minimize the number of parts and subassemblies
  • Avoid tools, separate fasteners, and adjustments
  • Use standard parts when possible and repeatable, well-understood processes
  • Design parts for many uses, and modules that can be combined in different ways
  • Design for ease of assembly, minimal handling, and proper presentation
  • Allow for efficient and adequate testing and replacement of parts
• Design for the Supply Chain (DFSC)


  • Means considering the capabilities of suppliers at each level of the supply chain when designing the product
  • Involves controlling product variation, designing components that can be used in multiple products, and building universal designs
• Final Design


  Detailed drawings and specifications for new product or service
• Process Plans


  • Workable instructions for manufacture
  • Necessary equipment and tooling
  • Component sourcing recommendations
  • Job descriptions and procedures
  • Computer programs for automated machines
• Technologies in Design


  • Computer Aided Design (CAD)
  • Computer Aided Engineering (CAE)
  • Computer Aided Manufacturing (CAD/CAM)
  • Product Life Cycle Management (PLM)
  • Collaborative Product Design (CPD)
• Collaborative Product Design (CPD)


  • A software system for collaborative design and development among trading partners
  • With product lifecycle management (PLM), manages product data, sets up project workspaces, and follows lifecycle of the product
  • Accelerates product development, helps to resolve product launch issues, and improves quality of design
• Design Review Techniques


  • Failure Mode and Effects Analysis (FMEA)
  • Fault Tree Analysis (FTA)
  • Value Analysis (VA)
• Failure Mode and Effects Analysis (FMEA)


  A systematic method of analyzing product failures
• Fault Tree Analysis (FTA)


  A visual method for analyzing interrelationships among failures
• Value Analysis (VA)


  Helps eliminate unnecessary features and functions
• Value Analysis (VA) Questions


  • Can we do without it?
  • Does it do more than is required?
  • Does it cost more than it is worth?
  • Can something else do a better job?
  • Can it be made by a less costly method?
  • With less costly tooling?
  • With less costly material?
  • Can it be made cheaper, better, or faster by someone else?
• Updated Value Analysis (VA) Questions


  • Is it recyclable or biodegradable?
  • Is the process sustainable?
  • Will it use more energy than it is worth?
  • Does the item or its by-product harm the environment?
• Design for Environment


  • Designing a product from material that can be recycled
  • Design from recycled material
  • Design for ease of repair
  • Minimize packaging
  • Minimize material and energy used during manufacture, consumption and disposal
• Extended Producer Responsibility


  Holds companies responsible for their product even after their useful life
• Sustainability


  Ability to meet present needs without compromising those of future generations
• Green Areas


  • Green Sourcing
  • Green Manufacture
  • Green Consumption
  • Recycling and Re-Use
• Quality Function Deployment (QFD)


  • A formal method for making sure that everyone working on a design project knows the design objectives and is aware of the interrelationships of the various parts of the design
  • Translates voice of customer into technical design requirements
  • Uses a series of matrix diagrams that resemble connected houses
• House of Quality


  First matrix in QFD that connects customer requirements to design characteristics