Transcript
OM 2
Product Design
Copyright 2009 John Wiley & Sons, Inc.
Dr. Bonivasius Prasetya,S.Si, M.Eng
Magister Teknik Industri Universitas Mercu Buana
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
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Design Process (cont.)
Product design
defines appearance of product
sets standards for performance
specifies which materials are to be used
determines dimensions and tolerances
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Design Process (cont.)
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Idea Generation
Company’s own R&D
department
Customer complaints or
suggestions
Marketing research
Suppliers
Salespersons in the field
Factory workers
New tech. developments
Competitors
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Perceptual Maps
Visual comparison of
customer perceptions
Benchmarking
Comparing
product/process
against best-in-class
Reverse engineering
Dismantling competitor’s
product to improve your
own product
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Perceptual Map of
Breakfast Cereals
GOOD
TASTE
Cocoa Puffs
LOW
NUTRITION
HIGH
NUTRITION
Rice
Rice
Krispies
Krispies
Cheerios
Cheerios
Wheaties
Wheaties
Shredded
Shredded
Wheat
Wheat
BAD
TASTE
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Feasibility Study
Market analysis
Economic analysis
Technical/strategic analyses
Performance specifications
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Rapid Prototyping
testing and revising a
preliminary design model
Build a prototype
form design
functional design
production design
Test prototype
Revise design
Retest
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Form and Functional Design
Form Design
how product will
look?
Functional Design
how product will
perform?
reliability
maintainability
usability
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Production Design
How the product will be made
Simplification
Standardization
using commonly available and interchangeable parts
Modular Design
reducing number of parts, assemblies, or options in a
product
combining standardized building blocks, or modules, to
create unique finished products
Design for Manufacture (DFM)
• Designing a product so that it can be produced easily and
economically
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Design
Simplification
(a) Original design
Assembly using
common fasteners
Source: Adapted from G. Boothroyd and
P. Dewhurst, “Product Design…. Key to
Successful Robotic Assembly.” Assembly
Engineering (September 1986), pp. 90-93.
(b) Revised design
(c) Final design
One-piece base &
elimination of
fasteners
Design for
push-and-snap
assembly
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Final Design and Process Plans
Final design
detailed drawings
and specifications
for new product or
service
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Process plans
workable instructions
necessary equipment
and tooling
component sourcing
recommendations
job descriptions and
procedures
computer programs for
automated machines
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Design Team
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Concurrent Design
A new approach to
design that involves
simultaneous design of
products and processes
by design teams
Improves quality of early
design decisions
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Involves suppliers
Incorporates production
process
Uses a price-minus
system
Scheduling and
management can be
complex as tasks are
done in parallel
Uses technology to aid
design
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Technology in Design
Computer Aided Design (CAD)
assists in creation, modification, and analysis of
a design
computer-aided engineering (CAE)
computer-aided manufacturing (CAD/CAM)
ultimate design-to-manufacture connection
product life cycle management (PLM)
tests and analyzes designs on computer screen
managing entire lifecycle of a product
collaborative product design (CPD)
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Collaborative Product Design
(CPD)
A software system for collaborative design and
development among trading partners
With PML, manages product data, sets up project
workspaces, and follows life cycle of the product
Accelerates product development, helps to resolve
product launch issues, and improves quality of design
Designers can
conduct virtual review sessions
test “what if” scenarios
assign and track design issues
communicate with multiple tiers of suppliers
create, store, and manage project documents
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Design Review
Review designs to prevent failures and
ensure value
Failure mode and effects analysis (FMEA)
Fault tree analysis (FTA)
a systematic method of analyzing product
failures
a visual method for analyzing interrelationships
among failures
Value analysis (VA)
helps eliminate unnecessary features and
functions
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FMEA for Potato Chips
Failure
Cause of
Effect of
Corrective
Mode
Failure
Failure
Action
Stale
Broken
Too Salty
low moisture content
tastes bad
add moisture
expired shelf life
won’t crunch
cure longer
poor packaging
thrown out
better package seal
too thin
lost sales
can’t dip
shorter shelf life
change recipe
too brittle
poor display
change process
rough handling
injures mouth
change packaging
rough use
chocking
poor packaging
perceived as old
outdated receipt
sales
lost
eat less
experiment with recipe
process not in control
drink more
experiment with process
uneven distribution of salt
health hazard
introduce low salt version
lost sales
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Fault tree analysis (FTA)
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Value analysis (VA)
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?
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Value analysis (VA) (cont.)
Updated versions also include:
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?
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Design for Environment
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Sustainability
Ability to meet present needs without compromising
those of future generations
Green product design
Use fewer materials
Use recycled materials or recovered components
Don’t assume natural materials are always better
Don’t forget energy consumption
Extend useful life of product
Involve entire supply chain
Change paradigm of design
Copyright 2009 John Wiley & Sons, Inc.
Source: Adapted from the Business
Social Responsibility Web site,
www.bsr.org, accessed April 1, 2007.
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Quality Function
Deployment (QFD)
Translates voice of customer into technical
design requirements
Displays requirements in matrix diagrams
first matrix called “house of quality”
series of connected houses
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Benefits of QFD
Promotes better understanding of
customer demands
Promotes better understanding of
design interactions
Involves manufacturing in design
process
Provides documentation of design
process
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Importance
House of Quality
5
Trade-off matrix
3
Design
characteristics
1
4
2
Customer
requirements
Relationship
matrix
Competitive
assessment
6
Target values
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A Series of Connected
QFD Houses
Part
characteristics
Process
characteristics
A-2
Parts
deployment
A-3
Process
planning
Operations
Process
characteristics
House
of
quality
Part
characteristics
A-1
Product
characteristics
Customer
requirements
Product
characteristics
A-4
Operating
requirements
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