1. Product Design & Process Selection-Manufacturing

2. Typical Phases of Product Development3

3. Design for Manufacturability
Traditional Approach-“We design it, you build it” or “Over the wall”
Design
Mfg
New
Product
Concurrent Engineering-“Let’s work together simultaneously” 9

4. 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
There are three types of teams
Program Management Team
Technical Team
Design-Build Teams
Time savings of CE programs are created by performing activities in parallel 4

5. Designing for the Customer
House of Quality
Ideal Customer Product
Value Analysis/
Value Engineering
QFD: An approach that integrates the “voice of the customer” into the product and service development process.

6. House of Quality
Customer requirements information forms the basis for this matrix, used to translate them into operating or engineering goals. 6 7

7. 7 7

8. House of Quality 8 7

9. 9
House of Quality 7

10. Designing for the Customer Value Analysis/Value Engineering (VA/VE)
Main aim is to eliminate unnecessary features and functions in product design.
To 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? 8

11. Design for Manufacturing and Assembly10

12. Design for Manufacturing and Assembly10

13. Process Flow Design
A process flow design can be defined as a mapping of the specific processes that raw materials, parts, and subassemblies follow as they move through a plant
Most common tools : assembly drawings, assembly charts
Example: Plug Assembly Drawing 14

14. Process Selection
refers to the strategic decision of selecting what kind of
production process to have in the plant.
Types of Process Basing on What they do :
Conversion Process
Fabrication Process
Assembly Process
Testing Process
Just to refresh:
Single, Multi stage, makes to order, …..are they types of
Process? If so what’s the base for consideration? 10

15. Process Flow Structures
It refers how a factory organizes materials flow using one or more of the process technologies listed below:
Job shop – A process structure suited for low volume production of a greatly variety of non-standard products.
Batch shop – A process structure that produces a variety of standard products relatively at low volume.
Assembly Line –A process structure designed to make discrete parts.
Continuous Flow – An often automated process that convert raw materials into finished products in one continuous process. 10

16. Product Process Matrix
IV.
Continuous
Flow
III.
Assembly
Line
II.
Batch I.
Job
Shop
Low
Volume,
One of a
Kind
Multiple
Products,
Volume
Few
Major
Higher
High
Standard-
ization
Machine
shop
Chemical,
Electronics
Automobile
Sugar
Refinery
Flexibility (High)
Unit Cost (High)
Flexibility (Low)
Unit Cost (Low)
These are the major stages of product and process life cycles
Process Structure
Process Life Cycle Stage
Effectiveness Measures 13

17. Virtual Factory
A virtual factory can be defined as a manufacturing operation where activities are carried out not in one central plant, but in multiple locations by suppliers and partner firms as part of a strategic alliance 14