1. Product Design and Process Selection
Manufacturing Operations

2. Product Design and Development
Sources
Developing New Products
Getting Them to Market
Improving Current Products
Design Considerations
MTSU

3. Possible Sources of Product Innovation
Customers
Managers
Marketing
Operations
Engineering
Research and Development (R&D)
Basic research
Applied research
MTSU

4. A Model for Developing New Products
Technical and Economic Feasibility Studies
Prototype Design
Market Sensing and Evaluation
Economic Evaluation of the Product Design
Production Design
MTSU

5. A Model for Developing New Products
Ideas
Market requirements
Functional specifications
Product specifications
Design review
Test market
Introduction
MTSU
Success? 8 8 8 8

6. A Model for Developing New Products
Ideas
 0: Understand / Observe
 1: Visualize / Realize
 2: Evaluate / Refine
Market requirements
Functional specifications
Product specifications
Design review
 3: Implement / Detailed Engrg
 4: Implement / Mfg. Liaison
Test market
Introduction
MTSU
Success? 8 8 8 8

7. Getting Them to Market Quickly
Speed Creates Competitive Advantages
Speed Saves Money
Tools To Improve Speed
Autonomous design and development teams
Computer-aided design/computer-aided manufacturing (CAD/CAM)
Design Procedures To Improve Speed
Simultaneous (Concurrent) Engineering
MTSU

8. Product Design: American and Japanese Philosophies Compared
Research
Product
Manufacturing
Process
Design
Development
Japanese
Research, Development, and Manufacturing Process Design
Manufacturing
Product
MTSU 10 10 10 10

9. MTSU

10. Air Bags
MTSU

11. Passenger-Side
Air Bags
Air Bags
MTSU

12. Side Impact Air Bags
Passenger-Side
Air Bags
Air
Bags
MTSU

13. MTSU

14. Building the House of Quality (1 of 2)
1. Identify customer requirements
2. Identify technical requirements
3. Relate the customer requirements to the technical requirements
4. Conduct an evaluation of competing products
MTSU

15. Building the House of Quality (2 of 2)
5. Evaluate technical requirements and develop targets
6 Determine which technical requirements to deploy to the remainder of the production process
MTSU

16. House of Quality Interrelationships Customer requirement
Technical requirements
Voice of
the
customer
Relationship
matrix
Technical requirement
priorities
Customer
requirement
Competitive
evaluation
Interrelationships

17. Some Methods of Improving the Design of Existing Products
Value Analysis/Value Engineering
Continuous Improvement
Failure Analysis
MTSU

18. Considerations During the Product Design Phase
Ease of Production (Manufacturability)
Specifications - A communication link between the designer and the operations personnel
Tolerances - Minimum and maximum limits on a dimension that allows the item to function as designed
Standardization - Reduce variety among a group of products or parts
Simplification - Reduce or eliminate the complexity of a part or product
Quality
MTSU

19. Process Planning and Design
What Process Technology Is the Correct Technology?

20. Major Factors to be Considered
Nature of demand
volume
variability
Type and degree of flexibility required by the market
Degree of vertical integration
Degree of automation
Quality
MTSU

21. Some Basic Types of Process Technology Alternatives
Product-Focused
Process-Focused
Group Technology/Cellular Manufacturing
MTSU

22. Product-Focused Process Technology (Production Line)
Processes (Transformations) are arranged based on the sequence of operations required to produce a product
Two general forms
Discrete unit
Process (Continuous)
Examples
MTSU

23. Process-Focused Process Technology (Job Shop)
Processes (Transformations) are arranged based on the type of process, i.e., like processes are grouped together
Products (Jobs) move from department (process group) to department based on that particular job’s processing requirements
Examples
MTSU

24. Group Technology/Cells Process Technology
Group technology forms parts with similar processing requirements into families or groups
A cell is an arrangement of the processes required to make the parts that make up the group
MTSU

25. Group Technology/Cells (continued)
Advantages (relative to a job shop)
Process changeovers simplified
Variability of tasks reduced
More direct routes through the system
Quality control is improved
Production planning and control simpler
Automation simpler
MTSU

26. Group Technology/Cells (continued)
Disadvantages
Duplication of equipment
Under-utilization of facilities
Processing of items that do not fit into a family may be inefficient
MTSU

27. Product-Process Matrix
Poor Strategy
(High variable costs)
Good Match
Poor Strategy
(Fixed costs and cost changing to other products are high)
MTSU 3 3 3 3 3 3

28. Factors to Consider When Selecting Among Processing Alternatives
Batch Size and Product Variety
Capital Requirements
Economic Analysis
Cost functions of alternatives
Operating leverage - relationship between a firm’s annual costs and its annual sales
Break-even analysis
Financial analysis
MTSU

29. Defining and Documenting the Product
Engineering drawings
Bills of material (BOM)
Computer-aided design (CAD)
Product quality
Shorter design time
Production cost reductions
Database availability
New range of capabilities
MTSU 13 13 13

30. Preparing for Production
Assembly drawing
Assembly (Gozinto) chart
Route/Process sheet
Process flow charts
Job instructions
Standards manuals
Engineering change notice
MTSU
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31. MTSU