1. Chapter 6 Product Design and Process Selection--Manufacturing
The Product Design Process
Concurrent Engineering
Designing for the Customer
QFD
Process Selection
Process Flow Design
Process Analysis
Globalization of Product Design and Development 2 2

2. The Product Design Process
Concept Development
Product Planning
Detailed Engineering
Engineering Release (Sign-Off) 3 3

3. Concurrent Engineering
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. 4 4

4. Designing for the Customer
Industrial Design
Aesthetics
Ergonomics 5 5

5. Quality Function Deployment
Interfunctional teams from marketing, design engineering, and manufacturing
Voice of the customer
House of Quality 6 6

6. House of Quality Customer Requirements Importance to Cust.
Easy to close
Stays open on a hill
Easy to open
Doesn’t leak in rain
No road noise
Importance weighting
Engineering Characteristics
Energy needed
to close door
Check force on level ground
to open door
Water resistance 10 6 9 2 3 7 5 X
Correlation:
Strong positive
Positive
Negative
Strong negative *
Competitive evaluation
X = Us
A = Comp. A
B = Comp. B
(5 is best) AB
X AB
XAB
A X B
X A B
Relationships:
Strong = 9
Medium = 3
Small = 1
Target values
Reduce energy
level to 7.5 ft/lb
Reduce force
to 9 lb.
to 7.5 ft/lb.
current level
Maintain
Technical evaluation 4 1 A BA
BXA
Door seal
resistance
Accoust. Trans.
Window
House of Quality 7 7

7. Value Analysis/Value Engineering (VA/VE)
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 8

8. Types of Processes
Conversion
Fabrication
Assembly
Testing 11 11

9. Process Flow Structures
Job shop
Batch
Assembly Line
Continuous Flow 12 12

10. IV. Continuous Flow III. Assembly Line II. Batch I. Job Shop Low
Exhibit 4.9
IV.
Continuous
Flow
III.
Assembly
Line
II.
Batch I.
Job
Shop
Low
Volume
One of a
Kind
Multiple
Products,
Few
Major
Higher
High
Volume,
Standard-
ization
Commercial
Printer
French Restaurant
Heavy
Equipment
Coffee Shop
Automobile
Burger King
Sugar
Refinery
Flexibility (High)
Unit Cost (High)
Flexibility (Low)
Unit Cost (Low)
Source: Modified from Robert Hayes and Steven Wheelwright, Restoring Our Competitive Edge: Competing through Manufacturing (New York: John Wiley & Sons, 1984). p. 209. 13 13

11. Global Product Design and Manufacturing
Joint Ventures
Strategic Suppliers
Global Product Design Strategy 17 17