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Unit 9 Manufacturing SystemsCHAPTER 21- PRODUCT AND PROCESS DESIGN
Product Design
Design is motivated by several factors:
1. The need for a specific product
2. The level of available technology
3. Production capability and production cost
4. Safety and Reliability
5. Marketability
Product Design
1. The Need for a specific product:
• Needs are usually identified by market research and/or customer requests
• Needs sell better than wants!
Product Design
1. The Need for a specific product:
• Needs are often created through the advertising of features and options, inducing a customer to buy
• Designers are engaged in a constant process of design and redesign to fulfill continuing needs
Product Design
2. The Level of available technology
• The capabilities of existing technology is very important in product design and development.
• “State of the Art” and “Best Available Technology” (BET) are frequently used terms to describe available technology
Product Design
2. The Level of available technology
• The evolution of electronics are a good example of increasing levels of technology
• Design/implementation of a process or procedure is at times mandated by government regulations to include “BET”
Product Design
3. Production Capability and Costs
• Most products made for general consumer use are only successful if they can be produced and marketed at affordable prices.
• The best product design is only as good as its ability to be competitively produced.
Product Design
Designers must consider the following:
1. Is the production capability presently available?
2. If not, will sales of the product justify development of new production technology?
3. Can the product be manufactured and marketed at a cost that will return investment and profits?
Product Design
Often times, these issues are determined at levels within an organization that are above the designer’s level … but, the designer’s input into these questions is necessary and should be considered.
Product Design
4. Safety and Reliability • Critical to the design
process• Safety concerns should
be #1 for the designer• Reliability and safety are
closed tied.• Safety is often largely
determined by reliability.
Product Design
4. Marketability• Invention is one thing,
successful distribution is everything.
• If a product cannot be properly marketed and sold, it will not be successful.
• The “market” in free enterprise economies is ruthless!
Product Design
4. Marketability• Even if a product is well
designed, cost-effectively manufactured, and readily available they may not be profitable if a successful marketing effort is not in place.
• Marketing can make up more than 90% of the costs of a product!
The Product Design Sequence
Product design generally begins with an idea that develops from a need determined in many cases by market research.
Designers must work just as closely with the marketing and distribution departments as they do with the manufacturing group.
The Product Design Sequence
Product design and development must be a company wide, integrated and coordinated effort that crosses department boundaries.
Each departmental entity within a company must be represented and heard from during the design process.
The Product Design Team
Members from each “department” within the company are part of the product design team.
A project/product manager is selected.
Usually from engineering or marketing
Team members rotate on and off the team depending upon the phase of the product development process
The Product Design Team
MANAGEMENT
SALES/MARKETING
ACCOUNTING/FINANCE
RESEARCH
ENGINEERING
MANUFACTURING
SERVICE
The Product Design Sequence
1. Conception
2. Prototype and testing
3. Design evaluation and review
4. Manufacturing prototype
5. Manufacturing review
6. Beta testing – Initial release
7. Formal release
8. Service of the product
9. End of product life cycle
The Product Design Sequence
1. Conception
Market research / Market perspective
Preliminary product specifications
Brainstorming
Initial sketches / Designs
Tentative cost estimates / Target sales price
The Product Design Sequence
2. Prototype and Testing Initial prototypes usually
built by research or engineering and not manufacturing
Often not a full function unit
Used to “work out the kinks” and to refine the technologies/concepts
The Product Design Sequence
3. Design Evaluation and Review
The engineering prototype phase ends with a critical design review and evaluation.
Review session(s) attended by all members of product development team.
Critical review – no holds barred
The Product Design Sequence
3. Design Evaluation and Review The engineering prototype
can be redesigned, changed, modified, etc. and the Review process repeated until a formal approval is given by the Product Development team.
“Final” documents are handed over to manufacturing.
The Product Design Sequence
4. Manufacturing Prototype
The initial manufacturing “run”
Develop manufacturing documentation
Work out the manufacturing processes and procedures
Development cost estimates
The Product Design Sequence
5. Manufacturing Review Similar to Engineering
review – a critical, no holds barred review of the initial manufacturing run
Changes made to documents, processes, and procedures
“Production” documentation is released
The Product Design Sequence
6. Beta Testing – Initial Release
Cooperative customers receive the first production units to help the product developers to “wring out” the initial problems that occur with all products.
Favorable price concessions given to “beta” customers
The Product Design Sequence
7. Formal Release The formal product release
occurs after the beta testing and any changes in the engineering or manufacturing aspects of the product are made from the results from the beta sites.
Marketing efforts in full swing!
The Product Design Sequence
8. Service of the Product
Quality companies provide first class service of their products.
Service aspects of the product need to be built-in and/or considered during the product design and development process.
The Product Design Sequence
9. End of Product Life Cycle
What to do with the product after its useful life is over?
Safety/environmental concerns
Cost issues – regulations, disposal
Other Issues in Product Development
Manufacturing Production Drawings
Finished drawings
Detailed part drawings
Assembly drawings
Bills of Materials
Other Issues in Product Development
Estimating Costs: Employee wages, salaries,
benefits Interest on borrowed
money Material prices Tooling and production
machinery Packaging and shipping Quality control and
assurance
Other Issues in Product Development
Estimating Costs: Service/warranty costs Sales/marketing costs Plant/equipment
maintenance/utilities Product liability costs Design expenses Profits! And more …
