Transcript PRODUCTIONS/OPERATIONS MANAGEMENT

COB 300C
Product and
Service Design
Reasons for Product or Service Design
• Be competitive
• Increase business growth & profits
• Avoid downsizing with development of
new products
• Improve product quality
• Achieve cost reductions in labor or
materials
Trends in Product & Service Design
• Increased emphasis on or attention to:
– Customer satisfaction
– Reducing time to introduce new product
or service
– Reducing time to produce product
Trends in Product & Service Design (Cont’d)
• Increased emphasis on or attention to:
– The organization’s capabilities to produce or
deliver the item
– Environmental concerns
– Designing products & services that are “user
friendly”
– Designing products that use less material
Objects of Product & Service Design
Beyond the overall objective to achieve customer
satisfaction while making a reasonable profit is:
Design for Manufacturing(DFM)
The designers’ consideration of the organization’s
manufacturing capabilities when designing a product.
The more general term design for operations
encompasses services as well as manufacturing
The Design Process
• Motivation
• Customer
• Marketing
• Competitors
• Forecasts
Reverse Engineering
Reverse engineering is the
dismantling and inspecting of a
competitor’s product to
discover product
improvements.
Manufacturability
• Manufacturability is the ease of
fabrication and/or assembly which is
important for:
– Cost
– Productivity
– Quality
Regulations & Legal Considerations
• Product Liability - A manufacturer is
liable for any injuries or damages caused
by a faulty product.
• Uniform Commercial Code - Products
carry an implication of merchantability
and fitness.
Research & Development (R&D)
• Organized efforts to increase scientific
knowledge or product innovation & may
involve:
– Basic Research advances knowledge about a
subject without near-term expectations of
commercial applications.
– Applied Research achieves commercial
applications.
– Development converts results of applied research
into commercial applications.
Product Design
• Product Life Cycles
• Robust Design
• Concurrent Engineering
• Computer-Aided Design
• Modular Design
Advantages of Standardization
• Fewer parts to deal with in inventory &
manufacturing
• Reduced training costs and time
• More routine purchasing, handling, and
inspection procedures
Advantages of Standardization (Cont’d)
• Orders fillable from inventory
• Opportunities for long production runs and
automation
• Need for fewer parts justifies increased
expenditures on perfecting designs and
improving quality control procedures.
Disadvantages of Standardization
• Designs may be frozen with too many
imperfections remaining.
• High cost of design changes increases
resistance to improvements.
• Decreased variety results in less consumer
appeal.
Figure 4-2
Life Cycles of Products or Services
Saturation
Maturity
Deman
d
Decline
Growth
Incubation
Time
Product design
•
•
•
•
•
•
Design for manufacturing (DFM)
Design for assembly (DFA)
Design for recycling (DFR)
Remanufacturing
Design for disassembly (DFD)
Robust design
Taguchi Approach Robust Design
• Design a robust product
– Insensitive to environmental factors either in
manufacturing or in use.
• Central feature is Parameter Design.
• Determines:
– factors that are controllable and those not
controllable
– their optimal levels relative to major product
advances
Concurrent Engineering
Concurrent engineering
is the bringing together
of engineering design and
manufacturing personnel
early in the design phase.
“Over the Wall” Approach
New
Product
Mfg
Design
Computer-Aided Design
• Computer-Aided Design (CAD) is product
design using computer graphics.
– increases productivity of designers, 3 to 10
times
– creates a database for manufacturing
information on product specifications
– provides possibility of engineering and cost
analysis on proposed designs
Modular Design
Modular design is a form of standardization
in which component parts are subdivided into
modules that are easily replaced or
interchanged. It allows:
– easier diagnosis and remedy of failures
– easier repair and replacement
– simplification of manufacturing and assembly
Figure 4-3
Goods-service spectrum
Steel production
Automobile fabrication
House building
Low service content Road construction
High goods content
Dressmaking
Farming
Auto Repair
Appliance repair
Increasing
goods content
Maid Service
Manual car wash
Increasing
service content
High service content
Low goods content
Teaching
Lawn mowing
Service Variability & Customer Influence Service Design
Figure 4-4
High
Customized
Clothing
Variability
Moderate
in Service
Requirements
Dept. Store
Purchase
Low
None
Telephone
Purchase
Internet
Purchase
None
Low
Moderate
Degree of Contact with Customer
High
Figure 4-7
The House of Quality
Correlation
matrix
Design
requirements
Customer
requirements
Relationship
matrix
Specifications
or
target values
Competitive
assessment
House of Quality Example
Correlation:
X
X
X
Water resistance
Check force
on level
ground
Energy needed
to open door
Door seal
resistance
Energy needed
to close door
Engineering
Characteristics
X
Accoust. Trans.
Window
X
X
*
Strong positive
Positive
Negative
Strong negative
Competitive evaluation
X = Us
A = Comp. A
B = Comp. B
(5 is best)
1 2 3 4
Customer
Requirements
Easy to close
7
X
Stays open on a hill
5
X AB
Easy to open
3
Doesn’t leak in rain
3
No road noise
Importance weighting
2
AB
XAB
A XB
X A
X
BA
X
B
X
A
BXA
3
Maintain
current level
B
A
X
2
Maintain
current level
9
Reduce energy
to 7.5 ft/lb.
B
A
6
Reduce force
to 9 lb.
5
4
3
2
1
6
Maintain
current level
Reduce energy
level to 7.5 ft/lb
10
Target values
Technical evaluation
(5 is best)
5
BA
X
Relationships:
Strong = 9
Medium = 3
Small = 1
B
Improving Reliability
• Component design
• Production/assembly techniques
• Testing
• Redundancy
• Preventive maintenance procedures
• User education
• System design