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
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The Product Design Process
 Concept
Development
 Product
Planning
 Detailed
Engineering
 Engineering
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Release (Sign-Off)
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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.
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Designing for the Customer
 Industrial
Design
» Aesthetics
» Ergonomics
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Quality Function Deployment
 Interfunctional
teams from marketing, design
engineering, and manufacturing
 Voice
of the customer
 House
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of Quality
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Correlation:
Strong positive
X
House of Quality
Positive
X
X
Water resistance
*
Accoust. Trans.
Window
Energy needed
to open door
Check force on
level ground
Door seal
resistance
Customer
Requirements
Energy needed
to close door
Engineering
Characteristics
Negative
Strong negative
X
X
X
Competitive evaluation
X = Us
A = Comp. A
B = Comp. B
(5 is best)
1
2
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
2
3
4
5
AB
XAB
A XB
X A
Importance weighting
10
6
6
9
2
3
B
Relationships:
Technical evaluation
(5 is best)
5
4
3
2
1
B
A
X
BA
X
B
B
A
X
X
A
BXA
Maintain
current level
Maintain
current level
Reduce energy
to 7.5 ft/lb.
Reduce force
to 9 lb.
Target values
Maintain
current level
Reduce energy
level to 7.5 ft/lb
Strong = 9
Medium = 3
Small = 1
BA
X
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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?
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Types of Processes
 Conversion
 Fabrication
 Assembly
 Testing
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Process Flow Structures
 Job
shop
 Batch
 Assembly
Line
 Continuous
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Flow
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Exhibit 4.9
Low
Volume
One of a
Kind
I.
Job
Shop
II.
Batch
III.
Assembly
Line
IV.
Continuous
Flow
Multiple
Products,
Low
Volume
Few
Major
Products,
Higher
Volume
High
Volume,
High
Standardization
Flexibility (High)
Unit Cost (High)
Commercial
Printer
French Restaurant
Heavy
Equipment
Coffee Shop
Automobile
Assembly
Burger King
Sugar
Refinery
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.
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Global Product Design and Manufacturing
 Joint
Ventures
 Strategic
 Global
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Suppliers
Product Design Strategy
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