Professional Documents
Culture Documents
Product Design
Lecture Outline
4-2
Learning Objectives
Explain the importance of the product design process and
provide an overview of each step of the process
Calculate the reliability and availability of a product or service
Understand the technologies involved in designing new
products and their related production processes
Utilize techniques for analyzing design failures and
eliminating unnecessary design features
Explain why and how each step of the product lifecycle can
be changed for improved environmental stewardship, and
provide examples of programs that support green efforts
Use quality function deployment as a design tool
4-3
Design Process
Effective design can provide a competitive edge
matches product or service characteristics with
customer requirements
ensures that customer requirements are met in the
simplest and least costly manner
reduces time required to design a new product or
service
minimizes revisions necessary to make a design
workable
4-4
Design Process
Product design
defines appearance of product
sets standards for performance
specifies which materials are to be used
determines dimensions and tolerances
4-5
4-6
Design Process
4-7
Idea Generation
Companys own R&D
department
Customer complaints
or suggestions
Marketing research
Suppliers
Salespersons in the
field
Factory workers
New technological
developments
Competitors
4-8
Idea Generation
Perceptual Maps
visual comparison of customer perceptions
Benchmarking
comparing product/process against best-in-class
Reverse engineering
dismantling competitors product to improve your
own product
4-9
4-10
Feasibility Study
Market analysis
Economic analysis
Technical/strategic analyses
Performance specifications
4-11
Test prototype
Revise design
Retest
4-12
Concurrent Design
4-13
Functional Design
how product will perform?
reliability
maintainability
usability
4-14
Computing Reliability
Components in series
0.90
0.90
4-15
Computing Reliability
Components in series
0.90
0.90
4-16
Computing Reliability
Components in parallel
0.90
R2
0.95
R1
4-17
Computing Reliability
Components in parallel
0.90
R2
0.95 + 0.90(1-0.95) = 0.995
0.95
R1
4-18
System Reliability
0.90
0.98
0.92
0.98
4-19
System Reliability
0.90
0.98
0.98
0.92
0.98
0.92+(1-0.92)(0.90)=0.99
0.98
4-20
SA =
MTBF
MTBF + MTTR
where:
MTBF = mean time between failures
MTTR = mean time to repair
4-21
System Availability
PROVIDER
MTBF (HR)
MTTR (HR)
A
B
C
60
36
24
4.0
2.0
1.0
SAA =
SAB =
SAC =
4-22
System Availability
PROVIDER
MTBF (HR)
MTTR (HR)
A
B
C
60
36
24
4.0
2.0
1.0
4-23
Usability
Ease of use of a product or service
ease of learning
ease of use
ease of remembering how to use
frequency and severity of errors
user satisfaction with experience
4-24
Production Design
How the product will be made
Simplification
reducing number of parts, assemblies, or options in a
product
Standardization
using commonly available and interchangeable parts
Modular Design
combining standardized building blocks, or modules,
to create unique finished products
Design for Manufacture (DFM)
Designing a product so that it can be produced easily
and economically
4-25
Design Simplification
4-26
4-27
Technology in Design
Computer Aided Design (CAD)
assists in creation, modification, and analysis of a
design
computer-aided engineering (CAE)
tests and analyzes designs on computer screen
4-28
4-29
4-30
Cause of
Effect of
Corrective
Mode
Failure
Failure
Action
Stale
Broken
Too Salty
tastes bad
wont crunch
add moisture
cure longer
poor packaging
thrown out
lost sales
too thin
too brittle
cant dip
poor display
change recipe
change process
rough handling
rough use
injures mouth
chocking
change packaging
poor packaging
perceived as old
lost sales
outdated receipt
process not in control
eat less
drink more
health hazard
introduce
low salt version
4-31
4-32
4-33
4-34
4-35
Green Areas
Green Sourcing
use less material
use recycled if possible
Green Manufacture
is energy from renewable sources
amount of waste produced
Green Consumption
products use of energy
is product recyclable and maintainable
Recycling and Re-Use
design products to be recycled or re-used
save energy and money
2014 John Wiley & Sons, Inc. - Russell and Taylor 8e
4-36
4-37
House of Quality
Importance
5
Trade-off matrix
3
Design
characteristics
4
1
Customer
requirements
Relationship
matrix
2
Competitive
assessment
Target values
4-38
Competitive Assessment of
Customer Requirements
Easy and
safe to use
Irons
well
Competitive Assessment
Customer Requirements
Presses quickly
Removes wrinkles
Doesnt stick to fabric
Provides enough steam
Doesnt spot fabric
Doesnt scorch fabric
Heats quickly
Automatic shut-off
Quick cool-down
Doesnt break when dropped
Doesnt burn when touched
Not too heavy
1
9
8
6
8
6
9
6
3
3
5
5
8
2
B A
AB
X
X
X
BA
AB
X AB
A XB
X
B
A
ABX
X
AB
AB X
X
A B
X
A
4-39
Easy and
safe to use
Irons
well
Automatic shutoff
Size of holes
Number of holes
Thickness of soleplate
Size of soleplate
Weight of iron
Customer Requirements
Presses quickly
Removes wrinkles
Doesnt stick to fabric
Provides enough steam
Doesnt spot fabric
Doesnt scorch fabric
Heats quickly
Automatic shut-off
Quick cool-down
Doesnt break when dropped
Doesnt burn when touched
Not too heavy
From Customer
Requirements
to Design
Characteristics
- + + +
+
+
+ + +
+
+
+ +
+
+ + +
+ - - + +
+ - +
- +
+
- - +
+ + +
+
+ - - - +
+
+
+ + +
4-40
4-41
Automatic shutoff
Size of holes
Number of holes
Thickness of soleplate
Size of soleplate
Weight of iron
Tradeoff Matrix
+
Objective
measures
Units of measure
Iron A
Iron B
Our Iron (X)
Estimated impact
Estimated cost
Target values
Design changes
2014 John Wiley & Sons, Inc. - Russell and Taylor 8e
Automatic shutoff
Size of holes
Number of holes
Thickness of soleplate
Size of soleplate
Weight of iron
ft-lb
lb
in.
cm
ty
ea
1.4
8x4
SS
27
15
0.5
45
500
1.2
8x4
MG
27
15
0.3
35
350
1.7
9x5
35
15
0.7
50
600
SS
30
30
500
1.2 8x5
*
*
4-42
Completed House
of Quality
SS = Silverstone
MG = Mirorrglide
T = Titanium
4-43
Part
characteristics
Process
characteristics
A-2
Parts
deployment
A-3
Operations
Process
characteristics
House
of
quality
Part
characteristics
A-1
Product
characteristics
Customer
requirements
Product
characteristics
Process
planning
A-4
Operating
requirements
4-44
Benefits of QFD
Promotes better understanding of customer
demands
Promotes better understanding of design
interactions
Involves manufacturing in design process
Provides documentation of design process
4-45
Robust design
Controllable factors
Uncontrollable factors
4-46
Consistency
consistent errors are easier to correct than random
errors
parts within tolerances may yield assemblies that are
not within limits
consumers prefer product characteristics near their
ideal values
4-47
4-48
4-49