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PERANCANGAN PRODUK Chapter 5 Gasal 2015/2016
Debrina Puspita AndrianiTeknik Industri Universitas Brawijaya
e-Mail : debrina@ub.ac.id Blog : http://debrina.lecture.ub.ac.id/
PRODUCT SPECIFICATIONS
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Needs and Specifications • Customer Needs describe What the end product or service
does for the user. • They are expressed in the “language of the customer”. • The “product__________”
• Product Specifications allow quantification of the customer needs. • A spec consists of a metric, a unit, and a value • Specs has a set of specs.
• The Product Metrics describe the measures used to determine IF the product meets the customer requirements.
• The Value is the actual numeric specification that the designers use to determine when the product meets the customer requirements.
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Needs and Specifications
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Tools for transforming Needs into Specifications
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A Product Spec for each Need
• It is important to identify the critical factors for success and make sure you have a way of quantifying these factors.
Prioritize the Needs.
Develop a measure and value for each need.
Some needs may have more than one specification.
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• Basic control and reference document for the design and manufacture
• Specific, measurable, testable criteria • “Unambiguous, Understandable, Correct, Concise,
Traceable, Traced, Design Independent, Verifiable, Unique, Complete, Consistent, Comparable, Modifiable, Attainable”
• Functional decomposition • Performance targets • Constraints (Demands, Musts) • Goals (Wishes, Wants) • Features
Product Design Specifications (PDS)
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Our Approach to PDS • Process recommended for high-risk new product design. • PDS development will be modified based on your product
or process.
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Importance of Clear Specifications • Product Specifications are the “blue prints” of a project.
• They will guide the project throughout the development.
• Developing product specifications is a two step process.
• Step 1 establish target specs to help channel the thinking during the product concept generation process.
• Target specs: the hope and aspiration of the design (ideal and marginal (Usually requires making assumptions as to what the final product configuration will be.)
• Step 2 is the refinement of the specifications once the team has picked a product concept and is ready to go into system level design. Refined specs: trade-offs among different desired characteristics.
• Completed after concept selection.
• Step 3 is determine Final Specs. It is in the project’s contract book.
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The Product Specs Process
• Based on customer needs and benchmarks
• Develop metrics for each need
• Set ideal and acceptable values
Set Target Specifications
• Based on selected concept and feasibility testing
• Technical and economic modeling
• Trade-offs are critical
Refine Specifications • Critical for ongoing
improvement
Reflect on the Results and the
Process
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What department in most companies is most concerned with Product Specifications?
• The QA department.
• What does a QA department do? • Works with design engineers to develop comprehensive
specifications for all critical customer requirements. • Develops test procedures to allow designers to test their designs
against the specifications. • Test products and processes to ensure the end product complies
with those design specifications.
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Example: Specialized mountain bike design • Customer need: The Customer expresses the need in
terms of What the product must do. • The Suspension enables high-speed descents on bumpy roads.
• The Product Specification sets metrics and values that allow quantification of the user need. • Attenuation from dropout to handlebar at 10 Hz. • Maximum value from the Monster (suspension test by Mountain Bike
Magazine.) • Minimum descent time on test track.
• Note: the metric does not yet have an actual value assigned at this point. • Why not? Product Specifications usually require a preliminary product definition.
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Product Specifications Example: Mountain Bike Suspension Fork
Start with the Customer Needs: Kebutuhan pelanggan untuk tiang suspensi dan derajat kepentingan The process of developing product specifications begins with your completed matrix of interpreted customer needs. *Again note that there are no values.
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# NEED Imp ST
Tritr
ack
Maniray 2
Rox T
ahx Q
uadra
Rox T
ahx T
i 21
Tonka P
ro
Gunhill H
ead S
hox
1 The suspension reduces vibration to the hands. 3 • •••• •• ••••• •• •••2 The suspension allows easy traversal of slow, difficult terrain. 2 •• •••• ••• ••••• ••• •••••
3 The suspension enables high speed descents on bumpy trails. 5 • ••••• •• ••••• •• •••4 The suspension allows sensitivity adjustment. 3 • •••• •• ••••• •• •••5 The suspension preserves the steering characteristics of the bike. 4 •••• •• • •• ••• •••••
6 The suspension remains rigid during hard cornering. 4 • ••• • ••••• • •••••7 The suspension is lightweight. 4 • ••• • ••• •••• •••••
8 The suspension provides stiff mounting points for the brakes. 2 • •••• ••• ••• •• •••••9 The suspension fits a wide variety of bikes, wheels, and tires. 5 •••• ••••• ••• ••••• ••• •
10 The suspension is easy to install. 1 •••• ••••• •••• •••• ••••• •11 The suspension works with fenders. 1 ••• • • • • •••••12 The suspension instills pride. 5 • •••• ••• ••••• ••• •••••
13 The suspension is affordable for an amateur enthusiast. 5 ••••• • ••• • ••• ••14 The suspension is not contaminated by water. 5 • ••• •••• •••• •• •••••
15 The suspension is not contaminated by grunge. 5 • ••• • •••• •• •••••16 The suspension can be easily accessed for maintenance. 3 •••• ••••• •••• •••• ••••• •
17 The suspension allows easy replacement of worn parts. 1 •••• ••••• •••• •••• ••••• •18 The suspension can be maintained with readily available tools. 3 ••••• ••••• ••••• ••••• •• •19 The suspension lasts a long time. 5 ••••• ••••• ••••• ••• ••••• •
20 The suspension is safe in a crash. 5 ••••• ••••• ••••• ••••• ••••• •••••
Interpretaion of Needs
Concept Development Process
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Perform Economic Analysis
Benchmark Competitive Products
Build and Test Models and Prototypes
Identify Customer
Needs
Establish Target
Specifications
Generate Product
Concepts
Select Product
Concept(s)
Set Final
Specifications
Plan Downstream Development
Mission Statement Test
Product Concept(s)
Development Plan
Target Specs
Based on customer needs and benchmarking
Final Specs
Based on selected concept, feasibility, models, testing, and trade-offs
TARGET SPECIFICATIONS
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Process for Establishing Target Specifications
1 Prepare the list of Metrics and measurement units based on your customer needs. 2 Collect the competitive benchmarking information. Establish what “best in class” products would require. 3 Set ideal and marginally acceptable target values for each metric (using at least, at most, between, exactly, etc.) 4 Reflect on the results.
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Membuat Daftar Metrik
Metrik harus komplit Beberapa metrik
merupakan variabel dependen, beberapa variabel independen
Metrik harus praktis
Beberapa kebutuhan tidak dapat dengan
mudah diterjemahkan menjadi metrik yang
terukur
Metrik harus merupakan kriteria yang populer untuk
perbandingan di pasar
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! Perhatikan:
Metrik harus komplit • Setiap kebutuhan harus berhubungan dengan sebuah/
beberapa metrik yang merefleksikan secara lengkap 1 kebutuhan pelanggan
• Nilai dari metrik harus dapat memuaskan kebutuhan terkait
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Metrik harus praktis • Metrik dapat langsung diteliti dan dianalisis dengan
mudah oleh tim.
Beberapa metrik merupakan variabel dependen, beberapa variabel independen
• Metrik independen dapat di-set oleh desainer. • misal “panjang pipa kemudi”, “ukuran roda”
• Metrik dependen adalah hasil dari keputusan desain. • misal “massa total sepeda”
• Sangat penting untuk mengidentifikasi variabel dependen untuk memastikan bahwa desain yang dipilih tidak mengecewakan pelanggan.
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Beberapa kebutuhan tidak dengan mudah diterjemahkan menjadi metrik yang terukur
• Misal Kebutuhan “menanamkan kebanggaan” • à hal yang penting dalam menentukan keberhasilan segmen
pasar akan pentingnya gaya dan penampilan.
• Bagaimana kebanggaan diukur? • à Pada kolom unit ditulis “subyektif” dan metrik ini akan dievaluasi
oleh sekumpulan pelanggan.
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Metrik harus merupakan kriteria yang populer untuk perbandingan di pasar
• Kebanyakan pelanggan di pasar membeli produk berdasarkan evaluasi publikasi yang diterbitkan secara bebas.
• Kinerja tinggi yang diinginkan (yang tercantum dalam media) à cerminan keinginan pelanggan à tim pengembang menggunakan metrik yang digunakan media.
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Establish Metrics and Units STEP 1 ESTABLISHING TARGET SPECIFICATION
Metr
ic #
Ne
ed
#s
Metric Imp Units1 1,3 Attenuation from dropout to handlebar at 10hz 3 dB2 2,6 Spring pre-load 3 N3 1,3 Maximum value from the Monster 5 g4 1,3 Minimum descent time on test track 5 s5 4 Damping coefficient adjustment range 3 N-s/m6 5 Maximum travel (26in wheel) 3 mm7 5 Rake offset 3 mm8 6 Lateral stiffness at the tip 3 kN/m9 7 Total mass 4 kg
10 8 Lateral stiffness at brake pivots 2 kN/m11 9 Headset sizes 5 in12 9 Steertube length 5 mm13 9 Wheel sizes 5 list14 9 Maximum tire width 5 in15 10 Time to assemble to frame 1 s16 11 Fender compatibility 1 list17 12 Instills pride 5 subj18 13 Unit manufacturing cost 5 US$19 14 Time in spray chamber w/o water entry 5 s20 15 Cycles in mud chamber w/o contamination 5 k-cycles21 16,17 Time to disassemble/assemble for maintenance 3 s22 17,18 Special tools required for maintenance 3 list23 19 UV test duration to degrade rubber parts 5 hours24 19 Monster cycles to failure 5 cycles25 20 Japan Industrial Standards test 5 binary26 20 Bending strength (frontal loading) 5 MN
Link Metrics to Needs: Quality Function Deployment, or a Needs-Metrics Matrix
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
Need
Metric
Atte
nuat
ion
from
dro
pout
to
hand
leba
r at
10h
z
Spr
ing
pre-
load
Max
imum
val
ue fr
om th
e M
onst
er
Min
imum
des
cent
tim
e on
test
trac
k
Dam
ping
coe
ffici
ent
adju
stm
ent
rang
e
Max
imum
trav
el (
26in
whe
el)
Rak
e of
fset
Late
ral s
tiffn
ess
at th
e tip
Tot
al m
ass
Late
ral s
tiffn
ess
at b
rake
piv
ots
Hea
dset
siz
es
Ste
ert
ub
e l
en
gth
Whe
el s
izes
Max
imum
tire
wid
th
Tim
e to
ass
embl
e to
fram
e
Fen
der
com
patib
ility
Inst
ills
prid
e
Uni
t man
ufac
turin
g co
st
Tim
e in
spr
ay c
ham
ber
w/o
wat
er e
ntry
Cyc
les
in m
ud c
ham
ber
w/o
con
tam
inat
ion
Tim
e to
dis
asse
mbl
e/as
sem
ble
for
mai
nten
ance
Spe
cial
tool
s re
quire
d fo
r m
aint
enan
ce
UV
test
dur
atio
n to
deg
rade
rub
ber
part
s
Mon
ster
cyc
les
to fa
ilure
Japa
n In
dust
rial S
tand
ards
test
Ben
ding
str
engt
h (f
ront
al lo
adin
g)
1 reduces vibration to the hands. • • •2 allows easy traversal of slow, difficult terrain. •3 enables high speed descents on bumpy trails. • • •
4 allows sensitivity adjustment. •5 preserves the steering characteristics of the bike. • •
6 remains rigid during hard cornering. • •7 is lightweight. •8 provides stiff mounting points for the brakes. •
9 fits a wide variety of bikes, wheels, and tires. • • • •10 is easy to install. •
11 works with fenders. •12 instills pride. •13 is affordable for an amateur enthusiast. •
14 is not contaminated by water. •15 is not contaminated by grunge. •
16 can be easily accessed for maintenance. •17 allows easy replacement of worn parts. • •18 can be maintained with readily available tools. •
19 lasts a long time. • •20 is safe in a crash. • •
Benchmark on Customer Needs STEP 2 ESTABLISHING TARGET SPECIFICATION
# NEED Imp ST
Tritr
ack
Maniray 2
Rox T
ahx Q
uadra
Rox T
ahx T
i 21
Tonka P
ro
Gunhill
Head S
hox
1 The suspension reduces vibration to the hands. 3 • •••• •• ••••• •• •••2 The suspension allows easy traversal of slow, difficult terrain. 2 •• •••• ••• ••••• ••• •••••
3 The suspension enables high speed descents on bumpy trails. 5 • ••••• •• ••••• •• •••4 The suspension allows sensitivity adjustment. 3 • •••• •• ••••• •• •••5 The suspension preserves the steering characteristics of the bike. 4 •••• •• • •• ••• •••••
6 The suspension remains rigid during hard cornering. 4 • ••• • ••••• • •••••7 The suspension is lightweight. 4 • ••• • ••• •••• •••••
8 The suspension provides stiff mounting points for the brakes. 2 • •••• ••• ••• •• •••••9 The suspension fits a wide variety of bikes, wheels, and tires. 5 •••• ••••• ••• ••••• ••• •
10 The suspension is easy to install. 1 •••• ••••• •••• •••• ••••• •11 The suspension works with fenders. 1 ••• • • • • •••••12 The suspension instills pride. 5 • •••• ••• ••••• ••• •••••
13 The suspension is affordable for an amateur enthusiast. 5 ••••• • ••• • ••• ••14 The suspension is not contaminated by water. 5 • ••• •••• •••• •• •••••
15 The suspension is not contaminated by grunge. 5 • ••• • •••• •• •••••16 The suspension can be easily accessed for maintenance. 3 •••• ••••• •••• •••• ••••• •
17 The suspension allows easy replacement of worn parts. 1 •••• ••••• •••• •••• ••••• •18 The suspension can be maintained with readily available tools. 3 ••••• ••••• ••••• ••••• •• •19 The suspension lasts a long time. 5 ••••• ••••• ••••• ••• ••••• •
20 The suspension is safe in a crash. 5 ••••• ••••• ••••• ••••• ••••• •••••
Benchmarking on Metrics
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etr
ic #
Ne
ed
#s
Metric Imp Units ST
Trit
rack
Manira
y 2
Rox
Tahx
Quadra
Rox
Tahx
Ti 2
1
Tonka
Pro
Gunhill
Head S
hox
1 1,3 Attenuation from dropout to handlebar at 10hz 3 dB 8 15 10 15 9 132 2,6 Spring pre-load 3 N 550 760 500 710 480 680
3 1,3 Maximum value from the Monster 5 g 3.6 3.2 3.7 3.3 3.7 3.44 1,3 Minimum descent time on test track 5 s 13 11.3 12.6 11.2 13.2 115 4 Damping coefficient adjustment range 3 N-s/m 0 0 0 200 0 0
6 5 Maximum travel (26in wheel) 3 mm 28 48 43 46 33 387 5 Rake offset 3 mm 41.5 39 38 38 43.2 39
8 6 Lateral stiffness at the tip 3 kN/m 59 110 85 85 65 1309 7 Total mass 4 kg 1.409 1.385 1.409 1.364 1.222 1.1
10 8 Lateral stiffness at brake pivots 2 kN/m 295 550 425 425 325 650
11 9 Headset sizes 5 in1.0001.125
1.000
1.1251.250
1.0001.125
1.000
1.1251.250
1.0001.125 NA
12 9 Steertube length 5 mm
150180
210230255
140
165190215
150
170190210
150170
190210230
150
190210220 NA
13 9 Wheel sizes 5 list 26in 26in 26in26in
700C 26in 26in
14 9 Maximum tire width 5 in 1.5 1.75 1.5 1.75 1.5 1.515 10 Time to assemble to frame 1 s 35 35 45 45 35 85
16 11 Fender compatibility 1 list Zefal none none none none all17 12 Instills pride 5 subj 1 4 3 5 3 518 13 Unit manufacturing cost 5 US$ 65 105 85 115 80 100
19 14 Time in spray chamber w/o water entry 5 s 1300 2900 >3600 >3600 2300 >360020 15 Cycles in mud chamber w/o contamination 5 k-cycles 15 19 15 25 18 35
21 16,17 Time to disassemble/assemble for maintenance 3 s 160 245 215 245 200 425
22 17,18 Special tools required for maintenance 3 list hex hex hex hexlonghex
hex,
pinwrnch
23 19 UV test duration to degrade rubber parts 5 hours 400+ 250 400+ 400+ 400+ 250
24 19 Monster cycles to failure 5 cycles 500k+ 500k+ 500k+ 480k 500k+ 330k25 20 Japan Industrial Standards test 5 binary pass pass pass pass pass pass
26 20 Bending strength (frontal loading) 5 MN 55 89 75 75 62 102
Assign Marginal and Ideal Values STEP 3 ESTABLISHING TARGET SPECIFICATION
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Metric Units Marg
inal V
alu
e
Ideal V
alu
e
1 Attenuation from dropout to handlebar at 10hz dB >10 >152 Spring pre-load N 480 - 800 650 - 7003 Maximum value from the Monster g 1.5 >1.7515 Time to assemble to frame s 518 Unit manufacturing cost US$ 360020 Cycles in mud chamber w/o contamination k-cycles >15 >3521 Time to disassemble/assemble for maintenance s 45024 Monster cycles to failure cycles >300k >500k25 Japan Industrial Standards test binary pass pass26 Bending strength (frontal loading) MN >70 >100
Values of Metrics
At least X – set a minimum amount
At most X – set a maximum
Between X and Y – set a range
Exactly X – set a fixed value
Discrete values – beberapa metrik mempunyai nilai beberapa pilihan
diskret.
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Reflect on the results. STEP 4 - ESTABLISHING TARGET SPECIFICATION • Tim memerlukan beberapa
kali pengulangan sampai target disetujui.
• Melakukan pertimbangan (refleksi) di tiap kali pengulangan à meyakinkan bahwa hasil yang diperoleh sudah konsisten dengan tujuan proyek.
Beberapa pertimbangan: Apa anggota tim “bertaruh”? – apa wakil bagian pemasaran
menyatakan bahwa nilai yang agresif diperlukan untuk metrik tertentu? Jika ditetapkan target tinggi, apa anggota tim mampu?
Haruskah tim mempertimbangkan untuk menawarkan berbagai produk/pilihan produk agar memenuhi lebih dari satu segmen pasar atau cukup satu produk saja?
Apakah ada spesifikasi yang hilang? Apakah spesifikasi merefleksikan karakteristik dalam kesuksesan komersial?
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FINAL SPECIFICATIONS
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Process for setting the final specifications
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Develop technical models to assess technical feasibility. The input is design variable and the output is a measurement using a metric.
Develop a cost model of the product.
Refine the specifications, making tradeoffs, where necessary to form a competitive map.
“Flow down” the final overall specs to specs for each subsystem (component and part).
Reflect on the results to see • Whether the product is a winner, and/or • How much uncertainty there is in the technical and cost model, or • Whether there is a need to develop a better technical model.
Develop technical models to assess technical feasibility STEP 1 – PROCESS FOR SETTING THE FINAL SPECIFICATIONS
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Misal Konsep terpilih: kumparan pegas yang dilumuri minyak untuk produk tiang suspensi
Develop a cost model of the product
• Produk yang dihasilkan sesuai dengan “target biaya/target cost” yang ditetapkan.
• Biaya à biaya manufaktur dimana perusahaan memperoleh cukup keuntungan dan mampu menawarkan produk ke pelanggan dengan harga yang bersaing.
• Perkiraan biaya berdasarkan daftar bahan & komponen sesuai BOM Tree.
STEP 2 – PROCESS FOR SETTING THE FINAL SPECIFICATIONS
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No Bahan/Komponen Jumlah
Harga Tertinggi
Harga Terendah
Total Tinggi
Total Rendah
1
2
:
n
Total
Profit Margin & Target Cost
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Where: M: profit margin P: price C: cost
Where: C = target cost P = price to the end user Mi = the margin at the ith stage.
Dengan à Markup = P/C - 1
Gross Margin - Industry
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Contoh
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Diketahui P=$250. Jika produk langsung dijual ke pelanggan oleh pabrik dan
keuntungan kotor yang ingin diperoleh pabrik, MM, adalah sebesar 40%, maka harga produk tersebut adalah: C = P (1 – MM) = $250 (1 – 0,40) = $150
Jika produk dijual ke pengecer dan keuntungan pengecer, MR,
adalah sebesar 45%, maka: C = P (1 – MM) (1 – MR) = $82.50
Jika produk dijual ke distributor dan pengecer, kemudian
keuntungan kotor yang ingin diperoleh distributor, MD, sekitar 20%, maka?
Refine the specifications, making tradeoffs, where necessary STEP 3 – PROCESS FOR SETTING THE FINAL SPECIFICATIONS
Peta Persaingan
Dibuat berdasarkan bagan analisis pesaing (competitive benchmarking chart)
Specification Trade-offs
07/10/15 40
Score on Monster (Gs)
Trade-off Curves for Three Concepts
Estim
ated
Man
ufac
turin
g C
ost (
$)
Set Final Specifications
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METRIC Units Value
1 Attenuation from dropout to handlebar at 10hz dB >122 Spring pre-load N 6503 Maximum value from the Monster g 759 Total mass kg 425
11 Headset sizes in1.0001.125
12 Steertube length mm
150170190210230
13 Wheel sizes list 26in14 Maximum tire width in >1.7515 Time to assemble to frame s 418 Unit manufacturing cost US$ 360020 Cycles in mud chamber w/o contamination k-cycles >2521 Time to disassemble/assemble for maintenance s 45024 Monster cycles to failure cycles >500k25 Japan Industrial Standards test binary pass26 Bending strength (frontal loading) MN >100
Flow down” the final overall specs to specs for each subsystem
• Masalah yang dihadapi: • Memastikan spesifikasi subsistem
dapat mencerminkan spesifikasi produk secara keseluruhan.
• Meyakini bahwa spesifikasi tertentu untuk subsistem yang berbeda mempunyai tingkat kesulitan yang sama untuk dipenuhi.
• Contoh: • Fungsi efisiensi bahan bakar mesin
tersusun dari bahan bakar mesin, daya tahan putaran mesin, koefisien putaran mesin,koefisien tarikan, aero dinamis, dll.
STEP 4 – PROCESS FOR SETTING THE FINAL SPECIFICATIONS
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Reflect on the results to see STEP 5 – PROCESS FOR SETTING THE FINAL SPECIFICATIONS
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Quality Function Deployment (House of Quality)
BACA: CONTOH 2 Soccer Robot
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Interpreted Customer Needs The process of developing product specifications begins with your completed matrix of interpreted customer needs. Again note that there are no values.
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Example of a customer needs table
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From 2nd & 3rd of needs
Needs-Metrics Tables
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Quality Function Deployment, or a Needs-Metrics Matrix
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Competitive Benchmarking – Evaluate the competition
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Example of a Product Specification table
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