EMBA-2, BUP

EO - 702

Product Design & Process Selection-Manufacturing

EMBA-2, BUP

EO - 702Typical Phases of Product Development

EMBA-2, BUP

EO - 702

Design for Manufacturability

Traditional Approach-“We design it, you build it” or “Over the wall”

DesignMfg

New Product

Concurrent Engineering-“Let’s work together simultaneously”

EMBA-2, BUP

EO - 702

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

There are three types of teams• Program Management Team• Technical Team• Design-Build Teams

Time savings of CE programs are created by performing activities in parallel

EMBA-2, BUP

EO - 702

Designing for the Customer

Value Analysis/Value Engineering

Ideal Customer Product

House of Quality

QFD: An approach that integrates the “voice of the customer” into the product and service development process.

+

VOICE OF THECUSTOMER

QFD

= CUSTOMERSATISFACTION

EMBA-2, BUP

EO - 7026

Customer requirements information forms the basis for this matrix, used to translate them into operating or engineering goals.

Customer requirements information forms the basis for this matrix, used to translate them into operating or engineering goals.

House of Quality

EMBA-2, BUP

EO - 7027

EMBA-2, BUP

EO - 7028

House of Quality

6. Targets6. Targets

4. Inter-relationships

4. Inter-relationships

2. P

lann

ing

Ma

trix

1. C

usto

me

rR

eq

uire

me

nts

3. TechnicalRequirements

3. TechnicalRequirements

5. Roof5. Roof

EMBA-2, BUP

EO - 7029

Hou

se o

f Q

uality

EMBA-2, BUP

EO - 702

Designing for the Customer

Value Analysis/Value Engineering (VA/VE)

Main aim is to eliminate unnecessary features and functions in product design.

To 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?

EMBA-2, BUP

EO - 702Design for Manufacturing and Assembly

EMBA-2, BUP

EO - 702

Design for Manufacturing and Assembly

EMBA-2, BUP

EO - 702

Process Flow Design

A process flow design can be defined as a mapping of the specific processes that raw materials, parts, and subassemblies follow as they move through a plant

Most common tools : assembly drawings, assembly charts

Example: Plug Assembly Drawing

EMBA-2, BUP

EO - 702

Process Selection

refers to the strategic decision of selecting what kind of production process to have in the plant.

Types of Process Basing on What they do : Conversion Process Fabrication Process Assembly Process Testing Process

Just to refresh:Single, Multi stage, makes to order, …..are they types of Process? If so what’s the base for consideration?

EMBA-2, BUP

EO - 702

Process Flow Structures

It refers how a factory organizes materials flow using one or more of the process technologies listed below:

Job shop – A process structure suited for low volume production of a greatly variety of non-standard products.

Batch shop – A process structure that produces a variety of standard products relatively at low volume.

Assembly Line –A process structure designed to make discrete parts.

Continuous Flow – An often automated process that convert raw materials into finished products in one continuous process.

EMBA-2, BUP

EO - 702

IV.Continuous

Flow

III.Assembly

Line

II.Batch

I.Job

Shop

LowVolume,One of a

Kind

MultipleProducts,

LowVolume

FewMajor

Products,HigherVolume

HighVolume,

HighStandard-

ization

Machine shop

Chemical,Electronics

AutomobileAssembly

SugarRefinery

Flexibility (High)Unit Cost (High)

Flexibility (Low)Unit Cost (Low)

These are the major stages of product and process life cycles

These are the major stages of product and process life cycles

Product Process Matrix

Process Structure

Process Life Cycle Stage

Effectiveness Measures

EMBA-2, BUP

EO - 702

Virtual Factory

A virtual factory can be defined as a manufacturing operation where activities are carried out not in one central plant, but in multiple locations by suppliers and partner firms as part of a strategic alliance