4.

2 (New Product Development and manufacturing process)

Product Design and Development

Product design is a term that refers to transforming an idea of how a product should be and the specification,
which are required for producing that product. These specifications are created keeping in mind the constraints
of the production process, feasibility to produce and meeting the customer expectation without sacrificing the
quality.

Product development refers to the process of creating new product or modifying the existing ones.

Need for product design and development

 The need of consumer keeps on changing over the period of time.

 To keep the existing market share
 Breaking the monotony in the design and feature of the product
 Filling in the missing product in the product range to provide consumer with all possible option.
 Attracting the consumer that is sensitive to changing fashions.
 Improving the life cycle of the product in the market
 Providing satisfaction to consumer by giving a new appearance or functionally or both immediately
 Utilising the production resource effectively.
 Keeping the advantage of already established product in the market by improving it from time to time.

Process of new product development.

 Need identification
 Advanced product planning
 Advanced design
 Detail engineering design
 Product process design and development
 Product evaluation and improvement
 Product use and support.

Product Development Techniques

 (i) Standardisation – It is a product technique in which a company establish standard, such as product
dimension, equipment used and quality for its product to maintain consistency.
(ii) Simplification – It refer to the elimination of superfluous varieties, size and dimension etc. It is an
economical process that helps minimize the product items to restrict the production of unbeneficial
products.
(iii) Specialisation – It is a technique that involves concentration of efforts upon a limited field of
endeavour. This technique enables the employee to gain specialised knowledge of that activity.
(iv) Diversification – Diversifying is the techniques that involve introducing new product and new
models of the old product. This techniques also involve introducing new markets , new techniques
and new product lines in a company.

Quality Function Deployment (QFD)

QFD is a method developed in Japan beginning in 1966 to help transform the voice of the customer [VOC]
into engineering characteristics for a product. Yoji Akao the original developer, described QFD as a
"method to transform qualitative user demands into quantitative parameters, to deploy the functions forming
quality, and to deploy methods for achieving the design quality into subsystems and component parts, and
ultimately to specific elements of the manufacturing process.The author combined his work in quality
assurance and quality control points with function deployment used in value engineering.

The QFD method identifies and classifies customer desires, identifies the importance of those desires,
identifies engineering characteristics which may be relevant to those desires, correlates the two, allows for
verification of those correlations, and then assigns objectives and priorities for the system
requirements. This process can be applied at any system composition level (e.g. system, subsystem, or
component) in the design of a product, and can allow for assessment of differently level abstraction systems
based on the output of QFDs matrices assessed for those system levels.[

Process Analysis / Type of Production system

A system is a logical arrangement of components designed to achieve particular objective according to a plan.
Production system is the frame work within which the production activities of an organisation are carried out.
At one end of system are inputs and at the other end output. Input and output are linked by certain processes or
operation or activities imparting values to the inputs. These process, operation or activities may be called
production system.
Production process can be defined as a set of activities that are preferred to modify and add value to the inputs
and convert it into the desired output.

Input – conversion process – output

Inputs of Production System

Input – They consists of raw material, parts, capital, equipment, human efforts etc.

Conversion Process – It refer to a series of operation which are performed on material and parts.

Output – Output are the product or completed parts resulting from the conversion process.

Storage – storage like place after the receipts of input between one operation and the other and after the outputs.

Transportation – Input are transported from one operation to another in the production process.

Information – It provides system control through measurement, comparison, feedback and corrective action.

Type of Process analysis

(i) Process Production – Process production is defined as a system for production where a similar
product is produced continually in large quantities year after year. This type of production system is
suitable where the requirement is to produce same product in huge quantities such as steel, cement,
sugar etc.

(ii) Mass production – Mass production is a production system designed to produce several standard
product in mass quantities. This type of system has a capability to produce large quantities of
product thereby providing the management with the advantage of economies of scale. For example
automobiles, steel, Petrochemical industries, cigarette industry ,oil refinery, sugar plant, paper
industry, cement industry,

(iii) Batch Production – The product are produced in lots and in the planned quantities. This type of
process is adopted where the requirement is to produce a limited number of products with varying
quantities at periodic interval. In comparison with the mass production and process production
system, the quantities are smaller and also the production is in batch not in a constant flow. For
example Pharmaceuticals, paints, chemical, sub contractor etc.
(iv) Job production – It is appropriate for that company which manufacture small number of different
type of product. Each of which is customer specific and require its unique set of process. The
product is provided to the customer as a single delivery. Volume is very low in this type of process.
The goods are manufactured specially to fulfil orders made for customer rather than for stock. Job
production is characterised by variety of customer designed goods in small volume. It involves
manufacturing of products to meets specific customer requirements of special orders. For example
general repair shop, building contractor, tailoring shop, ships, cranes and other manufacturing
articles.

(v) Assembly line – It is appropriate technology in production facilities that reduced a narrow range of
standardized product. In this case product design is relatively stable so specialized equipment and
manufacturing system can be designed. However assembling to produce product beyond the
standard range.