Product Design and

Development
Prof Harish rao
Typical product development process

Concept Generation Design

Yes
Idea Feasibility Preliminary Process Cost
Feasible?
Generation Study Design Planning Planning
No

No
Final Design Yes Prototype Yes
Commercial
Manufacturing Prototype OK? Development & Design OK?
Production
Specifications Testing
No

Production Development
Tools for product development

 Autonomous design and development teams

 Cuts bureaucratic red tape

 Computer aided design and manufacturing

 Reduces time needed for testing designs

 Simultaneous engineering or concurrent engineering

 Product or service design proceeds at the same time as process design

 Value engineering
 Reducing complexity of product
 Improving serviceability of the product
Improving designs of products
 Designing for ease of production
 Specification
 Standardization
 Simplification

 Designing for Quality

 Designing new services

 Degree of standardization
 Degree of customer contact
 Mix of physical goods and intangible services
Process Design

 Nature of product/service demand

 Integrate with sales volume
 Degree of vertical integration
 Value to be absorbed in-house
 Production flexibility
 Product Flexibility
 Volume Flexibility
 Degree of automation
 Labor vs capital
 Product/service quality
 Low volume no longer synonymous with quality.
Product focused process design

 Continuous production
 Discrete manufacturing

 High volume
 Low variability
 Low unit costs
 High fixed costs due to high capital to labor ratio
 Low product flexibility
 Process focused process design
 Intermittent production or job shops
 Jobs have no fixed path through the system
 Jobs spend a lot of time waiting
for resources to free up
 High skilled labor is employed
 Process flexibility is very high

 Hospitals, automobile repair shops, machine shops, etc.

Group Technology/ Cellular
Manufacturing
 Hybrid system to attempt to bring order to chaos of job shop
 Grouping certain resources together to create a cell
 Based on historical/expected flow of products

 Less changeovers
 Task variability is reduced
 More direct routes
 Less waiting time
 Possible automation
Process Design in Services

 Quasi-manufacturing
 Customer isn’t involved in production of goods

 Customer as participant
 High degree of customer involvement in production

 Customer as product
 Extremely high customer involvement
Product-Process Matrix
Generic Product Development Processes
Designing for Quality
Quality Functional Deployment
Designing for Quality
Reliability

 Probability that a given part or product will perform its intended function for
the specified length of time under normal conditions of use.

 Components in series, Rs = R1 * R2 …. * Rn

 Components in parallel, Rs = 1 – (1-R1)* (1-R2)…. * (1-Rn)

Example

R1 R2 R3

.90 .80 .99 Rs

Reliability of the process is

Rs = R1 x R2 x R3 = .90 x .80 x .99 = .713 or 71.3%

Reliability with Backup

Backup units are added to R1 and R2

R1 R2 R3
Reliability has
0.90 0.80 increased from
.713 to .94
0.90 0.80 0.99

RS = [1 – (1-.9) (1 - .9)] x [1 – (1-.8) (1 - .8)] x .99

= .99 x .96 x .99 = .94
Parallel redundancy

R1
0.95
R2 R3
0.975 0.975
R4
0.95

RS = ????
Maintainability

  MTBF (Mean Time Between Failures)

 Length of time a product or service is in operation before it fails
 Relationship between MTBF and failure rate
 MTBF = 1 / failure rate
 MTTR (Mean Time To Repair)
 Average time taken to get a product or service back to operational state
 System Availability (SA)
 SA =
Choosing between alternatives

 Break Even Analysis

 NPV Analysis

 Decision Tree Analysis

Designing for Robustness

 Quality of Conformance
 Manufactured wrong
 Statistical Process Control
 Quality of design
 Designed incorrectly
 Taguchi Method (Designing for Six Sigma)
 Consistent errors are better than random errors
 Parts within tolerance limits may produce assemblies that are not within limits
 Quality near target value better than quality within specifications
Designing for Robustness
Service Design – Adding Efficiency

 Limit Options

 Delay Customization

 Modularization

 Automation