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PRODUCT & SERVICE DESIGN
By: HAKEEMURREHMAN PCBAUCP
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
PRODUCT DESIGN defines appearance of product sets standards for performance specifies which materials are to be used determines dimensions and tolerances
SERVICE DESIGN specifies what physical items, physical benefits, and psychological benefits customer is to receive from service defines environment in which service will take place
Customer Marketing
R&D Competitors
Idea Generation
Concept
Feasibility Study
Performance Specifications Form Design
Rapid Prototyping:
Idea Generation: Ideas can come from variety of sources. They are: SupplyChain Based: Customers Suppliers, Distributors, Employees, and Maintenance or repair personnel Competitor Based: Competitors are also a source of ideas for new product or services. Benchmarking, Reverse Engineering can help companies learn from their competitors. Benchmarking: Comparing a product or process against the bestinclass product. Reverse Engineering: Carefully dismantling and inspecting a competitors product to improve your own product. Research & Development: Organized efforts to increase scientific knowledge or product innovations. (Medicine, Space technology can be attribute to R & D efforts at colleges and universities.)
Feasibility Study consists of : A Market Analysis An Economic Analysis, & A Technical and Strategic Analysis Market Analysis: Identifying the demand of the proposed product (through Customer survey, interviews, etc.) Economic Analysis: Estimate the production & development costs and compare them to estimated sales volume. Technical & Strategic Analysis: that answers such questions: Does the new product require new technology? Is the risk or capital investment expensive? Does the company have sufficient labour and management skills to support the required technology? Is sufficient capacity available for production? Does the new product provide a competitive advantage?
Maintainability (Serviceability): the ease with which a product is maintained or repaired. Regular maintenance schedules is part of maintainability. Usability: ease of use of a product or service. Production Design: how the product will be made. Approaches to production design: Simplification Standardization Simplification: Reduces the number of parts, assemblies, or options in a product. Standardization: When commonly available and interchangeable parts are used. Modular Design: Combines standardized building blocks, or modules, to create unique finished products.
DESIGN SIMPLIFICATION
(a) Original design (b) Revised design (c) Final design
Final design
Process plans
workable instructions
necessary equipment and tooling job descriptions and procedures computer programs for automated machines
RELIABILITY
the probability that a product will perform its intended function for a specified period of time. (OR)
The ability of a product, Service, Part, or system to perform its intended function under a prescribed set of conditions.
COMPUTING RELIABILITY
COMPONENTS IN SERIES
0.90 0.90 0.90 x 0.90 = 0.81
COMPONENTS IN PARALLEL
0.90 0.95
R2
R1
COMPUTING RELIABILITY
Three lamps have probabilities of 0.90, 0.80, and 0.70 of lighting when turned on. Only One lighted lamp is needed for success; hence, two of the lamps are considered to be backups. 0.70 0.80 0.90
Lamp-3 (Backup of Lamp-2)
Lamp-1
SYSTEM RELIABILITY
0.90 0.98 0.92 0.98
0.98
0.92+(1-0.92)(0.90)=0.99
0.98
PRACTICE QUESTION
0.98
0.90
0.95
= 0.98 X [0.90 + 0.90 X (1 0.90)] X [0.95 + 0.92 (1 0.95)] = 0.98 X 0.99 X 0.996 = 0.966
SA =
where: MTBF = mean time between failures MTTR = mean time to repair
SYSTEM AVAILABILITY
PROVIDER A B C MTBF (HR) 60 36 24 MTTR (HR) 4.0 2.0 1.0
SAA = 60 / (60 + 4) = .9375 or 93.75% SAB = 36 / (36 + 2) = .9726 or 97.26% SAC = 24 / (24 + 1) = .9473 or 94.73%
PRODUCT DESIGN
As the customer wanted it. As Marketing
interpreted
it.
1984-1994 T/Maker Co. 1984-1994 T/Maker Co.
As
Engineering
designed it.
1984-1994 T/Maker Co. 1984-1994 T/Maker Co.
REDUCING TIME-TO-MARKET
Establish multifunctional design teams Make design decisions concurrently rather than sequentially Design for manufacture and assembly
DESIGN TEAM
Traditional Approach We design it, you build it or Over the wall Concurrent Engineering
CONCURRENT ENGINEERING
Concurrent Engineering (CE) 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.
reducing number of parts in an assembly evaluating methods of assembly determining an assembly sequence
DFM GUIDELINES
Minimize number of parts and subassemblies Avoid tools, separate fasteners, and adjustments Use standard parts when possible and repeatable, well-understood processes Design parts for many uses, and modules that can be combined in different ways Design for ease of assembly, minimal handling, and proper presentation Allow for efficient and adequate testing and replacement of parts
APPLICATION OF DFA
QFD: An approach that integrates the voice of the customer into the product and service development process.
HOUSE OF QUALITY
Importance
5 Trade-off matrix 3 Design characteristics 4 Relationship matrix 2 Competitive assessment
1 Customer requirements
Target values
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?
Robust product
designed to withstand variations in environmental and operating conditions yields a product or service designed to withstand variations design parameters such as material used, dimensions, and form of processing users control (length of use, maintenance, settings
Robust design
Controllable factors
Uncontrollable factors
Tolerance
allowable ranges of variation in the dimension of a part 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
Consistency
Quality Loss
Lower toleranc e limit
Quantifies customer preferences toward quality Emphasizes that customer preferences are strongly oriented toward consistently Design for Six Sigma (DFSS)
Target
Performance Specifications Customer requirements Customer Activities Customer expectations Service Provider Cost and time estimates
QUESTION S