Manufacturing Realtime Process Plan Selection Based on System
Ch5(Product Design & Process Selection-Manufacturing)
Transcript of Ch5(Product Design & Process Selection-Manufacturing)
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Chapter 5Product Design & Process
Selection-Manufacturing
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• Typical Phases of Product Design
Development
• Designing for the Customer
• Design for Manufacturability
• Types of Processes
• Process Flow Structures
• Process Flow Design
• lobal Product Design and Manufacturing
!"#$CT%$S
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Typical Phases of Product Design
Development• Concept Development
• Product Planning
• Product'Process $ngineering
• Pilot Production'(amp-)p
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Concurrent $ngineering
Defined • Concurrent engineering can be defined
as the simultaneous development of
pro*ect design functions+ with open andinteractive communication e,isting
among all team members for the
purposes of reducing time to maret+decreasing cost+ and improving .uality
and reliability
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Concurrent $ngineering/Continued0
• Teams provide the primary integrationmechanism in C$ programs
• There are three types of teams – Program Management Team
– Technical Team
– Design-Buil Teams• Time savings of C$ programs are created
by performing activities in parallel
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Designing for the Customer
Quality Function
Deployment
Value Analysis/
Value Engineering
Ideal
Customer
Product
House of Quality
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Designing for the Customer1
2uality Function Deployment
• %nterfunctional teams from mareting+ designengineering+ and manufacturing
• oice of the customer
• 3ouse of 2uality
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Designing
for the
Customer1
The 3ouse
of 2uality
Customer
#e$uirements
% m p o r t a n c e t o
C u s t &
'as( to close
)ta(s open on a hill
'as( to open
Doesn*t lea+ in rain
,o roa noise
%mportance eighting
'ngineering
Characteristi
cs
' n e r g ( n e e e
t o c l o s e o o r
C h e c + . o r c e
o n l e / e l
g r o u n
' n e r g ( n e e e
t o o p e n o o r
0 a t e r r e s i s t a n c e
1 6 6 2 3
!
5
3
3
2
Correlation
)trong positi/e
Positi/e
,egati/e)trong negati/e
Competiti/e e/aluation
7s8 Comp& 8B Comp& B95 is :est;
1 2 3 4 5
8B
8B
8B
8 B
8 B
#elationships
)trong
Meium 3
)mall 1Target /alues
# e u c e e n e r g
(
l e / e l t o ! & 5 . t
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Designing for the Customer1
alue 4nalysis'alue $ngineering /4'$0
• 4chieve e.uivalent or better performance at a lower
cost while maintaining all functional re.uirements
defined by the customer – Does the item have any design features that are
not necessary5
– Can two or more parts be combined into one5
– 3ow can we cut down the weight5
– 4re there nonstandard parts that can be
eliminated5
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Design for Manufacturability• Traditional 4pproach
– 67e design it+ you build it8 or 6!ver the
wall8
• Concurrent $ngineering
– 69et:s wor together simultaneously8
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Design for Manufacturing and 4ssembly
• reatest improvements related to DFM4 arise
from simplification of the product by reducing thenumber of separate parts1
;< During the operation of the product+ does the part
move relative to all other parts already assembled5=< Must the part be of a different material or be
isolated from other parts already assembled5
>< Must the part be separate from all other parts to
allow the disassembly of the product for
ad*ustment or maintenance5
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Types of Processes• Conversion /e,< %ron to steel0
• Fabrication /e,< Cloth to clothes0
• 4ssembly /e,< Parts to components0
• Testing /e,< For .uality of products0
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Process Flow Structures• #ob shop /e,< Copy center maing a single copy
of a student term paper0
• "atch shop /e,< Copy center maing ;?+???copies of an ad piece for a business0
• 4ssembly 9ine /e,< 4utomobile manufacturer0
• Continuous Flow /e,< Petroleum manufacturer0
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%=&
Continuous
>lo
%%%&
8ssem:l(?ine
%%&
Batch
%&
@o:
)hop
?o
=olumeA
ne o. ain
Multiple
ProuctsA
?o=olume
>e
Maor
ProuctsA
Eigher =olume
Eigh
=olumeA
Eigh
)tanar-iFation
Commercial
Printer
>rench #estaurant
Eea/(
'$uipment
8utomo:ile
8ssem:l(Burger ing
)ugar
#e.iner(
>leGi:ilit( 9Eigh;
7nit Cost 9Eigh;
>leGi:ilit( 9?o;
7nit Cost 9?o;
Exhibit 5.10Exhibit 5.10
These are
the maor
stages o.
prouct an
process li.e
c(cles
These are
the maorstages o.
prouct an
process li.e
c(cles
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irtual Factory
Defined 4 virtual factory can be defined as a
manufacturing operation where activities are
carried out not in one central plant+ but inmultiple locations by suppliers and partner
firms as part of a strategic alliance
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"rea-$ven 4nalysis
• 4 standard approach to choosing among
alternative processes or e.uipment
• Model sees to determine the point in units
produced /and sold0 where we will startmaing profit on the process or e.uipment
• Model sees to determine the point in units
produced /and sold0 where total revenue andtotal cost are e.ual
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"rea-$ven 4nalysis /Continued0
This .ormula can :e use to .in an( o. its
components alge:raicall( i. the other parametersare +non
Brea+-e/en DemanBrea+-e/en Deman
Purchase cost o. process or e$uipment
Price per unit - Cost per unit
or
Total .iGe costs o. process or e$uipment7nit price to customer - =aria:le costs per unit
Purchase cost o. process or e$uipment
Price per unit - Cost per unit
or
Total .iGe costs o. process or e$uipment7nit price to customer - =aria:le costs per unit
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"rea-$ven 4nalysis /Continued0
• $,ample1 Suppose you want to purchase a new computer
that will cost @A+???< %t will be used to process written ordersfrom customers who will pay @=A each for the service< The
cost of labor+ electricity and the form used to place the order
is @A per customer< 3ow many customers will we need to
serve to permit the total revenue to brea-even with ourcosts5
• Brea+-e/en Deman
Total .iGe costs o. process or e$uip&
7nit price to customer – =aria:le costs 5A
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Process Flow Design
Defined • 4 process flow design can be defined as a
mapping of the specific processes that rawmaterials+ parts+ and subassemblies follow asthey move through a plant
• The most common tools to conduct a process
flow design include assembly drawings+assembly charts+ and operation and route sheets
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$,ample1 4ssembly Chart /oBinto0
8-2)8-2
4
5
6
!
?oc+ring
)pacerA etent spring
#i/ets 92;
)pring-etent
8-5
Component
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$,ample1 Process Flow Chart
MaterialReceived
from
Supplier
Inspect
Material for
efects efects
found!
Return to
Supplier for
"redit
$es
%o#
"ontinue$
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lobal Product Design and Manufacturing
Strategies• #oint entures
• lobal Product Design Strategy
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Measuring Product Development
Performance
Measures•>re$& . ne proucts introuce•Time to mar+et introuction• ,um:er state an num:er complete
•8ctual /ersus plan•Percentage o. sales .rom ne proucts
•>re$& . ne proucts introuce•Time to mar+et introuction• ,um:er state an num:er complete
•8ctual /ersus plan•Percentage o. sales .rom ne proucts
%ime&to&mar'et%ime&to&mar'et
(roductivit)(roductivit)
*ualit)*ualit)
•'ngineering hours per proect
•Cost o. materials an tooling per proect•8ctual /ersus plan
•'ngineering hours per proect•Cost o. materials an tooling per proect•8ctual /ersus plan
•Con.ormance-relia:ilit( in use•Design-per.ormance an customer satis.action
•Hiel-.actor( an .iel
•Con.ormance-relia:ilit( in use•Design-per.ormance an customer satis.action
•Hiel-.actor( an .iel
Per.ormanceDimension
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'n o. Chapter 5