1 dsci 3123 product and service design process planning concurrent design and engineering functional...
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Product and Service Design
• Product and Service Design
• Process Planning
• Concurrent Design and Engineering
• Functional Design
• Reliability and Analyzing Failures
• Design Process
• Quality Function Deployment
• Taguchi Robust Design
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Product Design
• Specifies materials
• Determines dimensions & tolerances
• Defines appearance
• Sets performance standards
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Service Design
• Specifies what the customer is to experience• Determines setting and degree of customer
involvement• Defines physical items, physiological benefits,
& psychological benefits the customer receives
• Sets standards for delivery
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An Effective Design Process
• Matches product/service characteristics with customer needs
• Meets customer requirements in the simplest, most cost-effective manner
• Reduces time to market
• Minimizes revisions
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Feasibility Study
• Market Analysis
• Economic Analysis
• Technical / Strategic Analysis
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Perceptual Map Of Breakfast Cereals
Bad taste
Good taste
High nutritionLow nutrition
• Cocoa Puffs
• Rice Krispies • Wheaties
• Cheerios
• Shredded Wheat
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Process Planning
• Create workable instructions for manufacture
• Select tooling & equipment
• Prepare job descriptions
• Determine operation & assembly order
• Network all systems
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Improving The Design Process
1. Implementing concurrent engineering/design and design teams
2. Analyzing functional design, reliability, and maintainability
3. Measuring design quality
4. Utilizing quality function deployment
5. Designing for robustness
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Concurrent Design
• Also known as simultaneous or concurrent engineering
• Simultaneous decision making by design teams
• Integrates product design & process planning
• Details of design more decentralized
• Encourages price-minus, not cost-plus pricing
• Needs careful scheduling because tasks are done in parallel
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Concurrent Design
Customers
Marketing
Design
Engineering
Suppliers Production
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Design Teams
• Cross-functional –Marketing, manufacturing, engineering, finance
• Vertical–Suppliers, dealers, customers
• Horizontal–Lawyers, accountants, insurance companies
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Break Down the Walls Between Functional Areas
Marketing
Customers
Design Engineers
Manuf. Engineers
Production
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Functional Design(How The Product Performs)
• Reliability–probability product performs intended function for specified length of time
• Maintainability–ease and/or cost or maintaining/repairing product
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Analyzing Failures
• Failure Mode and Effects Analysis (FMEA)• a systematic approach for analyzing causes and effects
of failures
• prioritizes failures
• attempts to eliminate causes
• Fault Tree Analysis (FTA)• more visual
• studies interrelationship between failures
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Failure Mode & Effects Analysis
FailureMode
Causes ofFailure
Effects ofFailure
CorrectiveAction
Stale Low moisturecontent, expiredshelf life, poorpackaging
Tastes bad, won’tcrunch, thrownout, lost sales
Add moisture, curelonger, betterpackage seal,shorter shelf life
Broken Too thin, toobrittle, roughhandling, roughuse, poorpackaging
Can’t dip, poordisplay, injuresmouth, choking,perceived as old,lost sales
Change recipe,change process,change packaging
Too Salty Outdated recipe,process not incontrol, unevendistribution of salt
Eat less,drink more,health hazard,lost sales
Experiment withrecipe, experimentwith process,introduce low saltversion
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Fault Tree Analysis
Moremoisture
Lessridges
Amountof heat
Lengthof time
Adjust fryingprocedure
(AND)
Too Brittle(OR)
Increasethickness
Reducesize
Too Thin(OR)
Chip Breaking(OR)
Solved Solved
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Computing Reliability
0.90 0.90
.95
.90
0.90 x 0.90 = 0.81
0.95 + 0.90(1-0.95) = 0.995
Components in series
Components in parallel
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Quality Function Deployment (QFD)
• Translates the voice of the customer into technical design requirements
• Displays requirements in matrix diagrams
• First matrix called house of quality
• Series of connected houses
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House Of Quality
6. Technical assessment and target values
1. Customerrequirements
4. Relationship matrix
3. ProductcharacteristicsImportance
2. Competitiveassessment
5. TradeoffMatrix
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House Of Quality for a Steam Iron
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Series of Connected Houses
A-1
A-2
A-3
A-4
House of Quality
PartsDeployment
ProcessPlanning
Operating Requirements
Product Characteristics
Part Characteristics
Process Characteristics
Operations
CustomerReq.
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Benefits Of QFD
• Promotes better understanding of customer demands and design interactions
• Increases customer satisfaction
• Breaks down barriers between functions & departments & fosters teamwork
• Improves design/development process documentation
• Reduces the # of engineering changes, cost of design & manufacture, and brings new designs to the market faster
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Taguchi’s Robust Design
• A product or service exhibits robustness if it performs consistently regardless of the operating conditions
• Designers must consider both controllable factors (design features) and uncontrollable factors (operating conditions) in design for robustness
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Consistency Is Important
• Consistent errors are easier to correct than random errors
• Parts within tolerances may yield assemblies which aren’t within tolerances
• Consumers prefer product characteristics near their ideal values
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Taguchi’s Quality Loss Function
TargetLowerTolerance
Limit
UpperTolerance
Limit
Qu
alit
y L
oss