2. manufacturing environment 1
Post on 16-Apr-2017
219 Views
Preview:
TRANSCRIPT
Product DesignProduct design is the process of
deciding the company’s product unique characteristics and features.Product design defines a product’s
characteristics like - Appearance, materials, dimensions, tolerances, performance standards
Product design must support the business strategy
Product design must match the needs and preferences of the targeted customer group
1Chapter 2 Manufacturing Environment
Objectives of Product Design• To generate profit in long run
• To achieve the desired product quality
• To reduce the development time
• To minimize the cost of product
• To ensure the manufacturability
2 Product Design and Development 2
Factors Influencing Product Design
• Customer requirements• Convenience of the user• Trade off between function and form• Work methods and equipments• Cost-price ratio• Product quality• Process capability• Effect on existing products• packaging
2 Product Design and Development 3
Characteristics of Good Design
• Functionality – Meeting the objective of customers need
• Reliability– Dependability on the performance for designed period
of time without deterioration in quality• Productivity
– Reducing number of operations– Replacing the operations that take more time than
stipulated– Replacing the operations that cost mores the budget
with improved technology2 Product Design and Development 4
…Characteristics of Good Design• Quality
– Process: Inspection only informs us about the quality but it is the process that builds the quality in a product.
– Material: Material play an important role in making the product durable and reliable.
– Tolerances in the dimensions of individual parts affect the final quality of assembled product.
• Standardization– Producing various types of products adds to the cost of
production– So, it is important to consider the options of
standardization in terms of• Parts to be used• Using common manufacturing facilities
2 Product Design and Development 5
…Characteristics of Good Design
• Maintainability– Product design should be such that maintaining would be
simple and cost effective in terms of repair and replacement of defective part
– Effective design minimizes the downtime thereby achieving customer satisfaction
• Cost effective– Cost of production for a product is influenced at the
designing stage– Design plays an important role in economical
manufacturing2 Product Design and Development 6
Product Design Development
1.Need Identification: Identify customer’s need
2.Concept Development: Description of form, functions, features
3.Product Design: Specification of geometry, materials, and tolerances
4.Production Process Design and Development: Design and develop systems like material acquisition, human resource, storing, transportation, distribution etc.
7Chapter 2 Manufacturing Environment
Product Design Process5. Testing and Refinement:
Prototypes are made and tested and improvements are done
6. Product Launch and Support: • Train workforce• Provide warranty• Avail repair parts and after sale services• Upgrade parts
8Chapter 2 Manufacturing Environment
Product Life Cycle• Product life cycle is the predictable pattern of demand
throughout the product life.• Products are born. They live and they die• Phases: Introduction, growth, maturity, decline• Product life cycles may be of few hours( a
newspaper), months (seasonal fashions), years (video cassette tapes) or decades (generators).
• Typically a firm has negative cash flow while it develops a product. When the product is successful, those loses may be recovered.
Chapter 2 Manufacturing Environment 9
Operational Issues in PLCIssues Introductory Growth Maturity Decline
Product variety Different variety
Increasing standardization
Emergence of dominant design
Commodity characteristics
Product Volume
Low Increasing High High
Industry Structure
Small competitors
Fall out and consolidation
Few large competitors
Survivors
Competition Product characteristics
Product quality and availability
Price and dependability
Price
Chapter 2 Manufacturing Environment 10
Stages in the Product Life Cycle
Introduction
Growth
Maturity
Decline
Gro
wth
ra
te mp3 players
mp4 players
CD players
iphone
Floppy Disks
cassette players
DVD’s
Fax Machine
¨ Best period to increase market share¨ R&D engineering are critical
Introduction
Strategy & Issues During Product Life
• Company Strategy & Issues
¨ Product design and development are critical
¨ Frequent product and process design changes
¨ Short production runs¨ High production costs¨ Utmost attention to quality¨ Quick elimination of market-revealed
design defects
¨ OM Strategy & Issues
Strategy & Issues During Product Life
¨ Sensitive to Changes in price or quality
¨ Marketing is critical¨ Strengthen niche
Growth
• Company Strategy & Issues
¨ OM Strategy & Issues
¨ Forecasting is critical¨ Product and process reliability¨ Competitive product improvements
and options¨ Enhance distribution
Strategy & Issues During Product Life
¨ Poor time to increase market share¨ Competitive costs become critical¨ Usually poor time to change quality or
price¨ Defend position via fresh promotional and
distribution approaches
Maturity
• Company Strategy & Issues
¨ OM Strategy & Issues
¨ Standardization - Increasing stability of manufacturing process
¨ Less rapid product changes and more minor annual model changes
¨ Optimum capacity¨ Long production runs¨ Re-examination of necessity of design
changes
Strategy & Issues During Product Life
¨ Cost control critical to market share
Decline
• Company Strategy & Issues
¨ OM Strategy & Issues
¨ Little product differentiation¨ Cost minimization¨ Overcapacity in the industry¨ Prune line to eliminate items not
returning a good margin¨ Reduce capacity
Process Life Cycle and Selection of Appropriate Technology
• Process technologies have life cycles similar to product life cycle
• Types of manufacturing technologies changes in its life cycle because of change in volume, process innovation, and automation
• Manufacturing process technology begin from job shop at start up and moves towards the continuous process technology.
• Volume and standardization are low in initial stages of life cycle making unit manufacturing cost higher
• High volume is produced and process are standardized during last stages of life cycle making unit cost lower
Chapter 2 Manufacturing Environment 16
Manufacturing Process Flow Design
• It is a method to evaluate the specific processes that raw materials, parts, and subassemblies follow as they move through the plant.
• A good way to start analyzing a process is with a diagram showing the basic elements of a process.
17Chapter 2 Manufacturing Environment
3 Process Selection 18
Types of Production Process
• Job shop• Batch production• Assembly line• Continuous production• Project production
Job Shop• A process technology suitable for a variety of
custom-designed products in small volumes• Customer and producer work on pre-decided
parameters in terms of specifications and costs of the products
• Example: Tailoring shops, printing shops, building contractors, etc.
3 Process Selection 19
…Job Shop• Characteristics
– Each product uses only a small portion of the shop’s human resources and general purpose equipment
– With large number of diverse jobs, elaborate job-tracking and control systems are used
– Much time is spent waiting for access to equipment
– Some equipment is overloaded while other is idle– Cost of production is not very competitive
3 Process Selection 20
Batch Production• A process technology suitable for a variety of
products in varying volumes
• Settings are frequently changed and form a formidable part of cycle time to producer
• Example: Pharmaceutical companies, paint manufacturing companies, steel pressed parts
3 Process Selection 21
…Batch Production• Characteristics
– Cost of infrastructure is high– General purpose machines and material handling
equipment are procured– Material handling and storage is immense– Heavy cost in terms of input materials that needs
to be stored to facilitate at short notice– Skilled and unskilled labor is required– Main consideration for management are: minimum
idle time, minimum in process inventory, perfect coordination between various production shops.
3 Process Selection 22
Assembly Line• Assembly Line: Specialized
equipments, skilled manpower are used and developed to produce limited range and high volume of products such as Automobile manufacturer
Chapter 2 Manufacturing Environment 23
Continuous Flow• Conversion or further processing of
undifferentiated materials such
• Example– Chemical manufacturer
Chapter 2 Manufacturing Environment 24
Product Process Matrix
• IV.• Continuous
• Flow
• III.• Assembly
• Line
• II.• Batch
• I.• Job
• Shop
• Low• Volume,• One of a
• Kind
• Multiple• Products,
• Low• Volume
• Few• Major
• Products,• Higher• Volume
• High• Volume,
• High• Standard-
• ization• Commerci
al• Printe
r• Frenc
h Restaurant
• Heavy• Equipment• Automobile
• Assembly• Burger King
• Sugar• Refinery
• Flexibility (High)• Unit Cost (High)
• Flexibility (Low)• Unit Cost (Low)
• These are the major stages of product and process life cycles
None feasible
None feasible
25Chapter 2 Manufacturing Environment
Product-Process Matrix• Representative industries are listed on the
diagonal of the matrix• Void corners represent incompatible product-
process combinations• Manufacturing flexibility and quality are
competitive priorities in earlier stages, priorities shift toward dependable and competitive cost in later stages
3 Process Selection 26
Product Process Matrix• Product process matrix helps us understand why
and how companies change their production operations
• As products, market requirement, and competition change, so must equipment, procedures, and human resources
• If process changes are not made to accommodate product life cycles, the result is competitive disadvantage
3 Process Selection 27
Process• A process is a sequence of activities that is intended to achieve some result
to create some added value for the customers.
• A process that does not meet the needs of the firm will punish the firm every minute.
• Objective– Meet or exceed customer requirements– Meet cost & managerial goals
• Has long-run effects– Production efficiency– Product & volume flexibility– Cost & quality
Chapter 2 Manufacturing Environment 28
Types of Processes• Conversion (ex. Iron ore into steel
sheets)
• Fabrication : Changing materials into specific form(ex. Forming gold into a crown for tooth)
• Assembly: Assembling parts into components (ex. The production process in a modern car plant)
• Testing :Not fundamental process, but acted as a stand–alone major activity (ex. quality of products)
29Chapter 2 Manufacturing Environment
Symbols for Process Design
• O: Operations
• Ð: Transportations
• : Inspection
• Ⅾ: Delay
• : Storage30Chapter 2 Manufacturing Environment
Tools• Assembly drawing: exploded view of
product showing its components• Assembly chart: Information presented
in the assembly drawing about order and flow pattern
• Route sheet: Specifies operations and process routing for a particular part
• Process flow chart: A graphic tool used to analyze and classify the inter-departmental activities. It is useful in visualization of all operations of operations. It divides activities into five categories: Operations, transportation, storage, inspection, delay.
31Chapter 2 Manufacturing Environment
Assembly Chart: Setting up Fan
• A-1• SA-1
• 1
• 2
• 3
• 4
• Frame
• Mount switch
• Motor housing
• Blade
• A-6• Component/Assembling Operation
• Inspection32Chapter 2 Manufacturing Environment
Process Flow ChartMaterial Received from Supplier
Inspect Material for Defects
Defects found?
Return to Supplier for Credit
Yes
No, Continue…
33Chapter 2 Manufacturing Environment
top related