product reliability update

8/14/2019 Product Reliability Update

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Product: A product is anything that is capable of satisfying

A felt need. A new product is the one which is truly innovative

and is significantly different from other existing products.

The development of a new product passess through SEVEN

stages.

NEW PRODUCT DESIGN/ PRODUCT

DEVELOPMENT PRCESS

Needsidentification

AdvanceProduct planning

Advancedesign

Detailed engineeringdesign

Prodn. ProcessDesign and

development

Product evaluation

& improvement

Product use

& support


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1. Needs Identification:Needs identification must be preceded by idea generation. New

product

Development starts with an idea. Idea emanates from

CustomersTop Management Staff of the marketing department Production deptt.

Engineering section2. Advance Product Planning or feasibility study:At this stage conceptual design of the product shall emerge. For

Example the Conceptual design for a pen would articulate its

length, Weight, strength, shape, colour, retail price and so on.in the market.

Concept design is finalised by the production and operation

Personnel, joining together.


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It includes:

preliminary market analysis ( sales projections)Crating alternative concepts for the product

Clarifying operational requirementsEstablishing design criteria and their prioritiesEstimating logisticsDistributing and maintaining the product

3. Advance Design

It involves detailed investigation by basic and applied researchers

Into technical feasibility and also identifying the trade-offs in

Product design.

4. Detailed Engineering Design

It involves a seroes pf emgomeeromg actovotoes tp develop a

Detailed definition of the product including its subsystems and

Components, materials, sizes and so on.


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The engineering process involves analysis, experimentation and

Data collection to find design that meet several design objectives:

design for function

design for reliability design for maintained (economically maintained) design for safety design for producibility (produced at the intended cost & volu

9. Production Process Design and DevelopmentIn this stage it is not only plans for material acquisition, production

Warehousing,transportation and distribution but also it involves

Planning for other supporting systems such as controls, informatio

And human resources.

6. Production Evaluation & ImprovementAfter the product has been launched, it needs constant evaluation

And improvement.


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7. Product use and SupportIn this stage it considers support for consumers who use the

Product. Support system might

Educate users on specific application of the product Provide warranty and repair services Distribute replacement parts or Upgrade the product with design improvements


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Since every product passes through a life cycle and the life cycle

Can have a direct bearing on a companys survival.

Product Life Cycle:Product life cycle is the pattern of demand throughout the

Products life ( over time).

(similar patterns and stages can identified for the useful life

of a process)

The life cycle of a product consists of four stages:

Introduction Growth

Maturity and Decline

The life cycle curve shows all the above stages are shown below:


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Demand/Sales volume(Rs.)

O lossTime in Year

Profit

Introduction

Growth

Maturity

Decline

Fig. Characteristic of the Product Life Cycle


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Low/noneDecliningannually

Strong,then

At a peak

NoneProfits

DeclineSlow, noannualgrowth

Raidgrowth

Low levels,

Then rising

Sales

DecreasingIntenseIncreasingLitter, if anyCompetition

Loyalcustomers

Massmarket

Massmarket

InnovatorsCharacteristicsof Customers

DeclineMaturityGrowthIntroduction

Table: Characteristics of Stage in Product Life Cycle


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PROCESS DESIGN

Process design means the complete delineation and description

of specific steps in the production process and the linkages among

the steps that will enable the production system to produce

products of the desired quality, in the required quantity, at the

time, customers want them and at the budgeted cost.

Process design is necessary to manufacture new products.

Process planning is intense because-

Business or market conditions change Technologically superior machines become available or As other changes occur


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Interrelationship of Product Design and Process

Design

Product Ideas

Feasibility Studies

Product Design Process Design

Advanced Product PlanningAdvance DesignProduction Process Design

& DevelopmentProduct Evaluation &

ImprovementProduct Use and Support

Organising the process flowsRelation of process design

to process flowEvaluating the process

design

Continuous interaction

Produce and market new products


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PRODUCT RELIABILITY

Product reliability as the probability that the product will

perform as intended for a prescribed lifetime under specifiedoperating conditions.

Reliability is the first, ahead of comfort, price, style and many

other product features.

Unreliability is reflected in the products failure rate. This is

shown in the following curve.


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Reliability Engineering determines the least height (failure rate)

and greatest length (useful performance life) for each new product

based on

Financial Technical and Consumer considerations

What reliability is required of each subcomponent to achieve theoverall product reliability ?

Which subcomponents should be used to most economically

meet this required reliability ?

The above two questions are quite relevant because often a final

product does not perform properly unless all of its subcomponents

function correctly.


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Therefore, the reliabilities of individual subcomponents mustbe greater than the reliability desired for the final product.

Product reliability is usually expressed in terms of a probability.Once reliability has been achieved subcomponents can be selectedon the basis of economic considerations.

Useful performance life Wear-out failuresInitialUsefailures

Failurerate

Fig. Product Failure curve


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Process Technology/Manufacturing Process TechnologyNew Products are not physical realities until they are

manufactured.

Process Technology(PT):

PT refers to the equipment, people, and systems used to produce

a firms products and services

Process technology decisions relate to

Organizing the process flows, Appropriate product-process mix,

To meet strategic requirements, and Evaluating automation and high technology process.


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Types of Process Technology

ProcessTechnology

Project

Technology

Job shop

Batch

Assembly line

Continuous

Manufacturing


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Project Technology:A process technology suitable for producing one-of-a-kind (unique

products.

e.g. General construction company (Flat for the consumers),

Construction of bridges, roads, dams etc.

Since the products cannot be standardized the conversion processmust be flexible in its equipment capabilities, human skills, and

procedures.

Conversion Process features

Problem solving Teamwork and co-ordinated design and Production of unique products


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Job shop Technology:A process technology suitable for a variety of custom designed

products in small volumes.

(It is appropriate for manufacturers of small batches of manydifferent products)

e.g. Jobs done by a Printing Shop, Hospital, Machine shop,

furniture company etc.

Batch Technology:

A process technology suitable for a variety of products in varying

volumes.

For the batch facilities the system must be flexible for the

low-volume/high variety products but the higher volume productscan be process differently.

e.g. Producing some batches for stocking rather than for

customer order.


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Assembly Line:A process technology suitable for a narrow range of standardized

products in high volumes.

e.g. Laundry Appliances

Continuous Flow Technology:

A process technology suitable for producing a continuous flow of

products.

Material and products are produced in continuous, endless flow,rather than in batches or discrete units.

Products is highly standardised It affords high-volume, around the clock operation with

capital-intensive

Specialised automation.e.g. Postal Services, Telephone company, Oil Refinery etc.


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So there are 36 (3x2x2x3) different computer systems from whichto choose.The modular design concept gives consumers a range of product

options and and advantages in manufacturing and product design.Now, rather than storing inventories of all 36 fininshed computersystems, only some of which will be needed we insteasd store just

the subsystems or modules.Thus, when a particular computer system is demanded the producercan focus on quickly retrieving and assembling the appropriatemodules into the desired configuratios and avoid the high costsof idle finished goods inventories.

Material planning and inventory control can be simplified


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PROCESS TECHNOLOGY LIFE CYCLE

Process technology life cycle are related product life cycles.

Over a period of time, manufacturing cost per unit diminishes in

mature products.

Product life cycle starts from the stage of start up and ends in the

stage of decline.

The through-put volume, rates of process innovation and degree

of automation will change from the stage of start-up to the stage

of decline.

Through-put volumes and automation are low at start-up and

high during the maturity stage.


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Assembly line

Continuousflow

Batch

JobshopManufacturing

Cost/unit

Time

Fig. Process Life Cycle

P d P Mi


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Product Process Mix

With changes in products, market requirements and competitions,the equipments, processes and human resources also will change.

If the process changes are not carried out to accommodate process life

cycles, products and processes become incompatible, resulting incompetitive disadvantages.

P d t P Mi


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4. Commodity,

high volume, highstandardisation ofproducts

3.Maturity, fewmajor products,high volume

2. Rapid growth,

low volume,multiple products

1.low volume

& lowstandardisation

Process life

Cycle stages

4. Continuousflow prodn.

3. Assemblyline prodn.

2. Batchprodn.

1.Job shopprodn.

Product Process Mix

Product Life Cycle stages

A

B

C

D

Feasible zone

Void

Void

A Commercial printer, B Heavy machineryC Automobile assembly, D Sugar Mill

h l d


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Process Technology Trends

Flexible Manufacturing Systems (FMS)

FMS is a computer controlled process technology suitable forProducing a moderate variety of products in moderate volumesWith high quality.

e.g. once the machine has finished one batch, th computer signalsThe next quantity or component and the machine automaticallyRepositions and retools accordingly. Meanwhile the just-finishedBatch is automatically transferred to the next work station in itsRouting.


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Characteristics of an FMS Produce a moderate variety of products in modest volumes with

high quality Reduces operating costs Lower direct labor costs Lower manufacturing costs

The benefits are not free. An FMS requires very large capital

Investments in equipment, planning and control systems and humanResources.

An FMS is appropriate when:

13. All products are variation of a stable basic design14. All products utilize the same family of components15. The number of components is only moderate (10 to 50)16. The volume of each component is moderate (1,000 to 30,000 units

but in lot sizes as small as one unit


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Goal of an FMS

The goal is to produce a moderate variety of products in moderate,

Flexible quantities.

An FMS is more flexible than conventional high-volume productionSystem but less flexible than a job shop that specialises in

one-of-a-kind products.


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Computer-integrated manufacturing functions

Manufacturingdatabase

InformationMgmt.

ManufacturingEngg.

Engg. design

Factory

Prodn.

Computer-AidedManufacturing

Group

Technology

ProcessPlanning

Robotics

Physical Drafting Computer-aidedsystems design

designDatabaseMgmt.

Prodn.Planning& control

Mgmt.InformationSystem

Decision

Supportsystem

Automated Quality Robotics Distributed RoutineMaterial Assurance & machines numerical Manufacturing

Handling tools control


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Computer Integrated Manufacturing (CIM)

CIM is a computer information systems utilizing a shared

manufacturing database for engineering design, manufacturing,engineering, factory production, and information management.

CIM centers around a shared database for four primarymanufacturing functions: Engineering design Manufacturing design Factory production and Information Management

The database stores all product and process related informationrequired to produce a component or product. It containsinformation about machine, tools, materials, manufacturing

stepsquantities demanded, due dates and vendors.

C Aid d D i (CAD)


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Computer-Aided Design (CAD)

CAD is a computer software programs that allow a designer to carry outGeometric transformations rapidly.

CAD uses computational and graphics software and has substantiallyenhanced design productivity.

Alternative designs can be posed and evaluated more quickly.

Once a design is satisfactory it is stored in the database and can betransmitted electronically to manufacturing engineering, production

and purchasing.

What does CAD accomplish ?Drafting productivity improves by a factor of three or more andEngineering lead time shrinks.

C t id d M f t i (CAM)


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Computer-aided Manufacturing (CAM)

CAM is a manufacturing systems utilising computer software progr

That control of the actual machine on the shop floor.

The computer programs can be stored in the manufacturing databas

Retrieved, updated, and revised as components are added or redesig

And transmitted electronically in-house or externally by satellite to

other divisions and facilities.

Benefits of CAM

More reliable than the skilled operator

product quality is more consistent closer tolerance low labor cost less time is required

Too much CAM can be costly as suggested by Aerospace manufactuDue to error in com uter ro ram.

Gro p Technolog


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Group Technology

GT is way of organising and using data for components that haveSimilar properties and manufacturing requirements.

Characteristics such as Length, Diameter, type of material andDensity are recorded for each component in the manufacturing system.The computer then sort for all similar components.


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Design of Services and Service Processes

Today the idea is that everything sold falls somewhere on the

continuum or service/product dominance.

To be competitive organisation have to organise differences

in the product/service elements of their market offerings and

develop process technologies accordingly.

Design of Services

Design of services involves the same stages as the design of

Products.

Differences between Product and Service DesignServices that do not include a physical component do not require

the Engg., Testing, components analyses, the process technology

involves different issues and considerations than those of

products

N i


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Salt

Dog food

HouseAutomobiles

Fast food shop

Television

Air-travel

TheaterNursing

ProductDominantentities

Service dominant

entities

Balanced entityEqually weightedBetween productAnd services

Fig. Scale of service Vs. product dominance


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Services Process Technologies

Process technologies for services are at least as diverse, and perhaps

More so, than product process technologies. Services vary in theamount of customer contact and in the intensiveness of labor Vs.Capital. Service process technologies vary accordingly.

Trends in Service AutomationOffice automation (OA) is a computer based system for managinginformation resources.Word processing, generating reports, and handling data may all be

part of OA.e.g. automated banking, electronic grocery scanners, and the like.

Val e Engineering/ Val e Anal sis


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Value Engineering/ Value Analysis

It is one of the techniques of cost reduction and cost prevention.It ensures the necessary function at minimum cost withoutcompromising on quality, reliability, performance and appearance.

The system which developed as a result of a project led by L.D.Milesof the GEC of the U.S.in the year 1947, after five years of work and

an expenditure of $3 millions and which aimed at finding the mosteffective method of improving the value of the product is known asValue Analysis (VA).

e.g. use of asbestos required for flooring

In 1954, the US Navy Bureau of ships applied VA to cost improve-ment during the design stage and termed it as Value Engineering (VE).


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In India, the Indian Value Engineering Society (INVEST) was formedin 1977. Now it is applied in both public and private sectors industriesin India.

When to apply Value Analysis ?

Companys product show decline in sales Companys prices are higher than those of its competitors

Raw materials cost has gone up suddenly New designs are being introduced the cost of manufacturing is rising disproportionate to the volume

of production

Rate of return on investment has a falling trend unable to meet its delivery commitments

V l A l i V V l E i i


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Value Analyis Vs. Value Engineering

VA VA is the application of a set of techniques to an existing productWith a view to improving its value. It is a remedial process.

VE It is the application of exactly the same set of techniques to a newProduct at the design stage, project concept when no hardware existsTo ensure that bad features are not added. It is a preventive process.

Aims/Objectives:

Simplify the product

Use cheaper and netter materials Modify and improve product design use efficient processes. Reduce the product cost. Increase the utility of the product by economical means

Save money or increase the profits

V l E i i P d


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Value Engineering Procedure

The steps of VE are :

5. Blast (I) identify the product(ii) collect relevant information(iii) define different functions

8. Create (iv) Different alternatives

(v) critically evaluate the alternative10. Refine (vi) develop the best alternative

(vii) Implement the best alternative

VE should be done with brain stormingsessionsPrinciples of Brain Storming

1. A quality idea comes from quantity of ideas


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1. Creative ideas emerge from unconventional thinking2. Spontaneous evaluation of ideas affects imaginative thinking and

retards the flow of creative ideas.

4. Hitch-hiking on the ideas often lead to better ideas5. Creeativity is a regenerative process and the recording of ideas asthey emerge help to generate more ideas

7. When ideas cease to flow, short diversions enable the mind torebound with new ideas

Advantages: It is a much faster cost reduction technique It is a less expensive technique

It reduces prodn. Costs and adds value to sales income of theproductApplications-Machine tool industries, Auto industries, import substitutes etc.

Standardisation


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Standardisation

Standardisation is the process of establishing standards or units ofMeasure by which quality, quantity, value, performance etc. may beCompared and measured.

Standardisation Procedure:Steps-

9. With the help of market research, sales statistics etc. determinewhat is tobe sold in future

11. Define a range of products12. From the range of products, select the minimum variety of

components matching the range for manufacturingAn approach to standardisation necessitates the classification ofMaterials and componentsA system ofclassification and codification is necessary for the designOf new products within the defined range.


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Advantages of Standardisation:

Fewer specifications

Better quality products Increased margin of profit Easy availability of spares Minimum inventory cost Quantity discount are possible due to purchase of large volume of

materials

Applications-

Finished products, e.g. cars and T.Vs. Sub assemblies and components e.g. automobile gearboxes Material e.g direct materials (plain carbon and alloy steels etc.) Production equipments e.g. machine tools, press, welding equipment

etc.

Make or Buy Decisions


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Make or Buy Decisions

A company can satisfy the customers wither by making the requiredProducts using the facilities which are available within the company

Or buying them from a subcontractor.Criteria for Make or Buy Criteria for Make:

1. Finished product can be made cheaper by the firm than

outside suppliers2. Finished product is being manufactured by the firm becauseother firms are unable so meet the demand3. For maintaining quality control etc.

Criteria for Buy:1. High investment is required2. The company does not have facilities to make3. Non-availability of skilled personnel4. Patent or other legal barriers

5. Demand for the product is either temporary or seasonal

Approaches for Make or Buy Decisions


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Approaches for Make or Buy Decisions

3. Cost analysis4. Economic analysis5. Break-even analyis

7. Cost AnalysisIn this case cost of making a product and that of buying a product

Are calculated. Then, the alternative which involves the minimum costIs suggested for implementation.

12. Economic Analysis

Inventory models are considered for economic analysis of make orBuy of a product. The inventory models are: Purchase Model Manufacturing Model

Th f l f l l i E i O d Q i (EOQ) d


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The formula for calculating Economic Order Quantity(EOQ) andTotal cost (TC) of each model are as follows:

Purchase Model Manufacturing Model

Q1 = (2C0D/Cc ) Q2 = [2SD/Cc(1-D/R)]

TC = DP + (DC0/ Q1) + (Q1x Cc)/2 TC = DP + (DS/ Q2 ) + Cc (R-D) Q2/2R

Where,D demand/year, P Purchase price/unit

Cc carrying cost/unit/year, C0 - Ordering cost/order

S Setup cost/setup, R Production rate (units/year)Q1Economic Order Quantity, Q2 Economic Production size

Break even Analysis


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Break-even AnalysisFor any organisation, for manufacturing a product it has to incur totalCost. Total cost is comprise of fixed cost (FC) and variable cost (VC).Fixed cost is independent of production volume(output) whereas,The variable cost is a function of the production volume of the product.Break-even Point The point at which TC is equal to the TR or salesRevenue. At this point there is no loss or gain to the organisation.This is analysis is known as Break-even analysis.

BEP = FC / (Selling price per unit Variable cost per unit)

Sales

TC

VC

FC

C

BA

Costs

Unit of sales per periodO

Profit

Loss


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