Description
This is a presentation describes the various processes for product design.It covers sequential design,product design and development,PLC etc.
PRODUCT DESIGN PROCESS SELECTION - Manufacturing
Structuring Operations
How do you structure your entire Operations ?
– No of Plants / Facilities – Plant/ Facility Sizes & their locations – Capacity of Plants – Choice of Equipment – Process Design / Technology – Work Force Measurement
Structuring Operations (Contd.)
• Process Planning forms the basis for » Plant Layout. » Selection of Equipment , M/Cs.
• Choice of Process Design decides Operation Strategy – e.g. Small Economic Batches, Make to order, Product Flexibility.
• Process Design and Product Design are Mutually compatible.
Factors affecting Process Design Decision
1. Nature of Demand » PV Relationship 2. Degree of Vertical Integration » More integration ? Risk of Capital Expense 3. Flexibility
– – Product Flexibility Volume Flexibility
(Multi Skills Labour, Quick change-over)
4. Degree of Automation.
Reasons For Product or Service Design
• Market opportunities and threats • Following changes gives rise to market opportunities and threats
– – – – – – Economic Social and demographic Political, liability, or legal Competitive Cost or availability Technological
ICFAI BUSINESS SCHOOL, MUMBAI
Strategic Importance
• Products & service offerings must support the company’s business strategy by satisfying the target customers’ needs & preferences • If not, the company will lose its customer base and its market position will erode
ICFAI BUSINESS SCHOOL, MUMBAI
Product Idea Mortality Curve
PRODUCT DESIGN
• Product Design is a Team Exercise, involving : Marketing Manufacturing R&D, Finance Sales, Purchase
ICFAI BUSINESS SCHOOL, MUMBAI
Sequential Design
ICFAI BUSINESS SCHOOL, MUMBAI
Phases in Product Design and Development
1. 2. 3. 4. 5. 6. 7. 8. 9. Idea generation Feasibility analysis Product specifications Process specifications Prototype development Design review Market test Product introduction Follow-up evaluation
ICFAI BUSINESS SCHOOL, MUMBAI
Product Life Cycle
• Concurrent Engineering Approach • Cross Functional Teams
ICFAI BUSINESS SCHOOL, MUMBAI
Stages in a Product’s Life Cycle
• Introduction- Sales begin, production and marketing are developing, profits are negative. • Growth - sales grow dramatically, marketing efforts intensify, capacity is expanded, profits begin. • Maturity - production focuses on high-volume, efficiency, low costs; marketing focuses on competitive sales promotion; profits are at peak. • Decline - declining sales and profit; product might be dropped or replaced.
Mfg Processes at diff. Stages of PLC
Product Focused To stock ( Batch) Process focused to Order ( Batch) Product Focused To Stock (Continuous)
Process focused to Order ( job Shop)
Stages of a Product’s Life Cycle
Automobile
Cell Phone
Color Laser Printer Color Copier
Video Recorder Compact Disc Player Fax Machine
B&W TV
Introduction
Growth
Maturity
Decline
Injecting New Blood
Design Concepts
• Design for Manufacturing (DFM) Product design & Process Design are the key product cost drivers Hence, take mfg process into account during DESIGN stage only. Design for Logistics (DFL) Product & Process Design approaches must help to control logistics cost and increase customer service levels.
•
•
How to make DFL ? Economic Packaging & Transportation ( IKEA furniture – DIY )
Concurrent & Parallel Processing: Components of Assy. Product to be physically separated for manufacturing parallely Standardization: Better forecasts possible for product family (rather than style). Hence standardize on product or process Design
How to shorten INTRODUCTION phase?
• Concurrent Engg. (CE)
• Cross Functional Teams (CFT) - Simultaneously developing Market concept,
Product Design, Mfg. Process & Product Support Structure.
The Learning Curve Effect
100
Cost/Time per repetition
90 80 70 60 50 40 30 20 10 0 20 40 60 80 100 Number of repetitions (Volume) Cost
Types of Processes
• Conversion Iron ore + coal etc ? Ingredient ? • Fabrication Sheet metal Gold ? ? Steel Tooth Paste
Component Tooth Crown
• Assembly Different components ?
Car
• Testing Not a fundamental process, But as a stand alone activity
IMP. DOCUMENTS IN PRODUCT / PROCESS DESIGNS.
1.
2.
3.
DRAWINGS & SPECS.
BILL OF MATERIAL (BOM)
PROCESS CHART
Operations Sequence
Desig n
Fabricat Procure e
SubFinal assembl assembl e e
Test
Stock as Pack & Inventory Ship
Manufacturing Environments
» Make to Stock ( MTS ) » Assemble to Order ( ATO) » Make to Order ( MTO ) » Engineered to Order ( ETO )
Make to Stock ( MTS ) Environment
Design
Procure
Fabricate
Subassemble
Final assemble
Test
Stock as Inventory
Pack & Ship
L.T.
Customer doesn’t have to wait He has a choice to select/ reject FG manufactured before Customer Order Hence “ Pushing the Sale “ philosophy
Assemble to Order ( ATO ) Environment
Design (Modular Product)
Procure
Fabricate
Subassemble
Stock Std. Modules as Inventory
Assemble as per Customer Selected Modules
Test
Pack & Ship
L. T. Key components are planned & stocked in anticipation of Customer Order CODP ignites the assembly of Customized Product
Make to Order ( MTO ) Environment
Design
Stock component Design & Standards Parts
(Customer design, if required) Procedure (Componen ts & RM)
Fabricate
Subassemble
Final assemble
Test
Pack & Ship
L. T. Goods & Services to be manufactured after receipt of customer order Adv. – Customer gets more options , Manufacturer curtails inventory
Engineered to Order (ETO) Environment
Unique Design or significant customization)
Procure – Raw Mat, Std. Compnt etc.
Fabricate
Subassemble
Final assemble
Test
Pack & Ship
L. T.
Highly customer focused environment requiring Unique Design, Significant Customization
Types of Process Designs
• Product focused • Process Focused • Group Technology / Cellular Manufacture
Types of Process Design (Contd.)
Product focused Design
• Discrete Unit Manufacture : TV, Fridge • Process Industry: Cement, Paper, Steel. • Delivery of Services : Waiter in Restaurant
?Advantage: Low Unit Cost. Production.
High Volume
Types of Process Design (Contd.)
Process focused Design
( Car Paint Shop, Fee Collection Centre)
• For small batches of variety of products • G P M Set-up • Requires more Skilled Labor • Zig-Zag movement of product
Types of Process Design (Contd.)
Group Technology / Cellular Manufacture
• Consists of Cells. • Cell is the smallest work centre. • Each cell produces a limited range of products. • A Cell consists of dissimilar machines. • A Cell produces products / parts of similar characteristics.
Process Flow Structures
• Project. • Job Shop.
• Batch.
• Assembly Line. • Continuous Flow.
Process Flow Structures (Contd.)
Project
• Unique.
• Large-size. • Time Limit. • Interdependent Activities -PERT/CPM ( Road, Bridge, Dam, New Business Set-up)
Process Flow Structures (Contd.)
Job Shop.
• One time job.
• Small-size. • Time limit. • Every time fresh marketing, – So also Fabrication, Printing, Design, PCB .
Process Flow Structures (Contd.)
Batch Production
• Standardized & Relatively stable products, Multiple products from one shop
• Production capacity greater than demand.
• Suitable for high product variety & low volume • Flexibility more important than efficiency. • General purpose M/Cs used.
Process Flow Structures (Contd.)
Batch (Contd.)
• Disadvantages:
– Expensive – if volume is too large – Planning & Control – Complex. – Some idling of Resources. – Large W.I.P.
Process Flow Structures (Contd.)
Assembly Line
• Discrete part moving from worker to workers • Constantly Moving Conveyor. • Line Balancing, Low Skills, Low Unit Cost, • Managerial Control – Simple • Maintenance-Difficult & Complex .
Process Flow Structures (Contd.)
Assembly Line (Contd.) • Disadvantages1. Repetitive/Monotonous.
2. If breakdown – Total stoppage of work.
3. Bottleneck operation determines capacity.
4. Obsolescence cost becomes heavy.
Service Design
• Service is an act, created and delivered simultaneously • Service delivery system includes
– Facilities
– Processes – Skills
• Many services are bundled with products
ICFAI BUSINESS SCHOOL, MUMBAI
doc_446982681.ppt
This is a presentation describes the various processes for product design.It covers sequential design,product design and development,PLC etc.
PRODUCT DESIGN PROCESS SELECTION - Manufacturing
Structuring Operations
How do you structure your entire Operations ?
– No of Plants / Facilities – Plant/ Facility Sizes & their locations – Capacity of Plants – Choice of Equipment – Process Design / Technology – Work Force Measurement
Structuring Operations (Contd.)
• Process Planning forms the basis for » Plant Layout. » Selection of Equipment , M/Cs.
• Choice of Process Design decides Operation Strategy – e.g. Small Economic Batches, Make to order, Product Flexibility.
• Process Design and Product Design are Mutually compatible.
Factors affecting Process Design Decision
1. Nature of Demand » PV Relationship 2. Degree of Vertical Integration » More integration ? Risk of Capital Expense 3. Flexibility
– – Product Flexibility Volume Flexibility
(Multi Skills Labour, Quick change-over)
4. Degree of Automation.
Reasons For Product or Service Design
• Market opportunities and threats • Following changes gives rise to market opportunities and threats
– – – – – – Economic Social and demographic Political, liability, or legal Competitive Cost or availability Technological
ICFAI BUSINESS SCHOOL, MUMBAI
Strategic Importance
• Products & service offerings must support the company’s business strategy by satisfying the target customers’ needs & preferences • If not, the company will lose its customer base and its market position will erode
ICFAI BUSINESS SCHOOL, MUMBAI
Product Idea Mortality Curve
PRODUCT DESIGN
• Product Design is a Team Exercise, involving : Marketing Manufacturing R&D, Finance Sales, Purchase
ICFAI BUSINESS SCHOOL, MUMBAI
Sequential Design
ICFAI BUSINESS SCHOOL, MUMBAI
Phases in Product Design and Development
1. 2. 3. 4. 5. 6. 7. 8. 9. Idea generation Feasibility analysis Product specifications Process specifications Prototype development Design review Market test Product introduction Follow-up evaluation
ICFAI BUSINESS SCHOOL, MUMBAI
Product Life Cycle
• Concurrent Engineering Approach • Cross Functional Teams
ICFAI BUSINESS SCHOOL, MUMBAI
Stages in a Product’s Life Cycle
• Introduction- Sales begin, production and marketing are developing, profits are negative. • Growth - sales grow dramatically, marketing efforts intensify, capacity is expanded, profits begin. • Maturity - production focuses on high-volume, efficiency, low costs; marketing focuses on competitive sales promotion; profits are at peak. • Decline - declining sales and profit; product might be dropped or replaced.
Mfg Processes at diff. Stages of PLC
Product Focused To stock ( Batch) Process focused to Order ( Batch) Product Focused To Stock (Continuous)
Process focused to Order ( job Shop)
Stages of a Product’s Life Cycle
Automobile
Cell Phone
Color Laser Printer Color Copier
Video Recorder Compact Disc Player Fax Machine
B&W TV
Introduction
Growth
Maturity
Decline
Injecting New Blood
Design Concepts
• Design for Manufacturing (DFM) Product design & Process Design are the key product cost drivers Hence, take mfg process into account during DESIGN stage only. Design for Logistics (DFL) Product & Process Design approaches must help to control logistics cost and increase customer service levels.
•
•
How to make DFL ? Economic Packaging & Transportation ( IKEA furniture – DIY )
Concurrent & Parallel Processing: Components of Assy. Product to be physically separated for manufacturing parallely Standardization: Better forecasts possible for product family (rather than style). Hence standardize on product or process Design
How to shorten INTRODUCTION phase?
• Concurrent Engg. (CE)
• Cross Functional Teams (CFT) - Simultaneously developing Market concept,
Product Design, Mfg. Process & Product Support Structure.
The Learning Curve Effect
100
Cost/Time per repetition
90 80 70 60 50 40 30 20 10 0 20 40 60 80 100 Number of repetitions (Volume) Cost
Types of Processes
• Conversion Iron ore + coal etc ? Ingredient ? • Fabrication Sheet metal Gold ? ? Steel Tooth Paste
Component Tooth Crown
• Assembly Different components ?
Car
• Testing Not a fundamental process, But as a stand alone activity
IMP. DOCUMENTS IN PRODUCT / PROCESS DESIGNS.
1.
2.
3.
DRAWINGS & SPECS.
BILL OF MATERIAL (BOM)
PROCESS CHART
Operations Sequence
Desig n
Fabricat Procure e
SubFinal assembl assembl e e
Test
Stock as Pack & Inventory Ship
Manufacturing Environments
» Make to Stock ( MTS ) » Assemble to Order ( ATO) » Make to Order ( MTO ) » Engineered to Order ( ETO )
Make to Stock ( MTS ) Environment
Design
Procure
Fabricate
Subassemble
Final assemble
Test
Stock as Inventory
Pack & Ship
L.T.
Customer doesn’t have to wait He has a choice to select/ reject FG manufactured before Customer Order Hence “ Pushing the Sale “ philosophy
Assemble to Order ( ATO ) Environment
Design (Modular Product)
Procure
Fabricate
Subassemble
Stock Std. Modules as Inventory
Assemble as per Customer Selected Modules
Test
Pack & Ship
L. T. Key components are planned & stocked in anticipation of Customer Order CODP ignites the assembly of Customized Product
Make to Order ( MTO ) Environment
Design
Stock component Design & Standards Parts
(Customer design, if required) Procedure (Componen ts & RM)
Fabricate
Subassemble
Final assemble
Test
Pack & Ship
L. T. Goods & Services to be manufactured after receipt of customer order Adv. – Customer gets more options , Manufacturer curtails inventory
Engineered to Order (ETO) Environment
Unique Design or significant customization)
Procure – Raw Mat, Std. Compnt etc.
Fabricate
Subassemble
Final assemble
Test
Pack & Ship
L. T.
Highly customer focused environment requiring Unique Design, Significant Customization
Types of Process Designs
• Product focused • Process Focused • Group Technology / Cellular Manufacture
Types of Process Design (Contd.)
Product focused Design
• Discrete Unit Manufacture : TV, Fridge • Process Industry: Cement, Paper, Steel. • Delivery of Services : Waiter in Restaurant
?Advantage: Low Unit Cost. Production.
High Volume
Types of Process Design (Contd.)
Process focused Design
( Car Paint Shop, Fee Collection Centre)
• For small batches of variety of products • G P M Set-up • Requires more Skilled Labor • Zig-Zag movement of product
Types of Process Design (Contd.)
Group Technology / Cellular Manufacture
• Consists of Cells. • Cell is the smallest work centre. • Each cell produces a limited range of products. • A Cell consists of dissimilar machines. • A Cell produces products / parts of similar characteristics.
Process Flow Structures
• Project. • Job Shop.
• Batch.
• Assembly Line. • Continuous Flow.
Process Flow Structures (Contd.)
Project
• Unique.
• Large-size. • Time Limit. • Interdependent Activities -PERT/CPM ( Road, Bridge, Dam, New Business Set-up)
Process Flow Structures (Contd.)
Job Shop.
• One time job.
• Small-size. • Time limit. • Every time fresh marketing, – So also Fabrication, Printing, Design, PCB .
Process Flow Structures (Contd.)
Batch Production
• Standardized & Relatively stable products, Multiple products from one shop
• Production capacity greater than demand.
• Suitable for high product variety & low volume • Flexibility more important than efficiency. • General purpose M/Cs used.
Process Flow Structures (Contd.)
Batch (Contd.)
• Disadvantages:
– Expensive – if volume is too large – Planning & Control – Complex. – Some idling of Resources. – Large W.I.P.
Process Flow Structures (Contd.)
Assembly Line
• Discrete part moving from worker to workers • Constantly Moving Conveyor. • Line Balancing, Low Skills, Low Unit Cost, • Managerial Control – Simple • Maintenance-Difficult & Complex .
Process Flow Structures (Contd.)
Assembly Line (Contd.) • Disadvantages1. Repetitive/Monotonous.
2. If breakdown – Total stoppage of work.
3. Bottleneck operation determines capacity.
4. Obsolescence cost becomes heavy.
Service Design
• Service is an act, created and delivered simultaneously • Service delivery system includes
– Facilities
– Processes – Skills
• Many services are bundled with products
ICFAI BUSINESS SCHOOL, MUMBAI
doc_446982681.ppt