Chapter 3 Product Design and Process Selection Flashcards
service design
is the process of establishing all the characteristics of the service, including physical, sensual, and psychological benefits.
What are the steps for Product Design Process?
- Idea Development
- Product Screening
- Preliminary Design and testing
- Final design
manufacturability
the ease with which the product can be made
Product Design Process step: Idea Development
Someone thinks of a need and a product/service design to satisfy it; customers, marketing, engineering, competitors, benchmarking, reverse engineering.
reverse engineering
buy a competitor’s new product and study its design features. Using a process called reverse engineering, a company’s engineers carefully disassemble the product and analyze its parts and features.
Product Design Process step: Product screening
Every business needs a formal/structured evaluation process; fit with facility and labor skills, size of market, contribution margin, break-even analysis, return on sales.
Product Design Process step: Preliminary design and testing
Technical specifications are developed, prototypes built, testing starts.
Product Design Process step: final design
Based on test results, facility, equipment, material, and labor skills defined, suppliers identified .
Early supplier involvement (ESI)
involving suppliers in the early stages of product design.
Factors Impacting Product Design, Design for manufacturing (DFM):
is a series of guidelines that we should follow to produce a product easily and profitably.
Factors Impacting Product Design, Design for manufacturing (DFM),
focuses on 2 issues:
design specification, design standardization
DFM, Design simplification
reducing the number of parts and features of the product whenever possible. A simpler product is easier to make, costs less, and gives higher quality.
DFM, Design standardization:
refers to the use of common and interchangeable parts. By using interchangeable parts, we can make a greater variety of products with less inventory and significantly lower cost and provide greater flexibility.
DFM guidelines:
- minimize parts
- design parts of different products
- use modular design
- avoid tools
- simplify operations
Factors in - Product life cycle:
A series of stages that products pass through in their lifetime, characterized by changing product demands over time.
stages of Product lifecycle:
1 introduction.
- Growth
- Maturity
- decline
concurrent engineering:
is an approach that brings many people together in the early phase of product design in order to simultaneously design the product and the process.
remanufacturing:
The concept of using components of old products in the production of new ones. Common with: computers, televisions, automobiles
Types of processes are:
intermittent operations and repetitive operations
type of process, Intermittent operations:
Processes used to produce a variety of products with different processing requirements in lower volumes (such as a healthcare facility)
type of process, repetitive operation:
Processes used to produce one or a few standardized products in high volume (such as a cafeteria or car wash).
Differences between Intermittent and Repetitive Operations, Product variety:
Intermittent Operations - great
Repetitive Operations - small
Differences between Intermittent and Repetitive Operations, Degree of Standardization
Intermittent ops - low
repetitive ops - high
Differences between Intermittent and Repetitive Operations, organization of resources:
Intermittent ops - grouped by function
repetitive ops - Line flow to accommodate processing needs
Differences between Intermittent and Repetitive Operations, path of products through facility:
intermittent ops - In a varied pattern, depending on product needs
repetitive ops - line flow
Differences between Intermittent and Repetitive Operations, factor driving production:
intermittent ops - customer orders
repetitive ops - Forecast of future demands
Differences between Intermittent and Repetitive Operations, critical resource:
intermittent ops - Labor-intensive operation (worker skills important)
repetitive ops - Capital-intensive operation (equipment automation, technology important)
Differences between Intermittent and Repetitive Operations, type of equipment:
intermittent ops - General-purpose
repetitive ops - specialized
Differences between Intermittent and Repetitive Operations, degree of automation:
intermittent ops - low
repetitive ops - high
Differences between Intermittent and Repetitive Operations, throughput time:
intermittent ops - longer
repetitive ops - shorter
Differences between Intermittent and Repetitive Operations, work-in process inventory:
intermittent ops - more
repetitive ops - less
Product design considerations must include the ____
process.
main differences between intermittent and repetitive ops are ….
1) the amount of product volume produced, and
2) the degree of product standardization.
process types (within intermittent and repetitive ops)
project process
batch process
line process
continuous process
intermittent ops, project process:
make a one-at-a-time product exactly to customer specifications.
intermittent ops, batch process:
small quantity of product in groups or batches based on customer orders or specifications
repetitive ops, line process:
large volume of a standardized product
repetitive ops, continuous process:
very high volumes of a fully standardized
product
designing processes, process design tools include ______ and ____
Process flow analysis
Process flowchart
designing processes, Process flow analysis:
A technique used for evaluating a process in terms of the sequence of steps from inputs to outputs with the goal of improving its design.
designing processes, Process flowchart:
A chart showing the sequence of steps in producing the product or service.
designing process terminology, Bottleneck:
Longest task in the process.
design processes, Design considerations include: _____, _____, and _____
Make-to-stock strategy
Assemble-to-order strategy
Make-to-order strategy
designing processes (strategies), Make-to-stock strategy:
Produces standard products and services for immediate sale or delivery.
designing processes (strategies), Assemble-to-order:
strategy Produces standard components that can be combined to customer specifications.
designing processes (strategies), Make-to-order strategy:
Produces products to customer specifications after an order has been received.
process performance metrics, Throughput time:
Average amount of time product takes to move through the system
A measure of wasted time in the system
(process performance metrics)
(what is the formula to find what?)
Process velocity = throughput time / value-added time
A measure of how well a company uses its resources
(process performance metrics)
(what is the formula to find what?)
Productivity = output/input
The proportion of time a resource is actually used
(process performance metrics)
(what is the formula to find what?)
Utilization = time a resource used/ time a resource available
Measures performance relative to a standard
(process performance metrics)
(what is the formula to find what?)
Efficiency = actual output/ standard input
Process performance metrics:
Measurements of different process characteristics that tell how a process is performing.
TRUE OR FALSE
Linking Product Design, Decisions concerning product design and process selection are not linked and can be made independently of one another.
False, correct answer below:
Decisions concerning product design and process selection are directly linked and cannot be made independently of one another.
Product Design Decisions: Intermittent Operations
Product design - Early stage of product life cycle
Competitive priorities - Delivery, flexibility, and quality
Facility layout - Resources grouped by function
Product strategy - Make-to-order/assemble-to- order
Vertical integration - Low
Product Design Decisions: Repetitive Ops
Product design - Later stage of product life cycle
Competitive priorities - Cost and quality
Facility layout - Resources arranged in a line
Product strategy -Make-to-stock
Vertical integration -High
TRUE OR FALSE
Linking Product Design and Process Selection, Type of operation is directly related to product and service strategy.
TRUE!
3 basic strategies (Product and service strategies):
- Make-to-stock: in anticipation of demand
- Assemble-to-order: built from standard components on order
- Make-to-order: produce to customer specification at time of order
Linking Product Design and Process Selection: Degree of Vertical Integration
Vertical integration refers to the degree to which a firm performs processes — from raw material to sales. (Think whether outsourcing is best for the company)
In summary, vertical integration is typically a better strategic decision for repetitive operations. For intermittent operations it is generally a poor strategic choice.
Technology Decisions, Information technology (IT):
is technology that enables storage, processing, and communication of information within and between firms.
Technology Decisions, enterprise resource planning (ERP)
These are large software programs used for planning and coordinating all resources throughout the entire enterprise. They allow data sharing and communication within and outside of the firm, enabling collaborative decision making.
Technology Decisions, Global positioning systems (GPS) A type of wireless technology that uses satellite transmission to communicate exact locations.
How has it impacted process and product design?
GPS has even found its use in advertising. Geo-advertising uses GPS to target and push advertising to devices in specific geographic areas. For example, in 2018 the jeans company True Religion needed to promote new products at its retail stores. Using geo-advertising the company sent customized e-mails to customers in areas in which the brand had a high concentration of stores and was able to drive up in-store traffic.
Technology Decisions, Radio frequency identification (RFID):
A wireless technology that uses memory chips equipped with radio antennas attached to objects used to transmit streams of data.
Technology Decisions, Radio frequency identification (RFID),
how has RFID impacted in the process and product design?
For example, RFID can be used to identify any product movement, reveal a missing product’s location, or have a shipment of products “announce” its arrival. Empty store shelves can signal that it is time for replenishment using RFID, or low inventories can signal the vendor that it is time to ship more products. RFID can also be used in the service environment, enabling innovative applications in locating and tracking people and assets. (wally world used it to track freshness of their produce out front)
Technology Decisions, automation:
Using machinery to perform work without human operators.
Technology Decisions, automated material handling: (what types)
automated guided vehicle (AGV), a small battery-driven truck that moves materials from one location to the other. The AGV is not operated by a human and takes its directions from either an onboard or central computer.
automated storage and retrieval systems (AS/RSs), which are basically automated warehouses.
Technology Decisions, Flexible manufacturing system (FMS):
A type of automated system that combines the flexibility of intermittent operations with the efficiency of repetitive operations.
Technology Decisions, robotics, Numerically controlled (NC) machine;
A machine controlled by a computer that can perform a variety of tasks.
Technology Decisions, E-manufacturing:
Today’s Web-based environment has created numerous opportunities for business collaboration. This includes collaboration in product and process design, where customers, buyers, and designers can share information and jointly make decisions in real time.
Technology Decisions, e-manufacturing, computer system’s that aid in e-manufacturing
Computer-aided design (CAD) A system that uses computer graphics to design new products.
Computer-integrated manufacturing (CIM) A term used to describe the integration of product design, process planning, and manufacturing using an integrated computer system. The purpose of CIM is to improve how quickly the company can respond to customer needs in terms of product design and availability, as well as quality and productivity, and to improve overall efficiency.
3D Printing 3D Printing is three-dimensional printing technology that deposits materials like plastics and metals in thick layers one atop the other with the process gradually building up one layer at a time until the object is produced.
