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Designing Products

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Title: Designing Products


1
Designing Products Engineering
2
People,Problem-Solving, and Practicality
  • Industrial Engineering
  • the People and Systems Engineers

3
What is Industrial Engineering?
  • Industrial engineers design, install, and improve
    the complex systems which provide both goods and
    services vital to our society and economy. These
    systems integrate people, materials, and
    equipment, and thereby place unique demands for
    breadth of preparation upon industrial engineers.
    The traditional arenas for the practice of
    industrial engineering are the manufacturing
    facilities of industry. However, today fully
    one-third of practicing industrial engineers are
    employed in non-manufacturing enterprises such as
    hospitals, banks, and government.

4
Industrial Engineering
  • Industrial engineers perform the following tasks
    in manufacturing and service industries.
  • Forecast the demand the product
  • Prepare a plan to produce the product
  • Analyze the cost and benefits of the product
  • Design the layout of the plant to produce the
    product
  • Select the manufacturing processes to make the
    product
  • Identify the people and their skills for
    production and supervision
  • Integrate people, materials, machines, and
    processes to work together
  • Schedule the machines and processes for
    production
  • Supervise the day-to-day operation of the
    facility
  • Design the workplace and procedures for workers
    to follow
  • Handle occupational and safety concerns
  • Model and analyze the performance of the system
    and find ways to improve it

5
Areas of Study Within Industrial Engineering 1.
Human Factors (Ergonomics)
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Areas of Study Within Industrial Engineering
Human 2. Facilities Design
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Work Cell Floor Plan
8
Emergency Room Layout
9
Store Layout - with Dairy, Bread, High Drawer
Items in Corners
10
Areas of Study Within Industrial Engineering
Human 3. Simulation
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(No Transcript)
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Areas of Study Within Industrial Engineering
Human 4. The Production Planning and Control
Aggregate Capacity Planning
Sales Marketing
Shipping Receiving
Capacity Requirement Planning
Operations Scheduling
Shop Floor Control
Warehousing
13
Areas of Study Within Industrial Engineering
Human 4. Quality Control
14
Areas of Study Within Industrial Engineering
Human 5. Optimization/Operation Research
Factories
Distributor/Retailer Warehouse
Customers
Product Flow
Information Flow
15
Sample Industrial Engineering Courses
  • Human Factors Engineering
  • Work Measurements and Work Design
  • Facilities Planning and Design
  • Reliability Engineering
  • Experimental Design For Engineering
  • Production Planning and Control
  • Engineering Project Management
  • Integrated Manufacturing Systems
  • Expert Systems in Engineering
  • Industrial Robotics
  • Quality Control
  • Automated Inspection
  • Integrated Product and Process Design
  • Queuing Methods for Services and Manufacturing
  • Introductory Decision Analysis for Engineering
  • Simulation Modeling and Analysis
  • Engineering Information Systems
  • Contemporary Topics in Industrial Engineering

16
Career Opportunities for Industrial Engineers
  • Industrial engineers are the problem solvers in
    all organizations. Career opportunities for
    industrial engineering are limitless.
  • A sample list of career opportunities for
    industrial engineers include
  • Manufacturing regardless of the product
    manufactured, every manufacturing company needs
    IEs to plan the facility, perform economic
    analyses, plan and control production, manage
    people, handle safety issues, improve quality,
    evaluate performance, etc.
  • Health Services hospitals and clinics need IEs
    to perform cost/benefit analyses, schedule work
    load, manage people, evaluate safety concerns,
    design and maintain facilities, etc.
  • Transportation airlines, ground transportation,
    trucking, and warehousing companies need IEs to
    design the best schedules and routes, perform
    economic analyses, manage crews, etc.
  • Financial banks and other savings and lending
    institutions need IEs to design financial plans,
  • perform economic analyses, etc.
  • Government local and federal governments need
    IEs to design and enforce safety systems,
    environmental policies, plan for and operate
    in a number of organizations.
  • Consulting IEs may work as consultants to help
    design and analyze a variety of systems including
    information systems, manufacturing and service
    systems.

17
What is Engineering Design?
  • The systematic and creative application of
    scientific and mathematical principles to
    practical ends such as the design, manufacture,
    and operation of efficient and economical
    structures, machines, processes, and systems.

18
The basic purpose of any organization is to
provide products or services to their customers.
Thus, the design of these products and services
is essential to the livelihood of a
company. But, what are the characteristics of an
Effective Design?
19
Effective Design
  • Effective designs provide a competitive edge by
  • Bringing new ideas to the market quickly
  • Doing a better job of satisfying customer needs
  • Making new products easier to manufacture,
    use, and repair than existing products

20
Types of Design and Redesign
  • Original Design (or Inventing)
  • Involves elaborating, original solutions for a
    given task. The result of original design is an
    invention.
  • Adaptive Design (or Synthesis)
  • Involves adapting a known system to a changed
    task or evolving a significant subsystem of a
    current product (such as antilock brakes).
  • Variant Design (or Modification)
  • Involves varying the parameters (size, geometry,
    material properties, control parameters, etc.) of
    certain aspects of a product to develop a new and
    more robust design.

21
Product Design
  • Specifies which materials are to be used
  • Determines dimensions and tolerances
  • Defines the appearance of the product
  • Sets standards for performance.

22
Design has a tremendous impact on the quality of
a final product or service.
  • Quality in the design process involves
  • Matching product or service characteristics with
    customer requirements
  • Ensuring that customer requirements are met in
    the simplest and least costly manner
  • Reducing the time required to design a new
    product or service, and
  • Minimizing the revisions necessary to make a
    design workable.

23
The Design Process
24
Sources of idea generation
  • Surveying suppliers, distributors,
  • and salespersons
  • Monitoring trade journals
  • Analyzing warranty claims, customer complaints,
    and other failures
  • Surveying potential customers
  • Bench marking
  • Comparing a product or process against the
  • best-in-class product.
  • Reverse engineering
  • Carefully dismantling a competitors product
  • in order to improve ones own product.

25
Involvement of Different Functional Departments
in the Design Process
  • Marketing Department takes the idea and
  • Forms a product concept
  • Conducts a study on the feasibility of the
    proposed product or service
  • If the proposed product meets certain
    expectations, performance specifications are
    developed.

26
Involvement of Different Functional Departments
in the Design Process
  • Design Engineers take the performance
    specifications and
  • Develop preliminary technical specifications, and
    later
  • Develop detailed design specifications.
  • Manufacturing Engineers take the detailed
    performance specifications and
  • Develop a process plan that includes specific
    requirements for equipment, tooling, and
    fixtures.
  • Production Engineers take these manufacturing
    specifications and schedule production

27
The Design Process
Yes
No
28
A Decision Making Process
  • Idea generation pre-design planning
  • Customer Requirements
  • Functional Specification
  • Product Specifications
  • Concept Generation
  • Concept Selection
  • Engineering Design
  • Engineering Evaluation
  • Prototype and Testing
  • Manufacturing Design

29
Breaking Down Barriers
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Final design is concerned with how the product
will perform.
  • It consists of three phases
  • 1. Functional design is concerned with
    how the product will perform.
  • 2. Form design refers to the physical
    appearance of a product.
  • 3. Production design is concerned with the ease
    and cost of manufacturing the product.

31
Form Design(How The Product Looks)
32
Functional Design(How The Product Performs)
  • Reliability
  • probability product performs intended function
    for specified length of time
  • A measure for reliability is Mean Time Between
    Failures (MTBF).
  • Maintainability
  • ease and/or cost or maintaining/repairing product
  • A measure for maintainability is Mean Time To
    Repair (MTTR).

33
DFM Guidelines
  • 1. Minimize the number of parts
  • 2. Develop a modular design
  • 3. Design parts for multi-use
  • 4. Avoid separate fasteners
  • 5. Eliminate adjustments
  • 6. Design for top-down assembly

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  • 7. Design for minimum handling
  • 8. Avoid tools
  • 9. Minimize subassemblies
  • 10. Use standard parts when possible
  • 11. Simplify operations
  • 12. Design for efficient and adequate testing
  • 13. Use repeatable understood processes
  • 14. Analyze failures
  • 15. Rigorously assess value

35
Design Simplification
(a) The original design
(b) Revised design
(c) Final design
Design for push-and-snap assembly
One-piece base elimination of fasteners
Assembly using common fasteners
36
Listening to Customers
37
Customers Requirements
  • Normal Requirements are typically what we get by
    just asking customers what they want.
  • Expected Requirements are often so basic the
    customer may fail to mention them - until we fail
    to perform them. For example, if coffee is served
    hot, customers barely notice it. If it's cold or
    too hot, dissatisfaction occurs. Expected
    requirements must be fulfilled.
  • Exciting Requirements are difficult to discover.
    They are beyond the customer's expectations. For
    example, if full meals were served on a flight
    from Chicago to Indianapolis, that would be
    exciting. If not, customers would hardly complain.

38
Kano Model Noriaki Kano 1984.
39
Making Economic Decisions
  • Engineering economy the discipline concerned
    with the economic aspects of engineering. It
    involves the systematic evaluation of the costs
    and benefits of proposed technical projects.

40
Rational Decision-Making Process
  • Recognize a decision problem
  • Define the goals or objectives
  • Collect all the relevant information
  • Identify a set of feasible decision alternatives
  • Select the decision criterion to use
  • Select the best alternative

41
Example Equipment Process Selection
  • How do you choose between Plastic Composite and
    Steel sheet stock for the auto body panel?
  • The choice of material will dictate the
    manufacturing process for the body panel as well
    as manufacturing costs.

42
Which Material to Choose?
43
Engineering Costs General Cost Terms
  • Manufacturing Costs
  • Direct materials
  • Direct labor
  • Mfg. Overhead
  • Non-manufacturing Costs
  • Overhead
  • Marketing
  • Administrative

44
Cost Classification for Predicting Cost Behavior
  • Cost Behaviors
  • Fixed costs
  • Variable costs
  • Average unit costs

45
Fixed Costs
Fixed costs per unit of production (F/Q)
Total fixed costs (F)
Production volume (Q)
Production volume (Q)
46
Variable Costs
  • Def Costs that vary depending on the level of
    production or sales
  • Cost behavior Increase or decrease
    proportionally according to the level of volume
  • Examples Costs of raw material, packaging
    material, direct labor, machine utilities are
    main variable costs.

47
Variable Costs
Variable costs per unit of production (V)
Production volume (Q)
Production volume (Q)
48
Break-Even Analysis (BEA)
  • The total revenue depends on the production
    level.
  • The higher the production, the higher the total
    variable costs.
  • In BEA, it is assumed that price of product is
    fixed.

49
BEA
Price per unit (P)
Production (and sales ) volume (Q)
Production (and sales) volume (Q)
50
BEA
  • Therefore, the overall break-even analysis can be
    pictorially represented in the following graph

Profit
Total costs (FVQ)
BEP FVQPQ
loss
Total revenue (PQ)
Production (and sales) volume (Q)
51
BEA
  • Total Cost (TC) Total Revenue (TR)
  • TCFVQ
  • TRPQ
  • At the break-even point FVQPQ
  • QBEQ F/ (P-V)

52
Example
  • 500,000 total yearly fixed costs.
  • 150 / unit variable costs
  • 200 / unit sale price
  • QBEQ500000/(200-150) 10000 units
  • If our market research indicates that the present
    demand is gt 10000, then this manufacturing system
    is economically feasible.

53
QUALITY FUNCTION DEPLOYMENT
  • Quality Function Deployment
  • Voice of the customer
  • House of quality

QFD An approach that integrates the voice of
the customer into the product and service
development process.
54
Quality Function Deployment
  • Identify customer wants
  • Identify how the good/service will satisfy
    customer wants
  • Relate customer wants to product hows
  • Identify relationships between the firms hows
  • Develop importance ratings
  • Evaluate competing products

55
Customer Requirements
CUSTOMER COMMENTS
  • Peels a variety of produce
  • Works both right and left handed
  • Creates minimal waste
  • Saves time
  • Durable
  • Easy to clean
  • Safe to use and store
  • Comfortable to use
  • Stays sharp or is sharpenable

Carrots and potatoes are very different. I cut
myself with this one. I just leave the skin
on. Im left-handed. I use a knife. This one
is fast, but it takes a lot off. How do you
peel a squash? Heres a rusty one. This
looked OK in the store.
56
  • Select a household product of your choice, your
    goal will be to describe how you think this
    design evolved. By looking at the product, can
    you tell
  • How and why the device functions?  Can you
    describe how it works, what energy sources are
    used, and what purpose that function serves?
  • How was human engineering involved? How would the
    human/machine interface affect this design? What
    safety issues would have been involved?
  • Why the original designers selected the materials
    used?  What properties of the materials were most
    important in selecting them?
  • What features make this product unique?  Compared
    to similar items, are there features on your
    example that would identify this as a better
    product?
  • How was the production process affected by this
    design? Are there specific features that might
    have been added to make production more
    efficient?

57
  • As your analysis continues, choose one aspect of
    the design that intrigues you. Study the design
    used, and consider how you might improve on it.
  • Develop a list of alternatives, and compare them
    to the existing design.
  • Develop some criteria that may help you select
    one of your alternatives as most likely to
    succeed.
  • Finally, select one alternative, and describe how
    it improves on the existing design, what its
    limitations are, and why you think this is a
    better alternative than the existing design.

58
Good Luck with your designs!
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