Product and Process Design

Takt time equation

(𝐴𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝑡𝑖𝑚𝑒 𝑎𝑣𝑎𝑖𝑙𝑎𝑏𝑙𝑒)/(𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑣𝑜𝑙𝑢𝑚𝑒)

Efficiency formula

(𝑇𝑜𝑡𝑎𝑙 𝑡𝑎𝑠𝑘 𝑡𝑖𝑚𝑒)/(𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑤𝑜𝑟𝑘𝑠𝑡𝑎𝑡𝑖𝑜𝑛𝑠 𝑥 𝑡𝑎𝑘𝑡 𝑡𝑖𝑚𝑒)

Minimum number of workstations equation

(𝑇𝑜𝑡𝑎𝑙 𝑡𝑎𝑠𝑘 𝑡𝑖𝑚𝑒)/(𝑇𝑎𝑘𝑡 𝑡𝑖𝑚𝑒)

What is product traceability?

Method of tracking products from final use to a point of origin in order to determine who is liable

What is the load-distance model?

Minimizes product flow between work centers

What is Muthers Grid?

Muther's Grid is behaviorally focused - Recognizes locating some equipment next to each other might be unsafe or impractical Example - cannot put acetylene welding tanks next to a baking kiln

What is a project? (Process continuum)

One time creation of new product Example: Yangtze River Dam Construction

What is the failure rate?

One way to evaluate reliability is through failure rate

How do you use Muthers Grid?

Outlines preferences for layouts What should (should not) be close to each other Creates a grid of all possible layouts on the floor A = absolutely necessary, E = very important, I = important, O = somewhat important, U = unimportant, X = Undesirable

What is a continuous process? (Process continuum)

Process flows from one place to another with little human interaction. Example: Flour mill

What are failure models and effects analysis? (FMEA)

Process used to identify where a components in a system can fail and what would be the consequences

What is a product life cycle?

Product life cycle is a graphical representation of the life phases that a product experiences

What is a fixed-position process design? (Advanced process design)

Product stays stationary but equipment and labor are transported into the work area (hangar-built airplanes)

1. What is the system reliability in a system with 3 components? Component 1 Reliability= 99% Component 2 Reliability= 91% Component 3 Reliability= 95% What if you had a TV with 700 components each with a 99% reliability for 5 years?

R = .99 x .91 x .95 = 85.6% reliability R = .99700 =.00088, this TV has less than a 1% chance of lasting 5 years

What is a process map?

Schematic picture of a process using symbols - Arcs between symbols represent progression from one step to the next

What is a batch? (Process continuum)

Set up production line, produce quantity required, reconfigure production line Example: Appliance manufacturer

What is design for maintainability?

Sometimes it's cheaper to replace a product than to fix it Avoid this problem by making components easy to replace

What are the two fundamental decisions in production?

What to make. (Product Design) How to make it. (Process Design)

What is a flexible manufacturing system? (Advanced process design)

- Hybrid of mass assembly and job shops - Automated production system with immediate changeovers

What is a cellular layout process design? (Advanced process design)

- Multiple job shops in a u-shaped production line - Several steps performed by the same person in the same cell - More efficient than job shop

What are the 7 motives for R&D

- Strengthening bottom line - Absorbing productive capacity - Emerging customer needs - Increasing market share - Regulatory mandates - Technological advances - Changes in materials

What are the 3 characteristics of product layout?

- Usually linear or U-shaped - Designed for high production levels and low unit costs - Requirements of the product dictate process layout

What are the 5 types of process continuum?

- Project - Job Shop - Batch - Assembly line - Continuous

What is continuous design?

Enhancement to existing products

Balance delay formula

(𝑠𝑢𝑚 𝑜𝑓 𝑠𝑙𝑎𝑐𝑘 𝑡𝑖𝑚𝑒𝑠)/(𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑤𝑜𝑟𝑘𝑠𝑡𝑎𝑡𝑖𝑜𝑛𝑠 𝑥 𝑡𝑎𝑘𝑡 𝑡𝑖𝑚𝑒)

What is a series reliability?

- Components in a system are in a series if the performance of the entire system depends on all of the components functioning properly - Series reliability is the reliability of the entire system based on the probability of each component functioning properly Rs=

What are the two general types of process design?

1. Basic Layouts already addressed (project, batch, etc.) 2. Advanced Process Designs:

What has changed from traditional process to extended process?

1. Competition has changed from company versus company to supply chain versus supply chain 2. Improving one link in the chain may not improve the overall chain's competitiveness 3. One firm's change in process might negatively impact another firm in the chain

How is a process map used?

1. Develop general process map 2. Interview those who perform each step of the work 3. Determine which steps add value. Eliminate those that do not.

What are the 9 product design process steps?

1. Product Idea Generation - Internal (marketing, R&D, etc.) and External (Customer) Inputs 2. Customer Future Needs Projection 3. Technology Selection - Technology feasibility statement considers performance parameters, limitations, etc. 4. Technology Development - Selection of processes used to transform materials into final product 5. Final Production Definition - Final drawings and specifications 6. Marketing and Distribution - Define customers and distribution networks 7. Product Design and Evaluation - Product Design Specification (PDS) developed identifying final product features, uses, etc. 8. Manufacturing System Design - Selection of process technologies that ensure a low cost, high quality product 9. Manufacture, Delivery, and Use

What 7 things determine Muthers Grid priorities?

1. Usage of common equipment or facilities 2. Usage of the same labor or information 3. Same work sequence or work flow 4. Need to communicate 5. Makes work unsafe 6. Makes quality of work life poor 7. Similar work

What is quality function deployment? (QFD)

A method for translating customer requirements into functional design (a.k.a. house of quality) Example: Designers need a means for implementing customer requirements into designs. The QFD house of quality shows how QFD is used to implement customer requirements into designs. The left side shows customer requirements. The roof on the house of quality lists technical requirements. By using the house of quality, engineering priorities are established that correlate most strongly with customer and market needs.

What is system availability?

Another way to evaluate reliability is through system availability

What is line balancing? What are the 9 steps?

Answers how to assign tasks to workstations in the most efficient way 9 Steps to Line Balancing: 1. Identify tasks to be performed to produce product 2. Determine task sequence 3. Determine task duration 4. Calculate takt time 5. Calculate theoretical minimum number of workstations 6. Choose heuristic such as longest operating time, most followers, etc. 7. Apply heuristic to assign tasks to workstations 8. Compare your number of workstations with theoretical number 9. Look for ways to improve layout

What is the difference between basic and applied research? (R&D)

Basic: Theoretical, not motivated by profit Applied: Practical exploration motivated by profit Example: nuclear fission versus nuclear power plants

What is discontinuous design?

Complete changes from existing products

WHat is concurrent engineering? What are two advantages?

Concurrent Engineering- Simultaneously performing multiple design process steps Advantages: 1. Communication among group members 2. Speed

What is Pull R&D?

Market Pull (continuous development): Improving on or creating complementary products to reinvigorate product life cycle

What is design reuse?

Designing a product so that it can be used in later generations of products Example: Ink toner cartridges are made to be refilled and reused Within design for reuse is design for disassembly - Designing a product so that the product is easy to take apart Example: Kodak FunSaver camera

What are the 3 characteristics of design for manufacture? (DFM)

Focuses on making a product easy to build Needed due to "over-the-wall syndrome" Utilizing product data management (PDM) to organize product design and manufacture data

What is an assembly line? (Process continuum)

High volume, high standardization Example: Automobile assembly factory

Example of Muthers Grid - 3 things

In the Muther's grid above there are a few things that are evident: 1. Those departments with an A should be collocated. So department A and department B should be next to each other. 2. Those departments with an X should not be collocated. So department C and department D should NOT be next to each other. 3. Department F may be difficult to find departments that it should be located next to as E and C are rated only as somewhat important

Load-distance model characteristics

Load-distance models are focused on only cost and distance - They ignore any behavioral reasons for layout Example - you do not want to put paint shop next to lunchroom because of the scent

WHat are flexible manufacturing systems?

Low volume and low flexibility

What is a job shop? (Process continuum)

Low volume batch processing of similar products Example: Copy center

What is Push R&D?

Technological Push (discontinuous development): Sending new product to market without clear idea of how customer will use it Example: personal computers

WHat is the bathtub reliability curve?

The "bathtub function" predicts that most appliances will fail during their initial use or after their expected, useful life. Because most major appliances include a first year warranty that covers labor and parts and this is the time that most appliances fail, it is probably not necessary to buy an extended warranty

What are the two dimensions of reliability?

Two Dimension of Reliability: 1. Failure Rate 2. Time Reliability Dimensions apply to: Component reliability (likelihood of a certain part not failing) System reliability (likelihood a system of components not failing)

7 other Green principles

Using nontoxic materials (non-lead paint) Using parts and materials that last longer Using processes and materials that require less energy Conduct life-cycle assessments Using renewable materials in production Make disposable products (think newspapers) Use process that conserve and don't pollute the water

What 5 questions should be asked during design stage?

What are the functions the customer wants? What are the capabilities of current products? What are the limitations of the selected materials? Are better materials available? How much will the product cost to make?

What is the load-distance model formula?

Where: C = cost n = number of work centers Lij = number of loads transported between work centers i and j Dij = distance between work centers i and j K = cost to move on load, one unit of distance