EOM chapter 3

design for manufacturing

(concurrent engineering improves this by engaging manufacturing early in the design process) ○ A set of methodologies and principles that can be used to guide the design process so that product fabrication and assembly will have low cost, low assembly time, high labor productivity, low manufacturing cycle time, low work in process inventory, high conformance quality, low manufacturing ramp up time, and short time to market

concurrent engineering

-one key to this success is cross functional teams ○ A systematic approach to the integrated, simultaneous design of products and their related processes, including manufacturing and support. Aka simultaneous engineering and integrated product development ○ Goal- to reduce time to market and quality problems, engage cross functional teams,

stage gate process

advantage over tradition un gated new product development process= uses "gates" (signoffs) to ensure that all functions are in agreement that the NPD should go forward. helps to filter out bad product designs earlier in process

A new product that adds or modifies features of an existing product line without significantly changing the product is called a: Select one: a. Modular product. b. Product line extension. c. New platform. d. Secondary product.

b

Question 1 Which ONE of the following is a key to the success of concurrent engineering? Select one: a. Computer-Aided Design (CAD). b. Cross-functional teams. c. Postponement. d. Modular design

b

Which ONE of the following best describes the concept development phase of the new product development process? Select one: a. Evaluating the trade-offs between product cost and quality (features) and creating the product specifications. b. Defining the market needs and evaluating different approaches for meeting those needs. .c. Building sample units to test if the product meets product specifications and market requirements. d. Designing the physical specifications of the new product.

b

Which ONE of the following is a key to the success of concurrent engineering? Select one: a. Postponement. b. Cross-functional teams. c. Computer-Aided Design (CAD). d. Modular design.

b

Which ONE of the following would be most helpful in getting customer opinions better represented in the new product development process? Select one: a. Six-Sigma DMAIC project. b. Quality Function Deployment (QFD). c. ISO 9000 certification. d. Total quality management (TQM).

b

Which ONE statement is the best reason for requiring sign-offs by senior managers between phases in the new product development process. Select one: a. It speeds the process up. b. It provides for better control. c. It allows for concurrent engineering. d. It slows the process down.

b

Which statement best describes how concurrent engineering improves Design For Manufacturing (DFM)? Select one: a. Concurrent engineering avoids interference from manufacturing early in the design process. b. Concurrent engineering engages manufacturing early in the design process. c. Concurrent engineering is careful to engage manufacturing only at the end of the design process. d. Concurrent engineering keeps manufacturing out of the design process.

b

Select ALL of the following statements that are generally true about value analysis (also known as value engineering). Select one or more: a. A process design concept often used to increase customer benefit while maintaining the same cost. b. A product design concept often used to improve customer benefit without increasing cost. c. A product design concept often used to reduce cost while maintaining the same customer benefit. d. A process design concept often used to reduce manufacturing cost while maintaining the same customer benefit.

b,c

Select ALL of the following statements that are generally true about value analysis (also known as value engineering). Select one or more: a. A process design concept often used to reduce manufacturing cost while maintaining the same customer benefit. b. A product design concept often used to reduce cost while maintaining the same customer benefit. c. A product design concept often used to improve customer benefit without increasing cost. d. A process design concept often used to increase customer benefit while maintaining the same cost.

b,c

Select ALL of the following benefits that are benefits of Design for Manufacturing (DFM). Select one or more: a. Less time for new product development. b. Less cycle time. c. Less direct labor time and cost. d. Less work-in-process (WIP) inventory.

b,c,d

Select ALL of the statements below that are advantages of the stage-gate process over the traditional un-gated new product development process. Select one or more: a. Makes the approval process less formal and requires less paperwork. b. Uses "gates" (signoffs) to ensure that all functions are in agreement that the NPD should go forward. c. Enables the firm to have different tasks for one NPD project in different stages at the same time. d. Helps to filter out bad product designs earlier in a process.

b,d

modular design

components and subassemblies that can be developed independently and then mixed and matched together

The basic concept of a robust component is that: Select one: a. Components that can perform well in harsh environments will lower maintenance cost. Incorrect. While this might be true in some cases, this is not the basic concept of a robust component. b. A component that is hard to break will decrease the life cycle cost. c. Robust parts are larger than other components. d. Increasing component commonality lowers cost and inventory and supports mass customization.

d

What is the number of possible combinations for a modular design for a bed with 5 cover colors, 4 mattress sizes, and 3 types of springs? Select one: a. Not enough information to compute. b. 5+4+3 = 12 combinations. c. 5!4!3! = 17,280 combinations. d. 5x4x3 = 60 combinations.

d

Which ONE of the following best describes what is involved in pilot production? Select one: a. Testing a product in a target market to see how potential customers react. b. Evaluating the trade-offs between product cost and quality (features) to create the product specifications. c. Defining the market needs and evaluating different approaches for meeting those needs. d. Building sample units to test if the product meets product specifications and market requirements.

d

integrated product development

he practice of systematically forming teams of functions disciplines to integrate and concurrently apply al necessary processes to produce an effective and efficient product that satisfies the customer's needs ○ Concurrent engineering/simultaneous engineering ○ Benefits= less development time, fewer engineering changes, less time to market, higher quality and higher white collar productivity

A new product development strategy that plans new products around a small number of basic product designs that allow for many different final products is called: Select one: a. A platform strategy. b. Value analysis. c. Design for Manufacturing (DFM). d. Quality Function Deployment (QFD).

a

Components and subassemblies that can be developed independently and then mixed and matched together is known as: Select one: a. Modular design. b. Commonality. c. Robust design. d. Standardization.

a

Question text A new product development strategy that plans new products around a small number of basic product designs that allow for many different final products is called: Select one: a. A platform strategy. b. Design for Manufacturing (DFM). c. Value analysis. d. Quality Function Deployment (QFD).

a

Reverse engineering is the process of: Select one: a. Dismantling a competitor's product to understand the strengths and weaknesses of the design. b. Ensuring that a product is designed such that one side of the product is the same as the reverse side. c. Disassembling a used product and preparing it for remanufacturing. d. Starting with the goal in mind and figuring out what the design should be to meet that goal.

a

Which ONE of the following best describes the technology push strategy? Select one: a. Seeks to develop products and services that can be easily marketed due to their superiority. b. Seeks to develop products and services that can be mass-produced cheaply. c. Seeks to develop products and services that are easy to market due to both their superiority and high consumer interest. d. Seeks to develop products and services that already have a high demand due to consumer interest.

a

Which ONE statement best describes how product design can create a competitive advantage? Select one: a. New products with better features will often generate greater market demand. b. Newer products are almost always better than older products. c. New products are easier to market than old products. d. Newer products are almost always cheaper than older products.

a

platform strategy

a new product development strategy that plans new products around a small number of basic product designs that allow for many different final products

value engingeering

a product design concept often used to improve customer benefit without increasing cost a product design concept often used to reduce cost while maintaining the same customer benefit ○ An approach for designing and redesigning products and services to achieve the same functionality at less cost or achieve better functionality at the same cost ○ Multi disciplined team

Select ALL of the following statements that are true about Quality Function Deployment (QFD). Select one or more: a. QFD can be applied to service design as well as product design. b. The basic tool for QFD is a matrix that links customer attributes to engineering attributes. c. QFD shows that trade-offs do not need to be made between engineering characteristics. d. QFD is an approach for implementing Design for Manufacturing (DFM).

a,b

Select ALL of the following that are benefits of building prototypes in the new product development process. Select one or more: a. Test the manufacturability of a product. Building prototypes can be a useful test of process capabilities. b. Reduce time to market for a new product. c. Get quick feedback from the market on product features. d. Test to see if suppliers can meet the volume requirements for the new product.

a,c

mass customization

○ A biz model that uses a routine approach to efficiently create a high variety of products or services in response to customer defined requirements ○ Reducing cost while maintaining or reducing variety

computer aided design

○ A combination of hardware and software that enables engineers and architects to design everything from furniture to airplanes

pugh matrix

○ A decision tool that facilitates a disciplined, team based process for concept generation, evaluation and selection ○ Scoring matrix- defines the important criteria for a decision, defines the weights for each criterion, defines the alternatives and then scores each. ○ Allows org to compare different concepts, create strong alternatives from weaker and arrive at the best one.

kano analysis

○ A quality measurement tool used to categorize and prioritize customer requirements based on their impact on customer satisfaction ○ Four categories of product attributes Must have, performance attributes, delighter attributes, indifferent attributes

design for disassembly

○ A set of principles used to guide designers in designing products that are easy to disassemble for re manufacturing or repair ops ○ Enable a product and its parts to be easily reused, re manufactured, re furbished or recycled at end of life

lean design

○ A set of tools for reducing the new product development cost and time with a focus on reducing variation, addressing bottlenecks, eliminating rework, and managing capacity

value proposition

○ A statement of the benefits offered by a product or service to a market ○ Statement of how a bundle of products or services propose to add value to a set of customers and how that value is differentiated from competitors' offerings. Difference between life cycle benefits and life cycle costs

phase review

○ A step in the new product development process where approval is required to proceed to the next step- stage gate review, tollgate review

quality function deployment

○ A structured method for translating customer desires into the design specification of a product; also known as house of quality ○ Cross functional teams

disruptive technology

○ A technological innovation, product, or service that eventually overturns the existing technology in the market despite the fact that the disruptive technology is radically different htatn the leading tech and ofte nhas poorer performance.

technology road map

○ A technology used by many biz and research organizations to plan the future of a particular process or product technology Goal- anticipate externally driven tech innovations by mapping them on a timeline

design for six sigma

○ An extension of six sigma tools and concepts used for developing new products. The rationale for dfss is that it is much easier to design quality into a product than it is to fix problems after the design is complete ○ IDOV- identify, design, optimize and validate or DMADV- define , measure, analyze, design and verify. ○ Designed for new products (old products use dmaic)

voice of the customer

○ Customer opinions, perceptions, desires and requirements

design for assembly

○ Design for manufacturing concepts applied to assembly

robust

○ Hard to break, useful in a wide variety of situations, useful in the presence of high variation, sometimes fault tolerant or error proof.

critical to quality

○ Key measurable characteristics of a product or process that require performance standards or specification limits to satisfy the customer requirements

product lifecycle management

○ Managing a product through its entire life, from concept to design, development, commercialization, manufacturing and phase out.

product data management

○ The business function and associated software that creates, publishes and manages detailed product info

early supplier involvement

○ The collaborative product development practice of getting suppliers involved early in the product design process

commonality

○ The degree to which the same parts are used in different products

target cost

○ The desired final cost for a new product development effort ○ The firm determines the price based on the market strategy and then determines the target cost by subtracting the desired margin. ○ Four major steps § Determine the price, set the target cost per unit and in total, compare the total target cost to the currently feasible total cost to create the cost reduction target, design or redesign products and processes to achieve the cost reduction target

fuzzy front end

○ The first step in the NPD process ○ The activities that generate and select concepts to be started into product development. Organizations should only start concepts that have a high probability of financial success

postponement

○ The principle of delaying differentiation (customization) for a product for as long as possible to minimize complexity and inventory ○ Change from make to order to assemble to order or configure to order

reverse engineering

○ The process of dismantling and studying a competitor's product to understand the strengths and weaknesses of the design to support the design effort for a similar product

new product development

○ The process of generating new product and service concepts, creating designs and bringing new products and services to market; also called product development ○ Three steps § The fuzzy front end, new product development, and commercialization ○ NPD- the process of translating product concepts into specific designs that can be manufactured and brought to market ○ Key issues: forming the NPD project team

error proofing (poke yoke)

○ The process of identifying likely causes of a failure and preventing the failure or at least mitigating the impact of the failure

time to market

○ The time it takes to develop a new product form an initial idea to initial market sales

Select ALL of the statements below that are advantages of concurrent engineering over a sequential process. Select one or more: a. It helps with interaction and communication with the customer. b. It involves more organizational units in product development. The number of organizations involved in the new product development process is the same for both sequential and concurrent engineering. c. It creates a better quality product in less time. d. It helps different organizations work better together to create a new product.

c

Which ONE of the following best describes a market pull strategy? Select one: a. Seeks to develop products and services that the market will want because of the low price. b. Seeks to develop products and services that the market will want based on the firm's current technology. c. Seeks to develop products and services that the market wants without regard for the organization's current technology. d. Seeks to develop products and services for the market that can be mass-produced at low cost.

c

Which statement best describes how concurrent engineering improves Design For Manufacturing (DFM)? Select one: a. Concurrent engineering is careful to engage manufacturing only at the end of the design process. b. Concurrent engineering keeps manufacturing out of the design process. c. Concurrent engineering engages manufacturing early in the design process. d. Concurrent engineering avoids interference from manufacturing early in the design process.

c

Select ALL of the following statements that are true about Quality Function Deployment (QFD). Select one or more: a. QFD shows that trade-offs do not need to be made between engineering characteristics. b. QFD is an approach for implementing Design for Manufacturing (DFM). c. QFD can be applied to service design as well as product design. d. The basic tool for QFD is a matrix that links customer attributes to engineering attributes.

c,d