Chapter 4

Rapid Prototyping and Concurrent Design?

Testing and revising a preliminary design model Step 1: Build a prototype - form design - functional design - production design Step 2: Test prototype Step 3: Revise design Step 4: Retest

Quality Function Deployment (QFD)?

Translates voice of customer into technical design requirements, Displays requirements in matrix diagrams - first matrix called "house of quality": series of connected houses

Extended producer responsibility?

holds companies responsible for their product even after its useful life

Production Design?

how the product will be made

Form design?

how the product will look?

Functional Design?

how the product will perform? - reliability -maintainability - usability

the design process begins with?

idea generation

Process plans?

workable instructions for manufacturing - necessary equipment and tooling - component sourcing recommendations - job descriptions and procedures - computer programs for automated machines

Robust design?

yields a product or service designed to withstand variations

Taguchi's Quality Loss Function?

- Quantifies customer preferences toward quality - Emphasizes that customer preferences are strongly oriented toward consistently meeting quality expectations - Design for Six Sigma (DFSS)

Consistency?

-Consistent errors are easier to correct than random errors - parts within tolerances may yield assemblies that are not within limits - consumers prefer product characteristics near their ideal values

Standardization?

using commonly available and interchangeable parts

Benefits of Quality Function Deployment?

-Promotes better understanding of customer demands -Promotes better understanding of design interactions -Involves manufacturing in design process -Provides documentation of design process

House of quality outline?

1. Customer requirements 2. competitive assessment 3. Design characteristics 4. Relationship matrix 5. Trade-off matrix 6. Target values

feasibility study analysis include?

1. Market analysis 2. Economic analysis 3. Technical/strategic analyses 4. Performance specifications

Product design?

1. defines appearance of product 2. sets standards for performance 3. specifies which materials are to be used 4. determines dimensions and tolerances

The design process steps:

1. idea generation 2. feasibility study 3. Rapid prototyping (form design, functional design, and production design) 4. Pilot run and final tests 5. New product launch

An effect design process?

1. matches product or service characteristics with customer requirements 2. ensures that customer requirements are met in the simplest and least costly manner 3. reduces time required to design a new product or service 4. minimizes revisions necessary to make a design workable

Tradeoff Matrix

A process that compares several solutions measuring how each meets the engineering criteria and constraints

Collaborative Product Design Systems (CPD)?

A software system for collaborative design and development among trading partners - With PML, manages product data, sets up project workspaces, and follows lifecycle of the product - Accelerates product development, helps to resolve product launch issues, and improves quality of design - Designers can * conduct virtual review sessions * test "what if" scenarios * assign and track design issues * communicate with multiple tiers of suppliers * create, store, and manage project documents

Design for Robustness includes?

Robust product, Robust design, Controllable factors, uncontrollable factors, Tolerance, and Consistency

Concurrent Design includes?

Breaking Down Barriers

Idea Generation can come from many sources including?

Company's own R&D department, Customer complaints or suggestions, Marketing research, Suppliers, Salespersons in the field, Factory workers, New technological developments, and Competitors

Technology in Design includes?

Computer Aided Design (CAD), computer-aided engineering (CAE), computer-aided manufacturing (CAD/CAM), product life cycle management (PLM), and collaborative product design (CPD)

Design for Manufacture (DFM)?

Designing a product so that it can be produced easily and economically

Usability?

Ease of use of a product or service - ease of learning - ease of use - ease of remembering how to use - frequency and severity of errors - user satisfaction with experience

Value Analysis (VA)?

Eliminate unnecessary features and functions - Used by multifunctional design teams - Define essential functions of an item - Determine the value of the functions - Determine the cost of providing the functions - Compute Value/Cost ratio - Design team works to increase the ratio

Green Areas include?

Green Sourcing, Green Manufacture, Green Consumption, and Recycling and Re-Use

Design for Environment Lifecycle?

Input (sourcing) -> Transformation (Manufacturing) -> Output (Consumption) -> Re-Use, Recycle, Discard

What Idea Generation tools can help companies learn from their competitors?

Perceptual maps, benchmarking, and reverse engineering

Design Quality Reviews?

Review designs to prevent failures and ensure value - Failure mode and effects analysis (FMEA): a systematic method of analyzing product failures - Fault tree analysis (FTA): a visual method for analyzing interrelationships among failures - Value analysis (VA): helps eliminate unnecessary features and functions

Perceptual maps?

visual method of comparing customer perceptions of different products or services

Approaches to production design include?

Simplification, Standardization, Modular Design, and Design for Manufacture (DFM)

Effective design can provide?

a competitive edge

House of Quality?

a matrix that helps a product design team translate customer requirements into operating and engineering goals

Concurrent Design?

a new approach to design that involves the simultaneous design of products and processes by design teams

Modular Design?

combining standardized building blocks, or modules, to create unique finished products

Tolerance?

allowable ranges of variation in the dimension of a part

Computer Aided Design (CAD)?

assists in creation, modification, and analysis of a design

to increase the reliability of individual parts, redundant parts can be built in to?

back up a failure

Reverse engineering?

carefully dismantling a competitor's product to improve your own product

Benchmarking?

comparing product or process against best-in-class

As the number of serial components increases, system reliability will?

continue to deteriorate

Controllable factors?

design parameters such as material used, dimensions, and form of processing

Recycling and Re-Use?

design products to be recycled or re-use, do save energy and money

Robust product?

designed to withstand variations in environmental and operating conditions

Design for environment?

designing a product from material that can be recycled - design from recycled material - design for ease of repair - minimize packaging - minimize material and energy used during manufacture, consumption and disposal

Final design?

detailed drawings and specifications for new product or service

Green Manufacture?

is energy from renewable sources, amount of waste produced

product life cycle management (PLM)?

managing entire lifecycle of a product

One quantitate measure of maintainability is?

mean time to repair (MTTR)

Green Consumption?

product's use of energy, is product recyclable and maintainable

Simplification?

reducing number of parts, assemblies, or options in a product

computer-aided engineering (CAE)?

tests and analyzes designs on computer screen

System Availability?

the average availability or "uptime of a system"

Maintainability (aka serviceability)?

the ease with which a product is maintained

Reliability?

the probability that a product will perform its intended function for a specified period of time

computer-aided manufacturing (CAD/CAM)?

ultimate design-to-manufacture connection

Green Sourcing?

use less material, use recycled if possible

uncontrollable factors?

user's control (length of use, maintenance, settings, etc.)