This document discusses various topics related to product design including:
1. Definitions of product and product design, as well as the product development process.
2. Quality function deployment (QFD) and its tools like the house of quality, which help translate customer needs into technical requirements.
3. Other topics covered are modular function deployment, factors influencing decision changes, process selection, automation, and process flow design.
4. Emerging issues in product design like design for manufacturing and assembly, design for disassembly, design for reliability, and design for customers.
The document provides an overview of process planning. It begins with product selection, which involves strategic decisions about technology, capacity, location, and other factors. Process planning then determines how the product will be manufactured through make-or-buy decisions, process selection, capacity planning, and assembly charts. It discusses different types of processes like projects, batch production, and mass production. Process analysis tools like flow charts and operation process charts are used to improve processes. The document emphasizes that process planning is key to converting product designs into manufacturing instructions.
Demand Forecasting: Forecasting as planning tool, Forecasting Time Horizon, Sources of Data for Forecasting, Accuracy of Forecast, Capacity Planning. Production Planning: Aggregate production Planning, Alternatives for Managing Demand & Supply, Mater Production Schedule, capacity Planning, Overview of MRP, CRP, DRP & MRP-II Production Control: Scheduling & Loading, Scheduling of Job Shops & Floor
Shops, Gantt Chart.
The document discusses Material Requirement Planning (MRP), a systematic methodology for production planning and inventory control. MRP answers three key questions: what is needed, how much is needed, and when is it needed. It does this by collecting information from the master production schedule, bill of materials, and inventory data to generate planned order releases and time-phase requirements. MRP aims to reduce inventory levels and costs while maintaining customer service levels.
Operations management involves managing the processes that convert inputs into outputs in the form of goods and services. The three main functions of any organization are marketing, production/operations, and finance/accounting. Operations managers are responsible for planning, organizing, staffing, leading, and controlling the resources needed for production. They make strategic decisions regarding process design, quality management, capacity, location, layout, supply chain management, and more. The goal is to optimize resource utilization and minimize waste while meeting customer demands. Key issues in operations management include productivity, supply chain management, and the impact of trends like globalization, technology, and outsourcing.
The document provides an overview of production management. It defines production as the process of converting raw materials into finished goods through value-addition. Production management refers to applying management principles to oversee production activities and ensure specified products are produced to meet sales targets. The objectives of production management are to produce quality products in the right quantities, at the right time and place, and at the lowest possible cost. The document also describes different production systems based on volume, including job shop, batch, mass and continuous production.
The document discusses different types of production systems and factors that influence process selection. It describes four main types of production systems: project, job, batch, and mass production. It also discusses intermittent and continuous manufacturing systems. Key factors that influence process selection include variety, volume, flexibility, and expected output. Process selection impacts capacity planning, facility layout, equipment design, and work design.
This document discusses production planning and control (PPC). It defines PPC as planning, directing, and coordinating a firm's resources to achieve production goals efficiently. PPC involves planning materials, methods, machines, manpower, routing, estimating, scheduling, dispatching, expediting, and evaluating manufacturing operations. It outlines the scope of PPC and discusses key aspects like routing, scheduling, dispatching, follow up/expediting, inspection, and benefits and limitations of PPC.
This chapter introduces production and operations management. It defines production as the process of converting raw materials into finished goods. A production system model includes the production system, conversion subsystem, and control subsystem. Operation managers make strategic, operating, and control decisions that fall under production and operations management. These decisions can provide competitive advantages like shorter lead times, higher quality, and better customer service. The chapter outlines characteristics, trends, and differences between production management and operations management.
Operations management involves planning, organizing, and controlling the processes that produce and deliver a company's goods and services. It includes activities like managing resources, designing production processes, and ensuring quality. Operations management aims to reduce costs, increase revenue through customer satisfaction, optimize resource usage, and drive innovation. It transforms various inputs like materials, money, and labor into outputs in the form of goods and services.
The document discusses capacity planning and management. It defines key terms like capacity, bottlenecks, utilization, and throughput. It outlines factors that determine effective capacity like facilities, processes, supply chain management and more. It discusses Eliyahu Goldratt's Theory of Constraints and how to identify, utilize, and elevate the constraint to improve the system. Common capacity planning strategies like leading, following and tracking capacity are also summarized. The document is intended to help participants plan capacity in their own areas and plants.
The document discusses product design concepts and the product design process. It defines product design as conceptualizing an idea for a product and transforming it into reality by considering constraints and analyzing all aspects of the product. The objectives and features of good product design are listed, including functionality, reliability, quality and cost-effectiveness. Concepts discussed include research and development, reverse engineering, and concurrent engineering. The steps of product design are outlined as synthesis, sketching, analysis, selection, engineering, prototyping, and manufacturing.
Production Planning and Control (Operations Management)Manu Alias
Production planning and control aims to efficiently utilize resources like materials, people, and facilities to transform raw materials into finished products in an optimal manner. It involves planning, coordinating, and controlling all production activities from procurement to shipping. The key objectives are proper coordination of activities, better control, ensuring uninterrupted production, capacity utilization, and timely delivery. The main stages are planning, action, and control. Important functions include production planning like estimating, routing, and scheduling, as well as production control functions like dispatching, follow up, and inspection. A master production schedule is a production plan that states what will be made, how many units, and when, to coordinate activities and resources.
This document discusses productivity and operation management. It defines productivity as the output of any production process per unit of input. The goal of production and operation management is to produce the right quality, quantity, and time at a pre-established cost. Productivity can be measured at the partial level looking at individual inputs like labor, capital, and materials, or at the total factor and total levels considering all inputs. Factors that affect productivity include product development, specialization, research, value analysis, process planning, and training. Improving productivity increases efficiency and leads to lower costs, higher sales, and greater profits.
Operation mangement vs project managementJeet Manojit
Project management involves planning, organizing, motivating, and controlling resources to achieve specific goals for projects that have a defined start and end, unique tasks, and success measured by project objectives. Operations management oversees production processes that are continuous with repetitive tasks, success measured by past performance, and implements evolutionary rather than revolutionary change with stable operational teams. The two differ in terms of timelines, task types, change implementation, team continuity and composition, governance structure, and budget estimation difficulty.
PRODUCTION AND OPERATIONS
MANAGEMENT
-Management function responsible for producing goods & services
-Objectives of production management
-Functions of production management
-Production system & models
This document discusses different types of process flows and classifications for production processes. It describes three main types of process flows: line flow, intermittent/batch flow, and project flow. Line flow involves a linear sequence of standardized operations, like an assembly line. Intermittent flow involves production in batches using flexible, general-purpose equipment. Project flow is for unique, one-off products like works of art. The document also discusses how process selection decisions impact costs, quality, flexibility and other operational factors.
This document provides an overview of a course on product design and development. It discusses key topics like product definition, characteristics of successful product development, who is involved in design and development, typical duration and costs, and challenges. The course will cover structured product development methods using step-by-step processes and industrial examples. It will also address organizational realities that can impact projects.
The document outlines the design process, including idea generation, feasibility studies, rapid prototyping, and final design. It discusses learning from competitors through perceptual maps and benchmarking against the best products. The design process aims to match products to customer needs efficiently and minimize revisions. Idea generation considers customer research, technology, and other internal and external sources to design new products and improvements.
This document provides an overview of operations management concepts related to the design of goods and services. It covers topics like product selection, new product development, product life cycles, quality function deployment for defining customer needs, and documents used in production like engineering drawings, bills of materials, and work orders. The document presents these concepts through text and diagrams/figures and provides learning objectives for understanding product design and development.
The document discusses product design and service operations. It defines product design as concerned with a product's form and functions. The product design process involves concept development, product planning, engineering, and pilot production. It also discusses various aspects of product design like design for function, manufacture, and sales. The document also defines different types of service operations and strategies for scheduling service operations to meet demand fluctuations and customer needs.
The document discusses the product life cycle and concurrent engineering. It provides the following key points:
1. A product goes through two main processes - design and manufacturing. The design process involves synthesis and analysis to conceptualize and model the product. The manufacturing process begins with planning and ends with the finished product.
2. Concurrent engineering brings together cross-functional teams from different departments to work in parallel from the beginning of product development. This reduces costs and time to market compared to traditional sequential engineering.
3. Product life cycle management (PLM) views the entire lifespan of a product as a process that can be managed, measured, and modified for continuous improvement. PLM helps collaboration both internally and with partners
The document provides an overview of Quality Function Deployment (QFD). QFD is a methodology for developing products that meet customer expectations. It involves linking customer needs to technical requirements through the use of matrices. Key aspects of QFD include capturing the voice of the customer, establishing technical requirements, and ensuring different departments work together to efficiently design and produce products. Benefits of QFD include increased customer satisfaction, reduced costs, and faster time to market for new products.
The document discusses the product development process. It describes the key stages as concept generation, design, development, and production. It also discusses tools and techniques used in product development like quality function deployment, value engineering, design for manufacturability, and mass customization. Performance measures to assess the effectiveness of the process are also outlined. Management accounting tools like life cycle costing and target costing help control product costs throughout the development cycle.
Designing Product for the Customer,House of quality matrix and design for man...Rohit K.
The document discusses design for manufacturing and assembly (DFMA) techniques. It defines design for manufacturing (DFM) as optimizing the manufacturing process to minimize part production costs. Design for assembly (DFA) is defined as optimizing the assembly process to minimize assembly costs. The key differences and similarities between DFM and DFA are explained. Some principles of DFMA include reducing the number of parts, using common features and axes, and utilizing standards. The overall goal of DFMA is to design products that can be easily and cost-effectively manufactured and assembled.
This presentation is an continuation of my earlier presentation of TQM. This Ppt covers Quality Function Deployment, Quality Control Tools - Old and New, Benchmarking, Business Process Reengineering, Six Sigma, etc
This presentation is in continuation of my earlier presentation on TQM. Here, I have discussed on Quality Function Deployment, Voice of Customer, Failure Mode Effect Analysis, Quality Control Tools - Old and New, Business process Reengineering, Benchmarking, and Six Sigma.
Product Development and Design BSMA-1101_20230901_081023_0000.pdfDanielLescano16
The document discusses product design and development. It covers several key points:
1) Product design is a strategic decision that determines a firm's growth, profitability and future. Superior product design can provide competitive advantage.
2) The product development process involves idea generation, design, testing, and production specification determination. It affects other business functions.
3) Operations management can contribute to product design through principles like simplicity, which enables lower costs and smaller inventories. Product design impacts quality, costs and customer satisfaction.
Quality function deployment (QFD) is a method used to translate customer needs and requirements into engineering specifications. It was developed in Japan in the 1960s and introduced to U.S. automakers in the 1980s. QFD is a four-phase process involving product planning, development, process planning, and production. The first phase is building a House of Quality matrix to prioritize customer requirements and technical characteristics. QFD helps improve customer satisfaction, promotes teamwork, and provides documentation to support future improvements.
The document discusses the product/service design process. It begins by outlining the importance of designing products/services that satisfy customer needs to ensure business success. It then describes the roles of marketing, engineering, and operations functions in the design process. The rest of the document details the steps in the design process from idea generation to production design to addressing quality and costs. It also compares characteristics of goods versus services.
Quality Function Deployment (QFD) is a systematic approach to design that focuses on customer needs. It involves translating customer requirements into technical specifications across each stage of product development. The QFD process involves building a House of Quality matrix to prioritize customer needs, technical attributes, and their relationships. It then translates the voice of the customer through subsequent phases of product design, process planning, and production control. Implementing QFD alongside Lean Six Sigma aims to reduce waste and variability to improve quality, efficiency and meet customer requirements.
This document provides an overview of product design, process development, and process selection. It discusses how product design defines product characteristics to satisfy customer needs. Process design seeks to effectively create products and services. The design of products and processes are interrelated and should be considered together. New product development involves progressively reducing design options through screening and testing. Process selection depends on factors like volume, variety, and operations. Project and jobbing processes handle low volumes and high variety, while batch, mass, and continuous processes are for higher volumes. The document outlines key aspects of product design, process development, and how they relate.
The document discusses various aspects of product design and development including brainstorming techniques, the product design process, contract manufacturing, core competencies, quality function deployment, designing for customers, value analysis/engineering, concurrent engineering, and measuring product development performance through metrics like time to market, productivity, quality, development costs, and financial analysis. It provides information on each stage of the product development lifecycle from planning and concept development through testing, production ramp-up, and measuring performance.
The document discusses designing and developing new services and products. It covers key topics such as identifying customer needs, generating ideas from internal and external sources, developing specifications, and using techniques like modular design and variety reduction. The learning objectives are to appreciate new development as important for organizations, identify alternative innovation strategies, and understand the steps and techniques for designing new offerings. Case studies are presented on topics like modular design, capitalizing on volume, and quality functional deployment.
production and operations management(POM) Complete note kabul university
The Introduction to POM, Scope, Role, and Objectives of POM, Operations Mgt. – Concept; Functions
Product Design and its characteristics;
Product Development Process, Product Development Techniques.
The document provides information about designing new products and services. It discusses trends in product design such as a shift toward services and information technology. It also covers product life cycles and strategies for different stages. The document presents methods for managing design processes, including concurrent engineering. It provides an example of quality function deployment to translate customer wants into product characteristics. Finally, it discusses tools for decision making in product design, including using a decision tree to analyze introducing a new product.
The document discusses product design engineering and reverse engineering. It defines products, triggers for new product development, and the product design process. The product design process involves concept development, feasibility studies including market research and product specifications, and consideration of user, manufacturer, and maintenance needs. It describes the stages of product development from concept to launch. Reverse engineering is defined as the process of analyzing and duplicating a product without documentation to understand its design and operation. Reasons for reverse engineering include updating old products or competing with former manufacturers. The reverse engineering process involves predicting function, observing, disassembling, analyzing subsystems, and documenting findings.
Similar to Chpter 2 manufacturing environment (20)
Toxicity assessment of dispersit SPC 1000 on Escherichia coli and Pseudomonas...Open Access Research Paper
Unsustainable techniques, human activities, and laws used in the exploration and extraction of petroleum resources have wreaked havoc on the environment of the Niger Delta Region. This research assessed the toxicity of oil spill dispersant- Dispersit SPC 1000 on Escherichia coli and Pseudomonas spp. in water habitats. The bacteria were isolated following standard procedures by the spread plate technique. Percentage log survival was used as the toxicity index. The result of the findings showed that the survival rate decreased with increased concentration of Dispersit SPC 1000 and as the exposure periods increased while the mortality rate increased. The study also investigated the susceptibility of the test organisms to the toxicant concentrations and the result revealed a significant difference between the toxicant concentration and the susceptibility of the test isolates though the degree of toxicity differed in the isolates studied. It was observed that Dispersit SPC 1000 exerted a greater toxic effect on Pseudomonas spp. than on E. coli. The result of the 24th-hour acute toxicity of the toxicant at various concentrations showed that Dispersit SPC 1000 was more toxic to Escherichia coli (386.93) than Pseudomonas spp (459.72) in Freshwater and more toxic to Pseudomonas spp (15.96) than Escherichia coli (1293.96) in Marine water. This was evident in the lower LC50 for Escherichia coli in freshwater and Pseudomonas spp. in marine water.
Novel biosynthesized nanosilver impregnated heat modified montmorillonite cla...Open Access Research Paper
We report here the preparation of highly stabilized nanosilver (AgNp) impregnated clay composites by the biological method. Characterizations by various techniques indicate that the silver nanoparticles were intercalated into montmorillonite clay k10 (MMT k10) composite. The adsorption of malachite green dye onto silver nanoparticles impregnated clay (Ag/MMT K10) and calcined clay (Ag/CMMT K10) in aqueous solution was investigated. Experiments were performed out as function of different dosages (1-3g/L). pH (4.7, 6.7 and 8.7) and temperature (30-60oC).The equilibrium adsorption data of cationic dye on both (Ag/MMT K10) and calcined clay (Ag/CMMT K10) were investigated by Langmuir and Freundlich models. The maximum adsorption capability (k) has been found to be 34.3- 44.3mg/g. High adsorptive nature of the calcined clay Ag/CMMT K10 provided reasonable dye removal capacity. The kinetics of cationic dye adsorption suitably followed the pseudo- first and second order rate expression which shows that intraparticle diffusion plays an important role in the mechanism of adsorption. The experimental results indicate that calcined clay Ag/CMMT K10 is potential material for adsorption of cationic dye from aqueous solutions.
Profitability and efficiency analyses of organic temperate vegetable producti...Open Access Research Paper
This research analyzed the profitability and efficiency of organic temperate vegetable production through the supply chain approach. Survey, key informant interviews, participant observation and archival research were used to gather data. Thirty eight (38) producers and 11 traders in the Cordillera Administrative Region (CAR), Region III and Region IVA served as respondents. Descriptive statistics, cost and return analysis and efficiency analysis were used to analyze research results. The emergence of new breeds of players makes the marketing channel of organic vegetables in the CAR complex compared to a simpler, more modern and integrated chain in the regions outside of the CAR. The six key players in the marketing of organic vegetables are the cooperative, assembler-wholesaler-retailer, assembler-wholesaler, assembler- retailer, retailer and institutional buyers. Returns to total expenses were highest for native cucumber, cauliflower, Japanese spinach, broccoli and lettuce ranging from 100 percent to 235 percent. Native cucumber, cauliflower, Japanese spinach, broccoli, French beans, and lettuce give higher profits to farmers ranging from 49.00 pesos to 71.00 pesos per kilogram. The production of cabbage, native cucumber, cauliflower, Japanese spinach, broccoli, French beans, and lettuce requires low capital, labor and land use intensity indicating high efficiency. Value chain and marketing margin analyses show cost and margin differentials across players and across geographic locations indicating variations in the distribution of benefits among key actors. With the premium price that organic products command and the low capitalization, land and labor utilization needed, organic temperate vegetable production is profitable and efficient which determine its sustainability in the long run.
Emergency response preparedness for Monsoon in humanitarian response.Mohammed Nizam
Emergency Preparedness for Monsoon presentation will help to know the protection risks due to heavy monsoon in refugee camps, emergency response plan, anticipatory action plan, challenges for monsoon and mitigation measures.
2. PRODUCT DESIGN
#Meaning and definition of Product:
Product is anything that can be offered to a market that might satisfy a want
or need. There Is two concepts of product-narrow concept and wide concept.
• In narrow concept, a product is a bundle of physical or chemical
properties which has some utility. Product means an object which satisfies
the need of the customer. Thus fan, table, pen, cooler, chair etc. are the
products.
• In its wider concept, all the brands, all the colors, all the packaging or all
the designs of a product is taken to be different products. Example if a
tooth paste is produced in three different sizes, these are thee products
because they satisfy needs of different customers. Thus, if there is a
change in the size or color or brand or packaging, it produces a new
product.
3. • According to W. Alderson,” A product is a
bundle of utilities consisting of various
features and accompanying services.”
• According to Phillip Kotler,” A product is a
bundle of physical services and symbolic
particulars expected to yield satisfaction or
benefits to the buyer.”
4. #Meaning and definition of product design
• Product design is the process of creating a new
product to be sold by a business to its customer. A
very broad concept, it is essentially the efficient
and effective generation and development of ideas
through a process that leads to new product.
• According to C.S. Deverell, “ Product design in
its broadest sense includes the whole development
of the product through all the preliminary stages
until actual manufacturing begins”.
6. # Product development Process
• Need identification : New product of advancement of existing
product should be able to satisfy customer needs, requirements and
expectations.
• Feasibility study (product planning): in this stage; market
analysis, creating alternative concepts of products, clarifying the
operational requirements, establishing design criteria and their
priorities, logistic requirement are accomplished.
• Advance design: in this stage, product concept or design concept
obtained from feasibility study are examined technically. It is
concerned with developing and evaluating the design alternative if
necessary.
7. • Product development and engineering: several engineering
activities are carried out to analyze experiment and collect data for
product development.
• Process design and development: working with the detailed
product design , engineers and manufacturing specialists prepare
plans for materials acquisitions, productions, warehousing ,
transportation and distributions for designed product.
• Product evaluation and improvement: most products are
continually re-evaluated for improvement possibilities throughout
their lives.
• Product use and support: The ultimate stage of product design and
development is to fulfill the customer needs and expectation about
the products. Educating people, providing warranty, repairs,
guarantee after sales services.
8. # QFD (Quality Function Deployment)
• QFD theory was first defined by Yoji Akao in 1966 and its
initial application was at the Kobe shipyard of mitsubishi in
1972.
• QFD is a system for translating customer requirements into
appropriate company requirements at every stage, from
research through product design and development, to
manufacture, distribution, installation and marketing, sales
and services.
• QFD is a way that defines wining business by helping in
creation of conquering business model, Products/services.
9. According to Dr. Yoji Akao, QFD is a “method to
transform user demands into design quality, to
deploy the functions forming quality, and to deploy
methods for achieving the design quality into sub
system and component parts, and ultimately to
specific elements of the manufacturing process.”
According to Sullivan, QFD is “the main
objectives of any manufacturing company to bring
new product to market sooner than the competition
with lower cost and improved quality.”
10. Features of QFD
It captures the customer voice: customer’s voice is captured in order to
define product or service specifications.
It Ensures Strong Cross-Functional Teamwork: Teamwork is ensured
between the various functions involved with the design, such as marketing,
R&D, and manufacturing.
It links the main phases of product development: A more thorough use of
QFD ensures the generation of four matrices for a company’s success.
I. Product planning
II. Product design
III. Process planning
IV. Process control (production planning)
The three main goals in implementing QFD are:
Prioritize spoken and unspoken customer wants and needs.
Translate these needs into technical characteristics and specifications.
Build and deliver a quality product or services by focusing everybody toward
customer satisfaction.
11. House of Quality (HoQ)
• House of Quality Diagram is a graphic tool analyzing the
relationship between customer desires and the firm/product
capabilities. It is a part of the Quality Function Deployment and it
utilizes a planning matrix to relate what the customer wants to how a
firm is going to meet those wants.
• Some companies that uses house of quality concept are: Ford,
General Motors, HP, P&G, Jaguar etc. In Japan its design
application include public services, retail outlets, and apartment
layout.
• The primary tool for QFD is House of Quality. It is an excellent
quality planning tool and consists of six major building blocks as
shown in figure below.
12. Figure: simplified HoQ
3.
Inter-relationship matrix
between wants and hows.
1.
What? Or Customer
requirements or voice of the
customer
2.
How? Technical requirements
or voice of the organizations
5
Planning matrix/
customer perception
6.
Prioritized Technical
requirements
Technical
correction matrix
or inter-
relationship
between hows
4
Technical/Design
requirementsCustomer
requirements
13. # Modular Functions Deployment
It is a support for good product structure creation. It
uses QFD to establish customer requirements and to
identify important design requirement with a special
emphasis on modularity. MFD consists of 5 steps.
• Clarify product specification
• Analyze functions and select technical solutions
• Identify possible modules
• Evaluate concepts
• Improve each models
14. # Frequency of Decision Changes
Manufacturing environment is dynamic and product
decisions do change often in every manufacturing
company to cope high competition. The various reasons
that lead to the change are:
• Changing demand of customer
• Product failure
• Accident or injuries
• Low demand
• Change in technology and innovation
15. The major techniques that are used in minimizing
the frequency of decision change are given below:
• FMEA (Failure Mode and Effect Analysis): it
analyzes the cause and effects of product failures.
• FTA (Fault Tree Analysis): it analyzes
interrelationship among failures.
• VA (Value Analysis): elimination of unnecessary
features and functions of product design.
16. #Process Selection
• Process basically is sequence of activities that are
carried out with intention to achieve a desired level of
result. In manufacturing or service firms process
converts inputs like raw materials, labour, capital,
information etc. into desired output through the help of
conversion system(machines and equipment).
• Process design: means the complete delineation and
description of specific steps in the production process
and the linkages among steps that will enable the
production system to produce products of the desired
quality, quantity, at right time, estimated cost to fulfill
the customers need.
17. #Manufacturing process technology/ types of conversion process
The conversion process can be divided into five types:
• Project technology: is suitable for producing similar kind of
products of unique character like buildings, bridges, dams, roads etc.
it requires highly skilled-large number of labour.
• Job shop technology: small batches of different products are
produces after receiving customer orders, so it is hard for materials
resources planning, scheduling of operations and controlling
activities. Example tailor, printing shop etc.
• Batch technology: it is one step ahead the job shop technology i.e.
product are produced in larger quantity than job shop after customer
order or for immediate stock. Skilled labour are required. Example
heavy equipment manufacturing and electronic device
manufacturing etc.
18. • Assembly line technology: when the products are
relatively stable, high volume with limited
variety, assembly line technology is suitable.
More mechanized and automation requiring less
labour. Example production of goods like TV,
Radio, Automobile etc.
• Continuous flow technology: it is suitable when
the products are highly specialized/ standardized
and large volume of products are produced for
stock. More mechanized and automation requiring
less labour. Example soap, noodles, cold drinks,
biscuits etc.
19. # Process technology life cycle and selection of
appropriate technoloy
#Process technology life cycle………Azaya Sthatip page 61
#Product process mix matrix
VERY LOW VOLUMES VERY HIGH VOLUMES
LOW STANDARDIZATION LOW VOLUMES HIGH VOLUMES HIGH STANDARDIZATION
One-of-a-kind Products Many Products Few Products Commodity Products
JUMBLED FLOW
(Job Shop)
DISCONNECTED LINE FLOW
(Batch Flow)
CONNECTED LINE FLOW
(Machine or Worker paced)
CONTINUOUS FLOW
STRUCTURE
PROCESS
20. Automation
• Automation is a system, process or piece of equipment
that is self-acting and self-regulating. Automation is the
use of computers to control a particular process in order
to increase reliability and efficiency, often through the
replacement of employees. For a manufacturer, this
could entail using robotic assembly lines to
manufacture a product.
• Although automation is often thought to be necessary to
gain competitive advantages, manufacturers use two
type of automation:
@Fixed automation: when demand volume are high,
product designs are stable, and product life cycle are long
fixed automation become appropriate. example chemical
processing plant, oil refineries etc
21. @Flexible (programmable) automation: The automation which can be
handle and change easily for various products is called flexible
automation for example cold drinks production
#Advantages of automation
• Increased output and higher productivity
• Improved and uniform quality
• Reduced cost
• Reduced numbers of accident
• Better production control
• Dangerous and unpleasant task
#Disadvantages of automation
• Displacement of labour
• Heavy capital investment
• Benefit of employee suggestion cost.
22. #Process Flow design
Process flow design typically uses process flowcharts to
illustrate processes used within a company. These charts
show relationships between process components and to
improve processes within an organization.
In simple terms process flow design can be defined as a
mapping of specific processes that raw materials, parts
and sub assembles follows as the move through a plant.
The most common tools to conduct a process flow design
are:
• Assembly drawing: it is a presentation of the product
or structure put together, that shows all parts in their
operational positions. It is an explained view of the
product.
23. • Assembly chart: assembly chart shows the
sequence of operations in putting together
the product. Assembly charts are extremely
useful for making preliminary plans regarding
subassemblies.
• Operation and route sheet: it specifies
operations and process routing or showcases
types of equipment requirements. It shows
everything about the operation.
24. #Process flow diagram
A process flow diagram (PFD) is a diagram
commonly used I chemical and process engineering
to indicate the general flow of plant processes and
equipment. A PFD is a visual tool which describes
the sequence of flow of product or procedure.
Symbols used in process chart: (refer Azaya sthapit
page-66)
Example:
High-level flowchart for an order-filling process
26. #Emerging issues in product design
• Design for Manufacturing and Assembly: design of
assembly focuses on optimization of parts system
assembly. Design of manufacturing selects the most
cost effective materials and process to be used in
the production in the early stage of product design.
• Design for disassembly: in this design the products
would be designed in such a way that they never
become waste as these products would be inputs for
other products at the end of their lives.
27. • Design for reliability (DFR): in this design
product development team works together with
design engineers to design reliable products
with low overall life cycle cost.
28. • Design for six sigma (DFSS): DFSS follows- DMADV
(Define, Measure, Analyze, Design and Verify) framework.
A product said to be of six sigma quality if there are no
more than 3.4 non-conformities per million opportunities at
the part and process step level.
• Design of Experiments (DOE): it take into consideration
of statistical tools to build the quality into the product an
process. It helps product development team for running a
series of experiments so as to build model of processes.
• Designing for Customers: it helps to design the ideal
product/service taking into consideration of there principles:
Quality Function Deployment (QFD), House of Quality
(HoQ), and Value Analysis.