Product Design and Process Selection: A Comprehensive Guide, Lecture notes of Production and Operations Management

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Product Design and

Process Selection

Product Design

 (^) Product Design is the process of deciding on the unique characteristics of a product in an organization.  (^) The unique characteristics may be its appearance, the materials it is made of, its dimensions and tolerances, and its performance standards.  (^) Product design brings together marketing analysts, directors, sales forecasters, engineers, finance experts, and other members of a company to think and plan strategically.  (^) Product design has impact on product quality, product cost, and customer satisfaction  (^) Designed product has to be manufactured using materials, equipment, and labor skills that are efficient and affordable( Manufacturability )  (^) Manufacturability is the ease with which a product can be made

Product Design Process Cycle Idea Generation Product idea developed: sources can be customers, competitors(Benchmarking and reverse engineering ), or suppliers Product Screening Product idea evaluated to determine the likelihood of success: need to consider operations, Marketing and financial requirements Final Design Final Product Specifications Completed Preliminary Design and Testing Customers requirement are translated into technical specification , Product prototype built, tested and refined

Factors Impacting Product Design

• (^) Design for Manufacture (Design simplification and Design standardization (use common and interchangeable parts )
• (^) Product life cycle(Introduction, Growth, Maturity and Decline)
• (^) Concurrent engineering
• (^) Remanufacturing (use component of old product)

Types of Product processes

• (^) All processes can be grouped into two broad categories: Intermittent operations and,  (^) Repetitive operations
• (^) Intermittent Process is used to produce a variety of products with different processing requirements in lower volumes.
• (^) Repetitive process is a Processes used to produce one or a few standardized products in high volume Read more on the differences between Intermittent process and repetitive process

Designing a process

• (^) Designing of a process to be used in producing a particular product is aided with a technique called Process flow analysis
• (^) Process flow Analysis is a technique used for evaluating a process in terms of the sequence of steps from inputs to outputs with the goal of improving its design.
• (^) The process flow analysis is a aided with the use of process flow chart
• (^) A process flowchart is used for viewing the sequence of steps involved in producing the product and the flow of the product through the process.
• It is useful for seeing the totality of the operation and for identifying potential problem areas.

Process Performance Matrix

• (^) An important way of ensuring that a process is functioning properly is to measure its performance.
• (^) Process performance metrics are measurements of different process characteristics that tell us how a process is performing.
• (^) Among the performance metrics include throughput time, process velocity, productivity, utilization and efficiency

Some of performance metrics