Design for product success

313 Pages·2002·8.253 MB·English

by  Shetty, Devdas

About the Book
Design influences the cost of a product as it grows from conception, through stages
of research, development, market testing, use, maturity, and, finally, disposal. An
organization has the greatest control over the ultimate success of a product at the
early stages of its creation, when the market, its factory and operational costs, and
life cycle are determined.
Design for Product Success presents the concepts used as a basis for developing high-
quality products through the examination of analytical tools and case studies, some
of the topics explored in this book include:
•product team building;
for
(cid:127)characteristics of self-directed product teams;
(cid:127)new product creation strategies and processes;
(cid:127)creative design techniques;
product
(cid:127)principles of design for manufacturing;
(cid:127)design for disassembly; and

(cid:127)ergonomics.
f
success
A section on lean and its influence on product development is included, along with o
information on creating virtual prototypes with computer-assisted design (CAD).
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About the Author
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o
Devdas Shetty, Ph.D. is a professor of mechanical engineering at the
University of Hartford in Hartford, Connecticut. He holds the Roosa Chair d
in Manufacturing Engineering and is the director of the Engineering Ap-
u
plications Center. Shetty has published more than 100 papers in scien-
tific journals and conferences. His last book, Mechatronics System Design, c
published in 1999, has been used as a text since Spring 1998 at 22 uni- t
versities.
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Shetty
Devdas Shetty
Society of
Manufacturing
Engineers Society of
www.sme.org Manufacturing Devdas Shetty
Engineers
www.sme.org
Design for Product Success
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Design for Product Success
Devdas Shetty
Society of Manufacturing Engineers
Dearborn, Michigan
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Copyright © 2002 by Society of Manufacturing Engineers
987654321
All rights reserved, including those of translation. This book,
or parts thereof, may not be reproduced by any means, in-
cluding photocopying, recording or microfilming, or by any
information storage and retrieval system, without permis-
sion in writing of the copyright owners.
No liability is assumed by the publisher with respect to use
of information contained herein. While every precaution has
been taken in the preparation of this book, the publisher
assumes no responsibility for errors or omissions. Publica-
tion of any data in this book does not constitute a recom-
mendation or endorsement of any patent, proprietary right,
or product that may be involved.
Library of Congress Catalog Card Number: 2002102724
International Standard Book Number: 0-87263-527-9
Additional copies may be obtained by contacting:
Society of Manufacturing Engineers
Customer Service
One SME Drive, P.O. Box 930
Dearborn, Michigan 48121
1-800-733-4763
www.sme.org
SME staff who participated in producing this book:
Cheryl Zupan, Staff Editor
Walter Kelly, Consulting Editor
Rosemary Csizmadia, Production Supervisor
Kathye Quirk, Graphic Designer/Cover Design
Jon Newberg, Production Editor
Frances Kania, Production Assistant
Printed in the United States of America
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Dedicated to the loving memory of my parents
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Table of Contents
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Process of Product Realization..................................................................................1
Concurrent Engineering in Design..........................................................................15
Materials and Management in Design....................................................................17
Additional Considerations for New Product Development ........................................18
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Techniques of Creative Concept Generation ...........................................................25
Defining the Problem ............................................................................................32
Design Concept Development Methodology ...........................................................37
Design for Function...............................................................................................40
Understanding the Customer.................................................................................46
Axiomatic Design Method......................................................................................55
Inventive Problem-solving Techniques.....................................................................70
Using a Systematic Approach to Problem Solving....................................................77
Appendix..............................................................................................................81
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Introduction..........................................................................................................87
Design for Manufacturability Methodology .............................................................88
Step-by-step Methodologies.................................................................................101
Comparison of DFM Methods..............................................................................138
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Systematic Process Selection.................................................................................147
Manufacturing Process Selection ..........................................................................148
General Guidelines for Efficient Manufacturing.....................................................153
Design for Reconditioning....................................................................................153
Design for Maintenance ......................................................................................154
Design for Recyclability........................................................................................154
Design for Disassembly .......................................................................................156
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Planning.............................................................................................................156
Design for Life-cycle Manufacture ........................................................................172
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Tools of Optimum Design....................................................................................179
Learning Curve Analysis ......................................................................................188
Design for Quality and Robust Design..................................................................190
Failure Modes and Effects Analysis.......................................................................197
Root Cause Analysis (RCA)...................................................................................205
Product Modeling Using CAD/CAM .....................................................................207
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Workplace Design...............................................................................................219
Production Capacity Model..................................................................................221
Choosing the Production Method .........................................................................221
Flexibility in Manufacturing..................................................................................222
Value Stream MappingSM .....................................................................................226
Summary............................................................................................................238
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World-class Product Development........................................................................241
Product Development Process ..............................................................................241
Technology Selection ...........................................................................................243
Management Phases of Product Development.......................................................244
Web-based Product Development ........................................................................247
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What is a Product Design Group? ........................................................................251
Characteristics of Self-directed Work Groups (SDWG) ...........................................255
Start-up Problems................................................................................................256
Conclusion .........................................................................................................260
Appendix: Beliefs of Proactive Product Group Members.........................................260
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Product and Process in Aerospace (Case Study 1)..................................................261
Improvement Using Assembly Analysis (Case Study 2)...........................................266
Application of Design Methodology (Case Study 3) ...............................................273
Header Attachment in a Heat Exchanger (Case Study 4)........................................277
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Preface
This book, Design for Product Success, cess has seen several changes. To survive,
delves into the techniques used by world- companies must produce products that are
class companies to guide the design and de- globally competitive in a changing environ-
velopment of high-quality products in a ment. Many companies have formed part-
step-by-step manner, using analytical tools nerships with suppliers, customers, and
and case studies. In a global economy that international partners.
is becoming more and more integrated, a Modern manufacturing industries are
shift is taking place in many companies. The adopting the concept of lean thinking. The
price of a product marketed globally is dic- new generation of lean companies is ex-
tated by world economy, and not by one’s pected to meet customer requirements with
own economy or by a company’s marketing products and services that meet function,
edge. Successful companies are the ones that time, and cost requirements, while being
focus on a product and process delivery sys- flexible to changing customer needs.
tem and know how to transform process in- Industries adopting lean practices will be
novations into technical success. expected to make changes in their policies
In today’s competitive environment of and programs. As a result, product design-
manufacturing, product cycles are short and ers and product managers of the future must
markets are fragmented, thus making qual- be more skilled at developing and imple-
ity and speed critical. The automation of menting strategies in totality, rather than
machines and processes has become perva- as a series of isolated steps. The measure of
sive, impacting every dimension of manu- the abilities of product managers to make
facturing. Micro-electromechanical systems, profits while reacting to sudden and unpre-
nanotechnology, and embedded systems dictable changes in customer service de-
have contributed to the development of in- mands is very important. The challenge
telligent products. Also noteworthy is the facing manufacturers today is the improve-
technology of rapid prototyping that assists ment of product development systems. As
in the creation of a product model before it companies feel more competitive pressure
is manufactured. from world-class manufacturers, it is essen-
Driven by global competition and the de- tial that they critically examine their prod-
mand for high quality, lower cost, and quick uct design strategies. The design of a product
delivery times, the product realization pro- determines its method of assembly, compo-
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