Product development : a structured approach to consumer product development, design, and manufacture

522 Pages·2015·17.32 MB·English

by  Anil Mital

Product Development
Product Development
A Structured Approach to
Consumer Product Development,
Design, and Manufacture
Second Edition
Anil Mital
Mechanical Engineering and Manufacturing
Engineering and Design, University of Cincinnati,
Cincinnati, Ohio, USA
Anoop Desai
Mechanical Engineering, Georgia Southern University,
Statesboro, Georgia, USA
Anand Subramanian
JF Associates, Vienna, Virginia, USA
Aashi Mital
History Department, University of Cincinnati,
Cincinnati, Ohio, USA
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First edition 2008
Second edition 2014
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Dedication
To our families and colleagues.
Preface to the second edition
Our intention in preparing the first edition was to provide a comprehensive coverage
of the product development process—from conceiving a product to designing it and,
finally, manufacturing it. The coverage also included a critical aspect of the product
development process, that is, design of the facility to manufacture the final product.
We felt that such coverage was lacking; most product design books on the market tend
to be single dimensional, covering only one aspect of the product development pro-
cess. The coverage tends to focus on manufacturing, marketing, materials, quality, or
some similar aspect. The excellent reviews the first edition received from professional
journals and peers, and its adoption by many universities in their curricula motivated
us to undertake the preparation of the second edition.
As we noted in the first edition, much of the information focuses on the funda-
mentals of the product development process; it is time-tested and covers the basics
of issues such as the product design process, selection of materials, and choice of
the manufacturing method, and is, therefore, not subject to drastic changes from edi-
tion to edition. The reader will find that much of the basic information has remained
unchanged, or has undergone only minor changes in the second edition as well. We
have added and corrected material throughout the text. As new research has come
to light, we have made additions accordingly. For instance, a new chapter has been
added integrating design guidelines pertaining to concurrent consideration of product
usability and its functionality. Basic information in Chapter 1 has also been updated.
The changes in the second edition, thus, are incremental in nature.
As before, the chapters are divided into three parts. One can focus as much attention
on each part as one desires. We would like to emphasize that the product development
process involves a wide variety of expertise that simply cannot be provided by a single
individual. It is a team process rather than a singular effort. And yet there are aspects
that rely more on the creativity of an individual than the whole team—for instance, con-
ceiving the physical form or the preliminary design. In a classroom setting, therefore,
one can emphasize both individual creativity as well as team effort.
It is our hope that this revised edition will be as useful as the first edition and will
continue to provide an overview of the entire product development process to indi-
vidual practitioners, students, and researchers.
We are very thankful to our colleagues and reviewers who have encouraged us to
undertake the preparation of the second edition by providing positive feedback. This
feedback is particularly appreciated as it has come unsolicited. For this we are very
grateful. We hope the revisions included in the second edition prove to be as useful as
the materials in the first edition and that we have not failed our readers.
Preface
Manufacturing is essential for generating wealth and improving the standard of
living. Historically, developed countries have devoted at least 20% of their gross
domestic product (GDP) to manufacturing. It is unlikely that any nation would
achieve the “developed” status without a significant proportion of its GDP-related
activities devoted to manufacturing. Furthermore, the manufacturing activities must
culminate in production of high-quality products that people need and want, globally.
The emphasis on a global market is critical in today’s economy, characterized by
shrinking national boundaries and globalization of the marketplace. Not only should
the products manufactured be wanted, these should be high-quality products that are
reliable, economical, and easy to use and produce, and are brought to the market in
a timely manner.
Efforts to develop, design, and manufacture a consumer product knowledge base,
by and large, have been fragmented and can be categorized into two main domains.
The first domain primarily comprises product developers who emphasize issues such
as identifying the market, defining product features, and developing promotional
strategies for the market. The second domain comprises mainly manufacturing and
design engineers involved in the technical details of product design and manufacture.
In this context, the emphasis to date has been on only manufacturing processes; to
a very limited extent engineers have focused on issues of product assembly and
maintenance.
As is evident, the development, design, and manufacture of consumer products
entails not only the interests of people in both domains but also those of the consumer
and the user (the two are not necessarily the same). Among their interests are attrib-
utes such as a product’s usability, its functionality, and how its function can be main-
tained and repaired. From the design and manufacturing perspective, there are many
other important considerations, such as how the product components are assembled,
how the product will be disassembled during the course of routine maintenance or
troubleshooting and at the end of its life, and how the material–manufacturing–cost
configuration will be optimized. Such a comprehensive approach to product develop-
ment, design, and manufacture is lacking at present. Also, no books are available that
propagate teaching such a comprehensive product development and design approach.
This book provides a comprehensive approach to product development, design,
and manufacture and attempts to fill the existing void. While this comprehensive
approach has been outlined in archival research publications and taught at the
University of Cincinnati at the graduate level in its College of Engineering, it is yet
to become widely available to students at large. This book is intended to share our
xiv Preface
perspective on the entire product “development to manufacture” spectrum and empha-
sizes the “how-to” process.
Chapters 1 through 3 outline the importance of manufacturing in the global
economy, what kinds of products to develop, and what is the general product design
process. In other words, they discuss why manufacture, what to manufacture, and
how to design what to manufacture. Then Chapters 4 through 10 discuss and describe
specific methodologies dealing with the selection of material and processes, and
designing products for quality, assembly and disassembly, maintenance, functional-
ity, and usability. In Chapters 11 through 13, we cover some basics of manufacturing
cost estimation, assessing (forecasting) market demand, and developing preliminary
design of the facility to manufacture the developed product. While not directly related
to product development and design, we consider this information critical in the overall
product manufacture cycle.
While this book is intended for senior and starting level graduate students, it
should prove useful to any product designer interested in cradle-to-grave design. It
should be particularly useful to all design and manufacturing engineers, production
engineers, and product design researchers and practitioners.
We wish to thank our numerous colleagues and many former students who have
encouraged us to undertake the writing of this book, telling us time and again how
much such an effort was needed. We hope we have not failed them and have met their
expectations, partially if not fully.
Biographies
Anil Mital is Professor of Mechanical Engineering and Manufacturing Engineering and
Design at the University of Cincinnati. He is also a Professor of Physical Medicine and
Rehabilitation at the University of Cincinnati. Formerly, he was a Professor and Director
of Industrial Engineering at the same institution. He holds a B.E. degree in Mechanical
Engineering from Allahabad University, India, and an M.S. and Ph.D. in Industrial
Engineering from Kansas State University and Texas Tech University, respectively.
He is the Founding Editor-in-Chief Emeritus of the International Journal of Industrial
Ergonomics, and the Founding Editor-in-Chief Emeritus of the International Journal
of Industrial Engineering. He is also the former Executive Editor of the International
Journal of Human Resource Management and Development and author/coauthor/
editor of over 500 technical publications, including 24 books and over 200 journal
articles. His current research interests include Design and Analysis of Human-Centered
Manufacturing Systems, Application of DFX Principles to Product Design, Economic
Justification, Manufacturing Planning, and Facilities Design. He is the founder of the
International Society (formerly Foundation) of Occupational Ergonomics and Safety
and winner of its first Distinguished Accomplishment Award (1993). He is a Fellow of
the Human Factors and Ergonomics Society and recipient of its Paul M. Fitts Education
Award (1996) and Jack A. Kraft Innovator Award (2012). He is also a recipient of the
Liberty Mutual Insurance Company Best Paper Award (1994) and a Fellow of the
Institute of Industrial Engineers and Past Director of its Ergonomics Division. In 2007,
he received the Dr. David F. Baker Award from the Institute of Industrial Engineers
for lifetime research activities. He has also received the Eugene L. Grant Award from
the American Society of Engineering Education and the Ralph R. Teetor Award from the
Society of Automotive Engineers.
Anoop Desai is an Associate Professor of Mechanical Engineering in the College
of Engineering and Information Technology at Georgia Southern University. He
received his Ph.D. in Industrial and Manufacturing Engineering from the University of
Cincinnati in 2006. His main research interests are product life cycle management and
design. His research deals extensively with design for “X” principles, focusing on green
design, environmentally conscious manufacturing, and design for maintainability. He is
also actively involved in research and teaching in the areas of Engineering Economy,
New Product Development, CIMS, and Quality Control. He has written over 70 articles,
including over 25 journal papers, and his work has been widely cited.
xvi Biographies
Anand Subramanian is a Senior Managing Engineer at JFAssociates, Inc. based in
the Washington, DC, area. He received his doctoral and master’s degrees in Industrial
Engineering from the University of Cincinnati, OH, and bachelor’s degree in Production
Engineering from the University of Bombay, India. He is a Certified Six-Sigma Black
Belt and also a registered Certified Professional Ergonomist with the Board of Certified
Professionals on Ergonomics. Since 2003, he has been associated with JFAssociates,
Inc., where his responsibilities include leading and conducting time and motion studies,
experimental design, data collection, statistical data analysis, data modeling and report-
ing, identifying and evaluating specific needs and requirements of users, performing
ergonomic evaluations of office workstations and manufacturing workstations, devel-
oping and implementing ergonomic programs, and preparing reports and presentations.
His areas of specialty include time and motion studies, process improvement, ergo-
nomic evaluations, economic analyses, facilities planning, and warehouse design. He is
coauthor of a number of national and international journal publications and has made
presentations at a number of prestigious Industrial Engineering and Ergonomics confer-
ences. Currently, he is the coeditor of the Industrial and Systems Engineering Review
(ISER), an open access journal aimed at the advancement of industrial and systems
engineering theory and practice as applied to any enterprise system. He also serves as a
member of the Board of Directors of the Institute of Industrial Engineers (IIE) National
Capital Chapter since 2011. From 2007 to 2011, he served as the managing editor of
the International Journal of Industrial Engineering: Theory, Applications, and Practice.
Aashi Mital currently attends the University of Cincinnati, where she continues her
advanced studies in Nineteenth-Century American History and Classical Archaeology.
Her research and publication interests focus on Received Memory in Post-Civil War
Southern Culture, Radical Reconstruction, the Industrial Revolution, and Geopolitical
Relations of the Greek Archaic Period. She is the Assistant Historian at the Cincinnati
Observatory and serves as a professional consultant for the collaborative Museums and
Historic Sites of Greater Cincinnati organization. All of this allows her to fulfill an ever-
growing passion for outreach education, museum operations, and public relations, as
well as groundbreaking research. Throughout her ongoing duties for the International
Journal of Industrial Engineering: Theory, Applications and Practice, she strives to
create parallels, by means of interdisciplinary work, in order to reexamine historical
methodologies and create new approaches within the industry. The young historian finds
inspiration through her interests, including astronomy, sailing, cooking, wine tasting,
and the arts.
The Significance of 1
Manufacturing
1.1 Globalization and the world economy
Globalization of the marketplace is synonymous with, or akin to, the free flow of
goods and services, labor, and capital around the world. Aided by huge improvements
in global communication and the transport industry, the barriers to free trade are being
eroded, and most countries are advancing on the path to embracing market capital-
ism. This includes not only traditional capitalist nations such as the United States and
United Kingdom, but communist giants such as China and social republics such as
India. In countries such as India and Brazil, large pools of inexpensive and relatively
skilled workers are putting pressure on jobs and wages in the rich countries in Europe
and North America and, lately, China (a machine operator in China earns about $6405
compared to $4817 in India; Time, 2013). For consumers, the benefits of free trade
are reflected in cheaper and better quality imports, giving them more for their money.
This, in turn, forces the domestic producers to become increasingly competitive by
raising their productivity and producing goods that can be marketed overseas.
For a long time, the West (North America and Western Europe) dominated the
world economy by accounting for most of the global output of products and services.
This picture has undergone a major change in the last few years; currently over half
the global economic output, measured in purchasing power parity (to allow for lower
prices in economically poorer countries), is accounted for by the emerging world.
Even in terms of GDP (gross domestic product), the emerging world countries (also
referred to as the Third World or poor countries) account for nearly one-third the total
global output and more than half the growth in global output. The trend clearly indi-
cates that economic power is shifting from the countries of the West to emerging ones
in Asia (King and Henry, 2006; Oppenheimer, 2006). At the present time, developing
countries consume more than half the world’s energy and hold nearly 80% of the
foreign exchange reserves; China leads the pack, with nearly $3.66 trillion in foreign
exchange reserves (The Wall Street Journal, 2013). The exports of emerging econo-
mies in 2012 were approximately 50% of total global exports. Clearly, this growth in
the emerging world countries, in turn, accelerated demand for products and services
from traditionally “developed” countries. Globalization, therefore, is not a zero-sum
game: China, India, Brazil, Mexico, Russia, and South Korea are not growing at the
expense of Western Europe and North America. As individuals in emerging econo-
mies get richer, their need and demand for products and services continue to grow.
Product Development. DOI: http://dx.doi.org/10.1016/B978-0-12-799945-6.00001-6
© 22001145 Elsevier Inc. All rights reserved.