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Product design for new products or requirement (Broad-based design methods…
Product design for new products or requirement
Traditional over-the-wall design vs collaborative design
Traditional design
Marketing sends customer needs and attitude information to engineer
Engineer incorporates the information into design drawing and schematics
Purchasing sources the materials necessary for production
Production looks at the design and realizes that it would require expensive process
Production and purchasing send the design back to engineer for revision
send back and forth several round
Logistics found the packaging and shipping costs exceed the budget and system lacks the capacity to get the product to market on time
so it goes until to the final distributor
Collaborative design process
A design team including engineer and other supply chain partner maybe
consider issue from material to final stage of product life cycle
Once all function and partner agree upon it, purchasing and product go to work to bring the design into function
How much collaboration
Over the wall
informal collaboration
formal collaboration
Implementing design collaboration
Proof of concept
Formalize concept
Formalize process
Prioritize opportunities based on best value to encourage adoption
Benefit of design collaboration
Fewer cost overrun
New and improved approaches to design
Improved customer satisfaction
Improved efficiency (fast to market
High product quality for the price
Broad-based design methods
Design for SC
Design for logistics
Design to minimize transportation and storage cost
Design to minimize manufacture and assemble time
Design to maximize standardization
benefit
lowering transportation and warehousing costs increases profit
Warehouses can store more goods, relieving capacity pressures
Recognizable master carton design helps retainers when looking for a particular item to restock from storerooms
Packaging design can allow some retainers to sell directly from a pallet
Tradeoffs
Maximizing items on pallet vs retainers' need
Product requirement may make standard box sizes problematic
density of items to balance between vehicle volume and weight
Design for X
Standardization
Component commonality
Benefits
Lower purchasing cost
More streamline production
simpler, cheaper storage
Tradeoffs
Cost of product modifications required to accept the new part
less flexibility for designers
Reduction in quality
Modularization
benefit
Reduce cost of design and manufacturing to create family of product, possibly leveraging postponement
Increase efficiency and decreased cost of production
Expand customer base
Easier, ,more cost-effective shipping, warehousing, and display of the product
Tradeoffs
While modular design may reduce logistics costs, the cost of each product in a family may go up
Errors in module assembly can create a poor end user experience
Integral design allows more emphasis on style
Univerality
Benefit
Increase sales vilume
Reduce design and manufacture cost compared to market-specific items
Tradeoffs
less suited to any given market
Simplification
Concurrent Engineering (CE)
benefit
Emphasizes design collaboration
shorten the design cycle
Can make use of newer collaborative design tools for interactive design participation in virtual meetings
Tradeoffs
CE has been replaces by design for manufacturing and assembly
Design for Manufacturing and Assembly(DFMA)
Goal
To select material for ease production
To design component , not require tight tolerances
To reduce number of parts
To reduce number instances parts need to be handled
To use concurrent and parallel processing to reduce work -in-process time
To make assembly obvious and easy
To simplify the process steps for assembly
To design in easy production testing
Benefit
Confusion, complexity and variability are reduced, reduced production delays, long setup times, and extensive training requirement
Standard and policy
DFMA make use of standardization
It assists lean philosophies, modular design , and mass customization
Software automates many features of DFMA
Tradeoffs
Odds with customer demand and market desire if simplification result in some demanded features being omitted
Design for service
benefit
Lower the total cost of ownership
A significant source of profit
Tradeoffs
Compete with other design goal
Quality
Design for Quality
Benefit
Fewer defect reduce waste and increase customer satisfaction
Order qualify to Order winner if the company's strategy is to compete for quality
Tradeoffs
significant initial expense
the saving is hard to trace back to quality program
Design for six sigma
Quality function deployment(QFD)
benefit
Provide all the benefit of design for quality
Improve customer service
Show relative levels of interactions between desired product characteristics so they can be prioritized when in conflict with one another
tradeoffs
requires the organization to wholeheartly champion , adopt ,and maintain it .
Customization
Mass customization
Benefit
Increase efficiency and expertise of workers who create assembled -to-order modules
Increase sales volume
Reduce inventory cost
Creation semiskilled jobs to benefit local communities
Saving due to economic scale
Tradeoffs
Cost of investing in equipment and training to enable distributors to assemble the product
Potential friction with distributors who dont want the added tasks
Potential for quality issue if the assembler is poorly trained
Postponement
benefit
a countermeasure against bullwhip effect
The amount of in transit inventory is reduced, insurance , handling cost decrease, cash flow incrase
Materials needed only locally can be locally sourced and produced
tradeoffs
Require process, equipment, product, and packaging redesign capital expenditures
Can actually increase cost if there are few varieties of the end product
glocalizaiton
Sustainability
Design for the environment(DFE)
Provision for reuse or recycling
Reduced energy consumption
Avoidance or mitigated danger of hazardous materials
Use of lighter components and less material
Benefit
Consistent with SC management's attention to all phases of the product life cycle
Enhanced corporation reputation and resulting goodwill
Limits on corporate liability and legal costs that can result from harm to the environment or violation of regulations
Increased marketability among ecology-minded customer
Tradeoffs
Increased manufacturing expenses and higher price to the consumer
Reduced safety and convenience when some products are small and light
Reduced longevity of natural, less- process products
Design for reverse logistic
Benefit
Enhanced customer royalty resulting from ease of repair
Lower cost of return
Improved product designs through attention to reasons for returns
Tradeoffs
the reverse logistic system is often underestimated
Design for remanufacture
Benefit
Lower cost, lower impact on the environment, and lower product development cost
Tradeoffs
cash can be tied up in inventory