Mata kuliah : J0444 - Manajemen Operasional Tahun : 2010 Product and Service Design Pertemuan 03 Learning Objectives • • • • Explain the strategic importance of product and service design. List some key reasons for design or redesign. Identify the main objectives of product and service design. Briefly describe the phases in product design and development. Learning Objectives Identify or Define: • Issues for Product Development – – – – – – – Robust Design Modular Design Computer-Aided Design (CAD) Computer-Aided Manufacturing Virtual Reality Technology Value Analysis Environmentally Friendly Design Explain • Product document • Service Design Humor in Product Design As the customer wanted it. As Marketing interpreted it. As Operations made it. As Engineering designed it. What is a Product? • Need-satisfying offering of an organization – Example • P&G does not sell laundry detergent • P&G sells the benefit of clean clothes • Customers buy satisfaction, not parts • May be a good or a service What Does Product and Service Design Do? • Translate customer wants and needs into product and service requirement (marketing, operations) • Refine existing products and services (marketing) • Develop new products and/or services (marketing, operations) • Formulate quality goals (marketing, operations) • Formulate cost targets (accpinting, finance, operations) • Construct and test prototypes (operations, marketing, engineering) • Document specifications Product Components Product Brand (Name) Physical Good Product Idea Features Quality Level Package Service (Warranty) Product and Service Design • Major factors in design strategy – Cost – Quality – Time-to-market – Customer satisfaction – Competitive advantage Product and service design – or redesign – should be closely tied to an organization’s strategy Reasons for Product or Service Design • Economic • Social and demographic • Political, liability, or legal • Competitive • Cost or availability • Technological Objectives of Product and Service Design • Main focus – Customer satisfaction – Understand what the customer wants • Secondary focus – – – – – – Function of product/service Cost/profit Quality Appearance Ease of production/assembly Ease of maintenance/service Life Cycles of Products or Services Saturation Deman d Maturity Decline Growth Introduction Time Introduction • Fine tuning – research – product development – process modification and enhancement – supplier development Growth • Product design begins to stabilize • Effective forecasting of capacity becomes necessary • Adding or enhancing capacity may be necessary Maturity • Competitors now established • High volume, innovative production may be needed • Improved cost control, reduction in options, paring down of product line Decline • Unless product makes a special contribution, must plan to terminate offering Sales, Cost & Profit . Product Life Cycle, Sales, Cost, and Profit Cost of Development & Manufacture Sales Revenue Profit Loss Introduction Growth Cash flow Time Maturity Decline Scope of product development team Product Development Stages • • • • • • • • • Idea generation Assessment of firm’s ability to carry out Customer Requirements Functional Specification Scope of design for Product Specifications manufacturability Design Review and value Test Market engineering teams Introduction to Market Evaluation Idea Generation Supply chain based Ideas Competitor based Research based Quality Function Deployment • Quality Function Deployment – Voice of the customer – House of quality QFD: An approach that integrates the “voice of the customer” into the product and service development process. The House of Quality Correlation matrix Design requirements Customer requirements Relationship matrix Specifications or target values Competitive assessment House of Quality Example Correlation: X X Water resistance Accoust. Trans. Window Check force on level ground Energy needed to open door Door seal resistance Energy needed to close door Engineering Characteristics X X X X * Strong positive Positive Negative Strong negative Competitive evaluation X = Us A = Comp. A B = Comp. B (5 is best) 1 2 3 4 Customer Requirements Easy to close 7 X Stays open on a hill 5 X AB Easy to open 3 Doesn’t leak in rain 3 No road noise Importance weighting 2 AB XAB A XB X BA X 9 Reduce energy to 7.5 ft/lb. B A X B X A 2 3 Maintain current level B A 6 Maintain current level 5 4 3 2 1 6 Maintain current level Reduce energy level to 7.5 ft/lb 10 Reduce force to 9 lb. X A Target values Technical evaluation (5 is best) 5 BXA BA X Relationships: Strong = 9 Medium = 3 Small = 1 B House of Quality Example You’ve been assigned temporarily to a QFD team. The goal of the team is to develop a new camera design. Build a House of Quality. © 1984-1994 T/Maker Co. House of Quality Example Customer Customer Requirements Importance Target Values High relationship Medium relationship Low Relationship House of Quality Example What the customer desires (‘wall’) Customer Customer Requirements Importance Aluminum Parts Auto Focus Auto Exposure Light weight Easy to use Reliable Target Values High relationship Medium relationship Low Relationship House of Quality Example Average customer importance rating Customer Customer Requirements Importance Light weight Easy to use Reliable Aluminum Parts Auto Focus Auto Exposure 3 2 1 Target Values High relationship Medium relationship Low Relationship House of Quality Example Relationship between customer attributes & engineering characteristics (‘rooms’) Customer Customer Requirements Importance Light weight Easy to use Reliable High relationship Aluminum Parts Auto Focus Auto Exposure 3 2 1 Medium relationship Low Relationship House of Quality Example Target values for engineering characteristics (‘basement’); key output Customer Customer Requirements Importance Light weight Easy to use Reliable Target Values High relationship Aluminum Parts Auto Focus 5 1 Auto Exposure 3 2 1 Medium relationship 1 Low Relationship House of Quality Example Customer Customer Requirements Importance Light weight Easy to use Reliable Target Values High relationship Aluminum Parts Auto Focus Auto Exposure 5 1 1 3 2 1 Medium relationship Low Relationship Issues for Product Development • • • • • • Robust design Time-based competition Modular design Computer-aided design Value analysis Environmentally friendly design Robust Design • Product is designed so that small variations in production or assembly do not adversely affect the product Modular Design • Products designed in easily segmented components. • Adds flexibility to both production and marketing Computer Aided Design (CAD) • Designing products at a computer terminal or work station – Design engineer develops rough sketch of product – Uses computer to draw product • Often used with CAM Benefits of CAD/CAM • Shorter design time • Database availability • New capabilities – Example: Focus more on product ideas • Improved product quality • Reduced production costs Extensions of CAD • Design for Manufacturing and Assembly (DFMA) • 3-D Object Modeling • CAD/CAM – CAD info is translated into machine control instructions (CAM) Virtual Reality • Computer technology used to develop an interactive, 3-D model of a product. • Especially helpful in design of layouts (factory, store, home, office) Value Analysis • Focuses on design improvement during production • Seeks improvements leading either to a better product or a product which can be more economically produced. Environmentally Friendly Designs • Benefits – Safe and environmentally sound products – Minimum raw material and energy waste – Product differentiation – Environmental liability reduction – Cost-effective compliance with environmental regulations – Recognition as good corporate citizen “Green” Manufacturing • • • • • • Make products recyclable Use recycled materials Use less harmful ingredients Use lighter components Use less energy Use less material Time-based Competition • Product life cycles are becoming shorter. Faster developers of new products gain on slower developers and obtain a competitive advantage Product Development Continuum External Development Strategies Alliances Joint Ventures Purchase Technology or Expertise by Acquiring the Developer Internal Development Strategies Migrations of Existing Products Enhancement to Existing Products New Internally Developed Products Internal ----------------------Cost of Product Development --------------------- Shared Lengthy --------------------Speed of Product Development---------------Rapid and/or Existing High ------------------------- Risk of Product Development ----------------------- Shared Product Documents • Engineering drawing – Shows dimensions, tolerances, & materials – Shows codes for Group Technology • Bill of Material – Lists components, quantities & where used – Shows product structure Engineering Drawings - Show Dimensions, Tolerances, etc. Bill of Materials – Manufacturing Plant and Fast-Food Restaurant Hard Rock Café’s Hickory BBQ Bacon Cheeseburger Bill of Material for a Panel Weldment Number A60-71 Description Panel Weldm’t Qt y 1 A 60-7 R 60-17 R 60-428 P 60-2 Lower Roller Assembly Roller Pin Locknet 1 1 1 1 60-72 R 60-57-1 A 60-4 02-50-1150 Guide Assem. Rear Support Angle Roller Assem. Bolt 1 1 1 1 A 60-73 A 60-74 R 60-99 02-50-1150 Guide Assm, Front Support Weldm’t Wear Plate Bolt 1 1 1 1 Description Qty Bun Hamburger Patty Cheddar Cheese Bacon BBQ Onions Hickory BBQ Sauce Burger Set Lettuce Tomato Red Onion Pickle French Fries Seasoned Salt 11-inch Plate HRC Flag 1 8 oz. 2 slices 2 strips ½ cup 1 oz. 1 leaf 1 slice 4 rings 1 slice 5 oz. 1 tsp 1 1 Make-or-Buy Decisions • Decide whether or not you want (or need) to produce an item • May be able to purchase the item as a “standard item” from another manufacturer Group Technology Characteristics • Parts grouped into families – Similar, more standardized parts • Uses coding system – Describes processing & physical characteristics • Part families produced in manufacturing cells – Mini-assembly lines Group Technology Code Example Round Rod 4mm x 45° chamfer 80mm 60mm 112mm Part function (round rod) Material (steel) Max. length (50 < L < 150) Primary machine (lathe) Product Code: 1 5 3 1 Group Technology Schemes Enable Grouping of Parts Group Technology Benefits • • • • • • • Improved product design Reduced purchases Reduced work-in-process inventory Improved routing & machine loading Reduced setup & production times Simplified production planning & control Simplified maintenance Production Documents • • • • Assembly Drawing Assembly chart Route sheet Work order Assembly Drawing • Shows exploded view of product Head Neck Handle End Cap Assembly Chart for A Tuna Sandwich 1 Tuna Fish SA1 Tuna Assy A1 Sandwich 2 Mayonnaise 3 Bread FG A2 Assembly Drawing and Assembly Chart Route Sheet • Lists all operations Route Sheet for Bracket Sequence Machine Operation 1 Shear # 3 2 Shear # 3 3 Drill press Brake press Shear to length Shear 45° corners Drill both holes Bend 90° 4 Setup Time 5 Operation Time/Unit .030 8 .050 15 3.000 10 .025 Work Order Authorizes producing a given item, usually to a schedule © 1984-1994 T/Maker Co. Service Design • Service is an act • Service delivery system – Facilities – Processes – Skills • Many services are bundled with products Service Design Nature of Customer Participation Service Design • Service – Something that is done to or for a customer • Service delivery system – The facilities, processes, and skills needed to provide a service • Product bundle – The combination of goods and services provided to a customer • Service package – The physical resources needed to perform the service Phases in Service Design 1. Conceptualize 2. Identify service package components 3. Determine performance specifications 4. Translate performance specifications into design specifications 5. Translate design specifications into delivery specifications Challenges of Service Design 1. 2. 3. 4. Variable requirements Difficult to describe High customer contact Service – customer encounter Differences Between Product and Service Design • • • • • • • • Tangible – intangible Services created and delivered at the same time Services cannot be inventoried Services highly visible to customers Services have low barrier to entry Location important to service Range of service systems Demand variability The End