Chapter 2
Product Development
2.1 Market Research
2.2 Quality Functional Deployment (QFD)
2.5 Design for Manufacture (DFM),
Concurrent Engineering (CE)
2.6 Drawings & Bill of Materials (BOM)
2.7 Economic Evaluation of Processes
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A. Market Research (1/4)
Consumer-desired Characteristics: (design)
– 產品功能、價格、市場潛力(未來)、外形顏色、
品質要求、消費習性、數量、…..
Market Potential → Sales potential:
type/volume/quantity
Approaches for Collection of Data (p.11)
– Mail survey → 回收率低、問卷
– Telephone survey → 人力較多、問卷
– Personal interview → Cost↑, 數量↓, 極詳細
Survey Form → See Figure 2.1/p.12
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A. Market Research (2/4)
Basic Steps in Market Research (p.12-13)
– Analyze → 目的、限制
– Plan → 何種方法、何種資料需求
– Collect data → 資料來源、正確性、預算
– Analyze the data → 統計分析
– Report → 達成目的、後續應用、…..
Market Decision (p.13-17)
– 決定是否有『利』可圖 → 何謂『利』？
– Profitable ??!! → 投資與獲利 → 工程經濟分析
An Example of Market Research (Decision)
– See text on p.13-17
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A. Market Research (3/4)
Basic Data for Steel Tables
– Products specifications → Table 2.1/p.14
– Estimate demands and prices → Table 2.2/p.14
Results (see p.14~15)
– Forecast demand for next 5 years: Figure 2.2/p.15
– Market share: 8%~17% next 5 years: Table 2.3/p.16
包含預測、生產與銷售量、公司政策、主管企圖心、…
Cost Estimation (p.15-16)
– Direct cost of small table = labor + mat’l. + equip.
= 11.40+12.20+5.72 = 29.32 $/table → Fig.2.3/p.16
– Estimate efficiency (90%) → 29.32/0.9 = 32.57 $/table
– Estimate indirect cost = (Direct labor cost) * (160%)
→ (11.40/0.9)*1.6 = 20.27 $/table
– Total mfg. cost = Direct + Indirect + (Package & Ship.)
= 32.57+ 20.27+1.20 = 54.04 $/table
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A. Market Research (4/4)
Profit Estimation (Concept from 工程經濟)
– Profit = (Price – Cost)* Q’ty.
– Profit for year 1: small + Medium + large =
(63.00 - 54.04)*1344 + 10.20*640 + 18.15*150
– Yearly profits from year 1 to year 5 (右下 & text p.16)
How to make this decision: Go or Not Go ?
– Additional investment: $125,000
– IRR (Internal Rate of Return) = 17% (in this case)
– MARR (Minimal Attractive Rate of Return)
= 15% (management decision)
– IRR > MARR → Go (Accept project)
Other Approaches ?
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B. Quality Functional Deployment
QFD 背景與目的
– First applied in Japan, For product development
– Converting customer requirements into product
design and manufacturing process.
QFD procedure: the coffee maker example
– Fishbone diagram (魚骨圖分析):
what, when, where, why, and how
Example in Figure 2.4/p.18 → 考慮的主/次要因
– QFD Chart:
Customers’ comments → design attributes
Example in Figure 2.5/p.19 → Cross Matrix
– Y: Customer wants, X: Design features
– Symbols: ⊙, ○, △ → Weights ← Customer wants
– Scores in each cell ↔ 重要性 (%顯示)
Results: design features 之重要性 → 其他應用?
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C. Other Topics in Product
Development
Design for Manufacture (DFM) (p.31-33)
–
–
–
–
–
Easy for production, assembly, automation, …..
Design for production → economic view point
Design for assembly → assembly view point
Design for automated Manufacturing
Design for XXXX → …..
Concurrent Engineering (CE) (p.33)
– 與DFM同義、擴充範圍
Drawings and Bill of Materials (BOM) (p.34-37)
– Assembly drawings (Fig.2.9/p.35), Isometric drawings
(Fig.2.10/p.35), Detailed drawings (Fig.2.11/p.36)
– Bill of Material (材料清單)
材質/規格/數量/重量/成本/原物料 → Fig.2.12/p.37
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D. Economic Evaluation of Processes (1/4)
The Example Problem: Basic Assumptions, Data
– Assume: Different processes perform same function
– Assume: Same quality in Process I and Process II
→ Which one is the best ? → from cost view point
– Data requirements: (Table 2.9 / p.38)
Production quantity per month (1000) & efficiency (80%)
Initial cost (機器期初投資) & Life time & Interest rate (何用?)
Setup+handling time per unit (即Operating time per unit)
Reject rate (defective %, 不良品率) & cost of reject per unit
Operating expense per hour & Operator cost per hour
Case A :
Process I:
Mill
Grind
OK (1000 pcs/mon)
Reject 1 (3%)
Process II: Wire-EDM
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Reject 2 (0.5%)
OK (1000 pcs/mon)
Reject 3 (0.5%)
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D. Economic Evaluation of Processes (2/4)
Compare “Monthly Costs” of Process I & II:
– Monthly Costs → Produce 1000 good products
– Capital recovery: p.38(中) → 工程經濟/App.A/p.735-736
i=1%, n=10*12=120 A/P=.0143 → Recovery/month (p.38)
– Reject cost: (# of reject)*(unit reject cost) → p.38-39
# of reject → Grander: 1005-1000=5
Mill
Grind
# of reject → Milling: 1037-1005=32
– Labor cost: (# of labor hour)*(labor $ per hour) → p.39
# of labor hour = (Quantity*Standard Time)/(Efficiency)
– Machine cost: (# of machine hour)*(machine $ per hour)
Assume: # of labor hour = # of machine hour
– Overhead cost: 150% of direct labor cost → p.39
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D. Economic Evaluation of Processes (3/4)
Calculation Results (1,000 pcs/mon)
– For Process I: Show Milling/p.39 only!
(1037*10) / (60X0.8)
= 216.04 hours
1人
1機
TTL cost Process I = 9191.60+6920.75 = 16,112.35
TTL cost of Process II = 11,750.65
Process II is selected: 較便宜!
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D. Economic Evaluation of Processes (4/4)
Case B: modify Process I → Process III
– Cost calculation:
Capital recovery = 35,000*0.0143 = 500.5 & 214.5 $/mon
# of reject = 1000/0.995 – 1000 = 5 (Grand: Input-output)
# of reject = 1005/0.995 – 1005 = 5 (CNC: Input-output)
Reject cost = (Q’ty) * (Unit Cost) = 5*18 + 5*15 = 165
Operation time = max.｛CNC time, Grand time｝=231.46
CNC time = (1010*11)/(60*0.8) = 231.46 hours
Grand time = (1005*11)/(60*0.8) = 230.31 hours
Cost per month (include: Labor + machines + overhead)
→ 231.46*(15 + 2 + 2 + 1.75*15) = 10473.56 $/mon.
1人
2機
– TTL cost = 500.5+214.5+165+10473.56 = 11,353.56 $/mon.
One Operator
Case B :
Process III:
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CNC-Mill
Grind
Reject 1 (0.5%)
OK
Reject 2 (0.5%)
11
End of Chapter 2
Product Development
↓
↓
Tables, Figures
↓
Chapter 2 Homework: #22/p.46-47
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Figure 2-11
Details of a
teakettle
Figure 2-9
Teakettle assembly
Figure 2-10
Teakettle:
Isometric view
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(1.50)
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