Chapter
1.4.1 Capital circulation or the production turn
1.4.2 Manufacturing capability
1.4.6 The S curve of the technology growth cycle
1.4.7 Simultaneous or concurrent engineering
1.4.9 The engineering problem-solving process
2 Developing Successful Products
2.2 Attributes of successful product development
2.3 Key factors to developing successful new products
2.3.2 Customer focus and market orientation
2.3.4 Sharp and early product definition
2.3.5 Execution of activities
2.3.6 Organizational structure and climate
2.3.7 Project selection decisions
2.3.8 Telling the world you have a good product
2.3.9 Role of top management
2.3.10 Speed without compromising quality
2.3.11 Availability of a systematic new product process
2.3.12 Market attractiveness
2.3.13 Experience and core competencies
2.3.14 Miscellaneous factors
2.4 Strategy for new product development
2.4.1 Determining the company’s growth expectations from new products
2.4.2 Gathering strategic information
2.4.3 Determining existing opportunities
2.4.4 Developing a list of new product options
2.4.5 Setting criteria for product inclusion in the portfolio
2.4.6 Creating the product portfolio
2.4.7 Managing the portfolio
2.4.8 Developing new product plans
2.4.8.1 Understanding consumers and their needs
2.4.8.2 Understanding the market
2.4.8.3 Product attributes and specifications
2.4.8.4 Schedules, resources, financials, and documentation
3 The Structure of the Product Design Process
3.2 The changing design process
3.3.1 The need for a model
3.3.2 The need for redundancy
3.3.4 Avoiding starting problem analysis in the middle
3.3.5 Avoiding confirming a false hypothesis
3.3.6 Avoiding tunnel vision
3.4 The requirements for design
3.5.1 Problem confronting the designers
3.5.2 Steps of the engineering design process
3.5.3 Defining the problem and setting objectives
3.5.4 Establishing functions, setting requirements, and developing specifications
3.5.5 Developing provisional designs
3.5.5.2 Analogies and chance
3.5.6 Evaluation and decision making
4 Design Review: Designing to Ensure Quality
4.1.1 Why quality control?
4.1.2 Reactive versus proactive quality control
4.2 Procedures for incorporating high quality in design stages
4.2.1 Design for six sigma
4.2.2 Mistake proofing (Poka-Yoke)
4.2.3 Quality function deployment
4.2.4.2 Failure mode and effects analysis
4.2.4.3 Experimental design
4.3.1 Design review case study
4.3.2 Six sigma case study
5 Consideration and Selection of Materials
5.1 Importance of material selection in product manufacture
5.2 Economics of material selection
5.2.2 Cost of direct labor
5.2.3 Cost of indirect labor
5.3 Material selection procedures
5.3.1 Grouping materials in families
5.3.2 Grouping materials based on process compatibility
5.3.3 Super materials and material substitution
5.3.4 Computer-aided material selection
5.4 Design recommendations
5.4.1 Minimize material costs
5.4.2 Ferrous metals, hot-rolled steel
5.4.3 Ferrous metals, cold-finished steel
5.4.4 Ferrous metals, stainless steel (Franson, 1998)
5.4.5 Nonferrous metals (Skillingberg, 1998)
5.4.5.2 Copper and brass (Kundig, 1998)
5.4.5.5 Zinc and its alloys
5.4.6 Nonmetals (Harper, 1998)
5.4.6.1 Thermosets and thermoplastics
5.4.6.3 Ceramics and glass
6 Selection of Manufacturing Processes and Design Considerations
6.1.2 Secondary processes
6.2.1 Design guidelines for casting (Zuppann, 1998 DeGarmo et al., 1984)
6.2.2 Design guidelines for forging (Heilman and Guichelaar, 1998)
6.2.3 Design guidelines for extrusion (Bralla, 1998)
6.2.4 Design guidelines for metal stamping (Stein and Strasse, 1998)
6.2.5 Design guidelines for powdered metal processing (Swan and Powell, 1998)
6.2.6 Design guidelines for fine-blanked parts (Fischlin, 1998)
6.2.7 Design guidelines for machined parts (Bralla, 1998 DeGarmo et al., 1984)
6.2.7.3 Component design (general)
6.2.7.4 Rotational component design
6.2.7.5 Nonrotational component design
6.2.8 Design guidelines for screw machine parts (Lewis, 1998)
6.2.9 Design guidelines for milling (Judson, 1998)
6.2.10 Design guidelines for planing and shaping (Bralla, 1998)
6.2.11 Design guidelines for screw threads (Engineering Staff, Teledyne Landis Machine, 1998)
6.2.12 Design guidelines for injection molding
6.3 Manufacturing technology decisions
6.4 A typical part drawing and routing sheet
7 Designing for Assembly and Disassembly
7.1.1 Definition and importance of the assembly process
7.1.2 Definition and importance of the disassembly process
7.2.2 Different methods of assembly
7.3 Design guidelines for different modes of assembly
7.4 Methods for evaluating DFA
7.4.1 The Hitachi assemblability evaluation method
7.4.2 Lucas DFA evaluation method
7.4.3 The Boothroyd-Dewhurst DFA evaluation method
7.5 A DFA method based on MTM standards
7.7 Design for disassembly
7.7.2 Disassembly process planning
7.8 Design for disassembly guidelines
7.9 Disassembly algorithms
7.9.1 Product recovery approach
7.9.2 Optimal disassembly sequence planning for product recovery
7.9.3 Disassembly sequence planning for a product with defective parts
7.9.4 Evaluation of disassembly planning based on economic criteria
7.9.5 Geometric models and CAD algorithms to analyze disassembly planning
7.9.6 Automation of disassembly technology and predicting future trends
7.10 A proactive design for disassembly method based on MTM standards
7.11 A design for disassembly case study
8 Designing for Maintenance
8.1.1 Importance of designing for maintenance
8.1.2 Factors affecting ease of maintenance
8.2 Maintenance elements and concepts
8.2.1 Maintenance elements
8.2.2 Maintenance concepts
8.2.2.1 Corrective (reactive) maintenance
8.2.2.2 Preventive (and predictive) maintenance
8.2.2.3 Maintenance of a degrading system
8.2.2.4 Aggressive maintenance
8.2.3 Design review for maintainability: planning for maintenance and its management
8.2.3.1 Review of design specifications
8.2.3.3 Equipment evaluation
8.2.3.4 Component analysis
8.3 Mathematical models for maintainability
8.3.2 An integrated approach to maintenance
8.3.3 Capital replacement modeling
8.3.4 Inspection maintenance
8.3.5 Condition-based maintenance
8.3.6 Maintenance management information systems
8.4 Prediction models for maintenance
8.4.2 The Federal Electric method
8.4.3 The Martin method: TEAM
8.4.4 The RCM method: maintenance management
8.4.5 Design attributes for enhancing maintainability
8.4.6 The SAE maintainability standard
8.4.6.4 Miscellaneous considerations
8.4.6.5 Frequency multiplier
8.4.7 The Bretby maintainability index
8.4.7.3 Operations section
8.4.7.6 General observations about the index
8.5 A comprehensive design for a maintenance methodology based on methods time measurement
8.5.1 A numeric index to gauge the ease of maintenance
8.5.2 Role of work standards and standard times
8.5.3 Common maintenance procedures and the parameters affecting them
8.5.4 Provision for additional allowances for posture, motion, energy, and personnel requirements
8.5.5 Design parameters affecting premaintenance operations
8.5.6 Structure of the index
8.5.6.1 Gaining access to components
8.5.6.2 Pre- and postmaintenance activities after access
8.5.6.3 Maintenance activities
8.5.6.4 Maintenance allowances
8.5.8 Priority criteria for design evaluation
8.6 Developing and evaluating an index
8.6.1 Numeric index and design method for disassembly and reassembly
8.6.2 Numeric index and method for maintenance
8.6.3 Priority criteria for maintenance
8.6.4 A holistic method for maintainability
8.6.5 Design modifications and measures to enhance ease of maintenance
8.7 Design for maintenance case study
9 Designing for Functionality
9.1.1 Definition and importance of functionality
9.1.2 Factors affecting functionality
9.2 Concurrent engineering in product design
9.2.1 Functionality in design
9.2.2 Function and functional representations: definitions
9.3 A generic, guideline-based method for functionality
9.3.1 Phase 1. Development of generic criteria for functionality
9.3.2 Phase 2. Validation and testing of developed criteria and processes
9.4 The procedure for guideline development
9.5 Functionality case study: can opener
9.5.1 Can opener architecture
9.5.2 Can opener manufacturing processes
9.5.3 Guideline development process for the can opener
9.5.4 Identification of important manufacturing variables affecting functionality
9.5.5 Functionality-manufacturing links
9.5.5.1 Design and technical requirements deployment
9.5.5.2 Product deployment
9.5.5.3 Process deployment
9.5.5.4 Manufacturing deployment
9.5.7 Statistical analysis and testing
9.5.8 Hypothesis test results
9.5.9 Discussion of the results
9.5.9.1 Discussion of the reliability test
9.5.9.2 Discussion of the validity test
9.5.9.3 Discussion of the comparison between the two checklists
9.6 Functionality case study: automotive braking system
9.6.1 The function of an automotive braking system
9.6.2 The components of an automotive braking system
9.6.3 Wheel cylinder architecture
9.6.4 Wheel cylinder manufacturing processes
9.6.5 Guideline development procedure for the automotive brake system
9.6.6 Functionality-manufacturing links
9.6.6.1 Design and technical requirements deployment
9.6.6.2 Product deployment
9.6.6.3 Process deployment
9.6.6.4 Manufacturing deployment
9.6.8 Testing and statistical analysis
9.6.8.1 Reliability test results
9.6.8.2 Validity test results
9.6.9 Discussion of the results
9.6.9.1 The reliability test
9.6.9.2 The validity test
10.2 Criteria for designing and manufacturing usable consumer products
10.2.5 Serviceability and maintainability
10.2.6 Environmental friendliness
10.2.7 Recyclability and disposability
10.3 Design support tools and methodologies
10.3.1 Design for producibility
10.3.2 Design for assembly
10.3.5 Quality function deployment
10.4 Design methodology for usability
10.4.1 Development of generic usability evaluation checklists
10.4.2 Development of generic design and manufacturing checklists
10.4.3 Reliability and validity testing
10.4.4 Testing the effectiveness of the design/manufacturing guidelines
10.5 Generic checklist design: methods and case studies
10.5.1 Product development for the usability of a can opener
10.5.1.1 Technical requirements deployment
10.5.1.2 Product deployment
10.5.1.3 Product architecture
10.5.1.4 Process deployment
10.5.1.5 Manufacturing processes
10.5.1.6 Manufacturing deployment
10.5.2 Product development for the usability of a toaster
10.5.2.1 User requirements
10.5.2.2 Technical requirements deployment
10.5.2.3 Product deployment
10.5.2.4 Product architecture
10.5.2.5 Process deployment
10.5.2.6 Manufacturing processes
10.5.2.7 Manufacturing deployment
10.5.3 Checklists for evaluating the usability of a consumer product
10.6 Case study for development of customized checklists
10.6.1 Gauging user requirements
10.6.2 Technical requirements
10.6.3 Product and process characteristics
10.6.4 Manufacturing process attributes
10.6.5 Development of usability and design checklists
11 Concurrent Consideration of Product Usability and Functionality
11.2.1 Developing generic integrated design guidelines
11.2.2 Case study: can opener
11.2.2.1 Identifying linkages
11.2.2.2 Establishing technical requirements and generating product features
11.2.3 Manufacturing process
11.2.3.1 Process deployment
11.2.4 Can opener assembly
11.2.4.1 Manufacturing deployment
11.2.4.2 Development of generic guidelines
11.2.5 Case study: mountain touring bike
11.2.5.1 Customized design and manufacturing guidelines
11.2.5.1.1 Development procedure
11.2.5.2 User requirements
11.2.5.3 Mapping design dimensions
11.2.5.4 Linkage identification
11.2.5.5 Technical requirement deployment
11.2.5.6 Product feature generation
11.2.5.7 Process characteristics
11.2.5.8 Checklist development
11.2.5.9 Survey deployment and testing
11.2.5.9.1 Data collection and analysis
11.2.5.10.1 Reliability and validity
11.2.5.11 Variable screening
11.2.6 Automatic transmission: case study
11.2.6.1 Components of an automatic transmission
11.2.6.2 Performance and usability of automatic transmissions as perceived by users
11.2.6.3 Usability–functionality design criteria
11.2.6.4 Description of group
11.2.6.5 Development of linkages using flow diagrams
11.2.6.6 Development of design guidelines
11.2.6.7 Survey deployment and analysis
11.2.6.8 Test results: reliability and validity
12 Establishing the Product Selling Price
12.2 Cost and price structure
12.3 Information needs and sources
12.4 Estimating direct and indirect costs
12.4.1 Direct labor costs
12.4.2 Direct material costs
12.4.3 Indirect or overhead costs
12.4.4.2 Cost of labor/piece
12.4.4.3 Material cost/piece
12.4.4.5 Total cost/piece
12.5 Product pricing methods
12.5.1 Conference and comparison method
12.5.4 Direct costing or contribution method
13 Assessing the Market Demand for the Product
13.1 Why assess the market demand?
13.2 Methods for assessing the initial demand
13.2.1 Expert evaluation technique
13.2.2 Jury of executive opinion
13.2.4 Sales force composite
13.2.5 Supply chain partner forecasting
13.2.7 Decision tree diagram
13.2.8 Market potential–sales requirement method
13.3 Methods for determining the annual growth
13.3.1 Graphical displays of data
13.3.2 Constant mean model
13.4 Adjusting for seasonal fluctuations
13.4.2 Moving average model
13.4.3 Exponential smoothing
14 Planning the Product Manufacturing Facility
14.2 Determining the location of the manufacturing facility
14.3 Developing the preliminary design for the manufacturing facility
14.3.1 Determining space requirements
14.3.2 Assembly line balancing
14.3.3 Systematic layout planning
Product Development
：A Structured Approach to Consumer Product Development, Design, and Manufacture
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