Since the publication of the first edition of Integrated Product and Process Design and Development: The Product Realization Process more than a decade ago, the product realization process has undergone a number of significant changes. Reflecting these advances, this second edition presents a thorough treatment of the modern tools used in the integrated product realization process and places the product realization process in its new context. See what’s new in the Second Edition: Bio-inspired concept generation and TRIZ Computing manufacturing cost, costs of ownership, and life-cycle costs of products Engineered plastics, ceramics, composites, and smart materials Role of innovation New manufacturing methods: in-mold assembly and layered manufacturing This book discusses how to translate customer needs into product requirements and specifications. It then provides methods to determine a product’s total costs, including cost of ownership, and covers how to generate and evaluate product concepts. The authors examine methods for turning product concepts into actual products by considering development steps such as materials and manufacturing processes selection, assembly methods, environmental aspects, reliability, and aesthetics, to name a few. They also introduce the design of experiments and the six sigma philosophy as means of attaining quality. To be globally viable, corporations need to produce innovative, visually appealing, quality products within shorter development times. Filled with checklists, guidelines, strategies, and examples, this book provides proven methods for creating competitively priced quality products.
Author(s): Edward B. Magrab, Satyandra K. Gupta, F. Patrick McCluskey, Peter Sandborn
Edition: 2
Publisher: CRC Press
Year: 2009
Language: English
Pages: 312
Tags: Финансово-экономические дисциплины;Инновации;Маркетинг инноваций;
Contents......Page 1
Dedication......Page 3
Contents......Page 4
Preface — Second Edition......Page 11
Preface—First Edition......Page 13
Authors......Page 15
1.1 Introduction......Page 17
1.2.1.1 Engineering Design......Page 19
1.2.1.4 Producibility......Page 20
1.2.2.1 Just-in-time (jit) Manufacturing......Page 21
1.2.2.3 Lean Manufacturing†......Page 22
1.3 Innovation......Page 23
1.4.1 A Brief History Of The Quest For Quality Products And Services......Page 25
1.4.2 Quality Quantified......Page 26
1.4.3 Six Sigma......Page 29
1.5 Benchmarking......Page 30
1.6 Partnering With Suppliers— Outsourcing......Page 31
1.7 Mass Customization......Page 33
2.1 Introduction......Page 34
2.2 The Ip2d2 Team And Its Agenda......Page 35
2.2.1 stage 1: product Identification......Page 37
2.2.4 stage 4: launch......Page 41
2.3 Technology's Role In Ip2d2......Page 42
2.4.1 Team Requirements......Page 43
2.4.2 Team Creativity......Page 45
2.4.2.2 Enlarging The Search Space......Page 47
3.1.2 Scope Of The Chapter......Page 49
3.2.1 The Cost Of Ownership......Page 51
3.2.3 Hidden Costs......Page 53
3.3.2 Manufacturing Costs......Page 54
3.3.3 Cost Of Manufacturing Quality......Page 58
3.3.4 Test, Diagnosis, And Rework......Page 59
3.4.1 Spare Parts And Availabiiity: Impact Of Reliability On Cost......Page 62
3.4.2 Warranty And Repair......Page 65
3.4.3 Qualification And Certification......Page 66
3.5.1 Return On Investment......Page 68
3.5.2 The Cost Of Money......Page 69
3.6.1 Process Flow Model: The Manufacture Of A Bicycle......Page 70
3.6.1.1 Consideration Of Manufacturing Yield......Page 72
3.6.2 The Total Cost, Selling Price, And Cost Of Ownership Of A Bicycle......Page 73
3.6.2.1 Cost Of Ownership......Page 76
3.6.3 Parametric Cost Model: Fabrication Of Application-specific Integrated Circuits......Page 77
3.6.4 The Return On Investment Associated With Web Banner Advertising......Page 80
3.6.5 Comparing The Total Cost Of Ownership Of Color Printers......Page 82
3.6.6 Reliability, Availabiiity, And Spare Parts Of New York City Voting Machines......Page 84
Bibliography......Page 86
4.1 Voice Of The Customer......Page 87
4.1.1 recording the voice of the customer......Page 89
4.1.2 analyzing the voice of the customer......Page 91
4.2.1 Introduction......Page 92
4.2.2 Qfd And The House Of Quality......Page 93
4.3 Product Design Specification......Page 99
5.1.1 Introduction......Page 104
5.1.2 Functional Decomposition And The Axiomatic Approach: Introduction......Page 105
5.1.3 Functional Decomposition And The Axiomatic Approach: Two Axioms......Page 108
5.1.4 Functional Decomposition And The Axiomatic Approach: Mathematical Representation......Page 110
5.2.1 Introduction......Page 112
5.2.2 Example 1—carton Taping System......Page 114
5.2.3 Example 2—intelligent V-bending Machine*......Page 117
5.2.4 Example 3—high-speed In-press Transfer Mechanism*......Page 119
5.2.5 Example 4—drywall Taping System......Page 121
5.2.6 Example 5—steel Frame Joining Tool......Page 123
6.1 Introduction......Page 125
6.1.1 Initial feasibiIity analysis......Page 126
6.1.3 estimation example 2......Page 128
6.2.1.2 Ideas That Can Come From A Brainstorming Session......Page 129
6.2.2 Morphological Method......Page 132
6.2.3 Triz......Page 135
6.2.4 Bio-inspired Concepts......Page 143
6.3 Product Modularity And Architecture......Page 146
6.4 Concept Evaluation And Selection......Page 148
6.5 Product Embodiments......Page 155
Bibliography For Bio- Inspired Concepts......Page 156
7.1 Introduction......Page 157
7.2.1 Why Assemble?......Page 158
7.2.2 Assembly Principles And Guidelines......Page 159
7.2.3 Summary Of Design-for-assembly Guidelines......Page 160
7.2.4 Manual Assembly Versus Automatic Assembly......Page 164
7.3.2 Dfd Guidelines And The Effects On The Design For Assembly......Page 165
8.1.2 Guidelines For Materials Selection......Page 167
8.1.2.3 Reliability And Environmental Resistance......Page 169
8.1.2.4 Cost......Page 170
8.2.1 Plain Carbon Steels......Page 174
8.2.2.1 Low- Alloy Steels......Page 175
8.2.2.2 Tool Steels......Page 178
8.2.3 Cast Irons......Page 179
8.2.3.2 Malleable Irons......Page 180
8.3.1.1 Zinc Alloys......Page 181
8.3.1.2 Aluminum Alloys......Page 182
8.3.1.4 Titanium Alloys......Page 186
8.3.2.1 Copper Alloys......Page 187
8.3.2.3 Tin Alloys......Page 190
8.3.3.2 Tungsten Alloys......Page 191
8.4.2 Permanent Magnet Materials......Page 192
8.4.3.1 Resistance Alloys......Page 193
8.4.3.3 Heating Alloys......Page 194
8.5.1 Introduction......Page 195
8.5.2.2 Polypropylene......Page 196
8.5.2.4 Nylons......Page 199
8.5.2.7 Cellulosic Materials......Page 200
8.5.3.4 Polyvinyl Chloride......Page 201
8.5.4.1.2 Solid Resins......Page 202
8.5.4.3 Polyesters......Page 203
8.5.5.3.1 Natural Rubber......Page 204
8.5.6 Engineered Plastics......Page 205
8.5.6.5 Flame Retardant Increase......Page 206
8.6.2 Electrically Insulating Ceramics......Page 207
8.6.4.2 Hard Ferrites......Page 209
8.7.2 Fiber-reinforced Composites......Page 210
8.7.5 Functionally Graded Materials......Page 211
8.8.1 Piezoelectric Materials......Page 212
8.8.3 Shape Memory Materials......Page 213
8.10 Coatings......Page 214
Bibliography......Page 215
9.1.1 Common Design Attributes......Page 216
9.1.2 General Guidelines For Reduced Manufacturing Costs Relative Cost......Page 217
9.1.3 Relationship To Part Shape......Page 220
9.1.4.2.3 Candidate Material And Manufacturing Process......Page 221
9.2.1 Pressure Die Casting......Page 222
9.2.2 Centrifugal Casting......Page 224
9.2.3 Compression Molding......Page 225
9.2.4 Plastic Injection Molding......Page 227
9.2.5 Metal Injection Molding......Page 229
9.2.6 In-mold Assembly......Page 230
9.3.1 Sand Casting......Page 232
9.3.2 Shell Mold Casting......Page 233
9.4.1 Investment Casting......Page 235
9.5.1 Single Point Cutting: Turning And Facing......Page 236
9.5.2 Milling: Multiple Point Cutting......Page 237
9.5.3 Grinding......Page 238
9.6.1 Electric Discharge Machining (edm)......Page 240
9.7.1 Blow Molding......Page 241
9.7.2 Sheet Metal Working......Page 243
9.8.1 Forging......Page 244
9.8.2 Rolling......Page 246
9.8.3 Extrusion......Page 247
9.9.1 Powder Metallurgy......Page 249
9.10.1 Introduction......Page 250
9.10.3 Fused Deposition Modeling......Page 253
9.10.5 Selective Laser Sintering......Page 255
9.10.6 Laminated Object Manufacturing......Page 256
9.10.8 Comparisons Of The Lm Processes......Page 257
Bibliography......Page 259
10.1.1 Introduction......Page 260
10.1.2 Reliability......Page 261
10.1.3 Failure Identification Techniques......Page 262
10.1.4 Design For Wear......Page 265
10.2.1 Introduction......Page 266
10.2.2 The Basic Functions Of Poka-yoke......Page 267
10.3.1 Introduction......Page 268
10.3.2 Standardization......Page 269
10.4.1 Environmental Impact Of Packaging......Page 270
10.5 Design For The Environment......Page 271
10.6 Ergonomics: Usability, Human Factors, And Safety......Page 273
10.7 Material Handling......Page 275
10.8 Product Safety, Liability, And Design......Page 276
10.8.1 Product Liability Law......Page 278
11.1 Introduction......Page 280
11.2 What Is Experimental Design?......Page 281
11.3.1 Designed Experiments And Statistical Process Control......Page 285
11.4.1 Analysis Of Variance (anova)......Page 286
11.4.2 Single-factor Experiment......Page 287
11.4.3 Factorial Experiments......Page 289
11.4.4 Factorial Experiments With One Replicate......Page 291
11.4.5 2k Factorial Analysis......Page 292
11.4.6 2k Factorial Analysis With One Replicate......Page 295
11.4.7 Regression Model Of The Output......Page 298
11.4.8 2k Fractional Factorial Analysis......Page 299
11.5.2 Example 2—optimum Performance Of An Air-driven Vacuum Cleaner......Page 300
11.6 The Taguchi Method......Page 306
11.6.1 Quality Loss Function......Page 307
11.7 Six Sigma......Page 308
Bibliography......Page 309
Appendix A: Material Properties and the Relative Cost of Raw Materials......Page 310
