Principles of Product and Process

Design
Production Process Roadmap
• Original concept (conceptual design, need
driven R & D)
• Preliminary design ( free-hand sketches)
• Design analysis
– value engineering (product, material and
process considerations)
– parametric design (dimensions and shape,
tolerances, design optimisation, DFM, CE,
FEM)
• Detailed working drawings (draughting)
• Material and Process selection
• First model (prototype, physical or
virtual)
• Testing or verification (laboratory, field
or simulation)
• Revised model (iterations)
• Production and Process details or
specifications (production drawings, part
lists, process flow diagrams)
• Production planning and scheduling
– Material specification and ordering
– Process selection and layout
– Machine, tooling and accessory
selection
– construction of tooling
– machine tool setting and trials
– manufacturing
• Planning storage and distribution
• planning for after sales activities, spare
parts, maintenance etc.
• managing manufacturing support
services
• Improvement of product and process
• Planning for next product innovation
cycle
 Computer-based Automation
• Computer-aided process planning (CAPP)
– process knowledge of shapes, sizes(universal,
shop level and machine level) representation
– process capability information (dimensional,
geometric and surface finish obtainable from
process)
– Geometric and technological constraints (Design
for Manufacture (DFM))
– Economics of processes
(Database and knowledge base combined)
 Computer Integrated
Manufacturing (CIM)
• Computer Aided Design (CAD), CAE
• Manufacturing Resources Planning
(MRP)
• Computer Sided Process Planning
(CAPP)
• Manufacturing by
NC/CNC/DNC/Robotics – CAM -
Statistical Process Control (SPC),
Barcoding, sensors and transducers for
data acquisition Programmable Logic
 Testing, Inspection, Storage
and Distribution systems
• Computer Aided Testing – CAT (e.g. engine
performance, Dynamic balancing machine)
• Measurement and Inspection (Metrology,
Computer Aided Inspection -CAI-, Coordinate
Measuring Machine (CMM)
• Automatic Storage and Retrieval Systems
(ASRS) (Automatically Guided Vehicles -AGVs-
robotic handing, stacker cranes, OCR, MCR)
• Distribution Requirements Planning (DRP/MRP
integration, warehousing & transport logistics)
 Summary

• Selection of a manufacturing process for any

given product has a wide range of alternative
choices of technology
• Choice among alternatives is governed by
business economic and strategic
considerations
• Product Design process continues into
process design and integrates with
manufacturing - DFM
• There is a road map to be followed for
commercialising innovative products