Manufacturing By Design

Group-1
Mude veera bramhendra naik
Shweta Srivastava
Manju Yadav
Kuldeep Merottha
Vijay Devra

Introduction
In many large companies, design has become a bureaucratic
tangle,
a process Cofounded by
fragmentation,
overspecialization,
power struggles, and
delays.
For Example :
1.According to General Motors executives, 70% of the cost
of manufacturing truck transmissions is determined in the
design stage.
2. Rolls-Royce reveals that design determines 80% of the
final production costs of 2,000 components

 So from these Examples we can say that DESIGN plays an imp

role in the manufacturing a product.
When company put most of its efforts into analysing current
production rather than product design it monitors what
accounts for only about a third of total manufacturing costs.
Establishing a products design calls for crucial choices
1) About materials made or bought,
2) About how parts will be assembled
Better product design has shattered old expectations for
improving cost through design or redesign

 In short, design is a strategic activity, whether by intention or

by default.
It influences flexibility of sales strategies,
speed of field repair,
and efficiency of manufacturing.
Converting a concept into a complex, high-technology product
is an involved procedure consisting of many steps of
refinement.
The initial idea never quite works as intended or performs as
well as desired. So designers make many modifications,
including increasingly subtle choices of materials, fasteners,
coatings, adhesives, and electronic adjustments.
In many cases, designers find that the options become more
and more difficult; negotiations over technical issues, budgets,
and schedules become intense

The Design Team and Its Task

Multifunctional teams are currently the most effective
way known to cut through barriers to good design.
Top executives should make their support and interest
clear.
Various names have been given to this team approach,
like simultaneous engineering and concurrent design.

Different companies emphasize different strengths

within the team

 In many Japanese companies, teams like this have been

functioning for so long that most of the employees cannot
remember another way to design a product.
Teams need a step-by-step procedure that disciplines the
discussion and takes members through the decisions that
crop up in virtually every design.
In traditional design procedures, assembly is one of the last
things considered.
Assembly should be considered much earlier. Assembly is
inherently integrative. Weaving it into the design process is
a powerful way to raise the level of integration in all aspects
of product design.

Design teams chief functions

Determine the character of the product, to see what it is and thus
what design and production methods are appropriate.
Subject the product to a product function analysis, so that all
design decisions can be made with full knowledge of how the item
is supposed to work and all team members understand it well.

Carry out a design-for-producibility-and-usability study to

determine if these factors can be improved without impairing
functioning.

Designing an assembly process appropriate to the products

particular character. This involves creating a suitable assembly
sequence, identifying subassemblies, integrating quality control,
and designing each part so that its quality is compatible with the
assembly method.

Designing a factory system that fully involves workers in the

The Products Character

This article to establish by what criteria one judges,
develops, or revamps the features of products.
Character defines the criteria by which designers judge,
develop, or revamp product features.
That manufacturing engineers should ensure that the
product is field repairable, how skilled users must be to
employ it successfully, and whether marketability will be
based on model variety or availability of future add-ons.

Product Function Analysis

Understand a products function in relation to production
methods
Product designers and manufacturing engineers used to
understand these relations by intuition and experience
Product function analysis can reduce the number of parts in
a product
This benefits to purchasing (fewer transactions),
manufacturing (fewer operations, material handlers) and
field services (fewer repair parts)

Design For Producibilty

The most important thing to manufacturing strategy is
designing for the production process.
Designing was only subjected for manufacturing and assembly,
and value engineering, which both strive to reduce costs.
But now we have to go beyond these goals.
Value Engineering comes into play only after when design is
finished.
Thoroughness in designs can only be achieved by making
decisions earlier.

 Design for producibilty differs from the design for

assembly.
Design for assembly cannot achieve the most
fundamental improvements
Considers the products as a collection of parts
instead of something to satisfy larger goals.
(reducing cost over the life-cycle).
For understanding the design for producibilty lets
take the example of Nippondenso

Nippondenso-Case

Manufacture Car products Radiator, antiskid breaks,

generators, alternators etc.
Problem-Daily orders for thousands of items in arbitrary
model mixes and quantities.
Solution 1) Combinatorial Method
2) In-house development
3) Methods that dont need jigs and fixtures

Combinatorial method1) Divides a product into subassemblies

2) Identifies variations of each assemblies
Product- Permutation of all this variations to go together physically
and functionally
In House Manufacturing1) Cooperates in designing the parts so that each variety of product
can be easily handled.
Jigless Production1) Design the parts with common jigging features.
2)One jig can hold all varieties, or by working with designers to
make the product
snap or otherwise hold itself together so that
no clamping jigs are needed.

 Without a guiding strategy, there is no way to tell what

suggestions for improvement really support long-range
goals.
Some product-design techniques depend too much on
rules, including rule-based systems stemming from
expert systems.
These are no substitute for experienced people.

Volkswagen, for example, recently violated

conventional ease-of-assembly rules to capture
advantages the company would not otherwise have
had.

Assembly Processes
Usually assembly sequence is looked at late in the design
process when industrial engineers are trying to balance the
assembly line.
But the choice of assembly sequence and the identification
of potential subassemblies can affect or be affected by
among other factors.
Product-testing options
Market responsiveness
Factory-floor layout
Indeed, assembly-related activities with strategic
implications include:
Subassemblies
Assembly sequence
Assembly method for each step
Integration of quality control

A product with six parts

Can build it many ways

such as :
Bottom up
Top down
From three subassemblies of two parts each.

What determines the best way?

Production strategy advantages:

Making subassemblies to stock that will be common
to many models, or that permit assembly from
commonly available parts.

Construction needs:

Process reasons:
Abilityto hold pieces accurately
for machine assembly;

What determines the best way?

A balance of many consideration

Quality control matters:

The operators ability to make crucial tests or easily
replace a faulty part.

Access to fasteners
Lubrication points
Ease of assembly

Role of software

Help the designer with the formidable problem of listing all the
possible assembly sequences.
It would be impossible for a team to attack so complex a series
of choices without a computer design aid to help, according to a
pre-stablished hierarchy of goals like that just discussedaccess
to lubrication points, etc.
It forces the team to specify choices systematically and
reproducibly, for team members own edification but also in a
way that helps justify design and manufacturing choices to top
management.

With respect to assembly machines and tooling,

manufacturers should consider the following
questions
**Can
Canthe
theproduct
productbe
bemade
madeby
byadding
addingparts
partsfrom
fromone
onedirection,
direction,or
or

must
mustititbe
beturned
turnedover
overone
oneor
ormore
moretimes?
times?
Turnovers
Turnoversare
arewasted
wastedmotion
motionand
andcostly
costlyininfixtures.
fixtures.

**As
Asparts
partsare
areadded
addedininaastack,
stack,will
willthe
thelocation
locationfor
foreach
eachsubsequent
subsequentpart
part
drift
driftunpredictably?
unpredictably?IfIfso,
so,automatic
automaticassembly
assemblymachines
machineswill
willneed
needexpensive
expensive
sensors
sensorstofind
tofindthe
theparts,
parts,or
orassembly
assemblywill
willrandomly
randomlyfail,
fail,or
orparts
partswill
willscrape
scrape
on
oneach
eachother
othertoo
toohard.
hard.
**IsIsthere
therespace
spacefor
fortools
toolsand
andgrippers?
grippers?
IfIfnot,
not,automatic
automaticassembly
assemblyor
ortesting
testingarent
arentoptions.
options.
**IfIfaamanufacturing
manufacturingstrategy
strategybased
basedon
onsubassemblies
subassembliesseems
seemswarranted,
warranted,are
arethe
the
Subassemblies
Subassembliesdesigned
designedso
sothey
theydo
donot
notfall
fallapart
apartduring
duringreorientation,
reorientation,
handling,
handling,or
ortransport?
transport?

Advantages to combining consideration of

assembly procedures and quality control
strategy with design

Designers who anticipate the assembly method can avoid

pitfalls that would otherwise require redesign or create
problems on the factory floor.

They can also design better subassemblies to meet functional

specifications:

Specifications that will be invaluable when the time comes to

decide whether to take bids from outside vendors or make the
part on the companys own lines
Specifications that will determine how to test the subassembly
before adding it to the final product.

With respect to assembly machines and tooling,

manufacturers should consider the following
questions:
**What
Whatisisthe
thebest
besteconomic
economiccombination
combinationofofmachines
machinesand
andpeople
peopletotoassemble
assemble
aacertain
certainmodel-mix
model-mixofofparts
partsfor
foraaproduct
productline
line(given
(giveneach
eachmachines
machinesor
orpersons
personscost
cost
and
andtime
timetotodo
doeach
eachoperation,
operation,plus
plusproduction-rate
production-rateand
andeconomic-return
economic-returntargets)?
targets)?
**How
Howmuch
muchtime,
time,money,
money,production
productionmachinery,
machinery,or
orin-process
in-processinventory
inventorycan
canbe
be
saved
savedifextra
ifextraeffort
effortisisput
putinto
intodesign
designofofthe
theproduct,
product,its
itsfabrication
fabricationand
andassembly
assembly
processes,so
that
there
are
fewer
quality
control
failures
and
product
repairs?
processes,so that there are fewer quality control failures and product repairs?
AAprocess
processthat
thatyields
yieldsonly
only80%
80%successful
successfulassemblies
assemblieson
onthe
thefirst
firsttry
trymay
mayneed
need
20%
extra
capacity
and
inventory
20% extra capacity and inventory
not
nottotomention
mentionhigh-cost
high-costrepair
repairpersonnelto
personneltomeet
meetthe
theoriginal
originalproduction
productiongoals.
goals.

**Where
Whereininthe
theassembly
assemblyprocess
processshould
shouldtesting
testingtake
takeplace?
place?
Considerations
Considerationsinclude
includehow
howcostly
costlyand
anddefinitive
definitivethe
thetest
testis,
is,
whether
whetherlater
laterstages
stageswould
wouldhide
hideflaws
flawsdetectable
detectableearlier,
earlier,
and
andhow
howmuch
muchrepaired
repairedor
ordiscarded
discardedassemblies
assemblieswould
wouldcost.
cost.

These are generic problems

They are hard to answer

They too are stimulating the development of new software

packages.

This new software enhances the ability of manufacturing

people to press their points in (often heated) debates about
design.

Hitherto, product designers, more accustomed to using

computer modeling, have had somewhat of an upper hand.

Factory system design

Many features of good product design pre-suppose that

machines will do the assembly.
But automation is not necessary to reap the benefits of
strategic design.
Indeed, sometimes good design makes automatic assembly
unnecessary or uneconomic by making manual assembly so
easy and reliable.
Regardless of the level of automation, some people will still
be involved in production processes, and their role is
important to the success of manufacturing.

Design means business

Strategic product design is a total approach to doing
business.
It can mean changes in the pace of design, the identity of
the participants, and the sequence of decisions.
It forces managers, designers, and engineers to cross old
organizational boundaries, and it reverses some old power
relationships.
It creates difficulties because it teases out incipient
conflict, but it is rewarding precisely because disagreements
surface early, when they can be resolved constructively and
with mutual understanding of the outcomes rationale.
Strategic design is a continual process, so it makes sense to
keep design teams in place until well after product
launching when the same team can then tackle a new
project.
Design is a companywide activity. Top management

THANK YOU!