Issuu

Chapter 1 Exercises 1.1.

Suggest possible improvements you would like to see made to a common household item. a. Let us consider a common household item like an ironing board cover. I would like to see an effective means of stretching it tight over the ironing board so it doesn’t bunch up and cause wrinkles. The commonly used elastic border is insufficient to accomplish this. The solutions would be Velcro patches on the cover that engage stick-on patches on the underside of the ironing board, or grommets in the edge of the cover that wraps under the board so that an elastic cord could be attached from edge to edge under the board to keep the cover pulled tight. b. Another example of household product is “Refrigerator”. Although lot of innovations have taken place, there are customer needs that need to be addressed. With the large size of many of today’s refrigerators, food can get pushed out of sight and forgotten. That is until they go bad and the smell lets you know that you have a problem. An improvement I’d like to see would be an internal air sampling device that tests for a few common bacteria that indicate food spoilage.

1.2.

List several tools and techniques required for product development. How would you use them effectively?

Concept Development Phase

• • • • •

Market Studies Voice of the Customer Quality Function Deployment Axiomatic Design TRIZ

Design & Development

• • • • • •

Function Analysis Design for Manufacturing Design for Disassembly and Maintenance Product Modeling by CAD/CAM Simulation & Optimization, Six-sigma Design for Life-cycle

Analysis & Testing

• • •

Failure Mode Effects Evaluation Robust Design Rapid Prototyping

Process of Product Creation

• • •

Workplace Design, Flexible Automation, Value Stream mapping Design for Supply Chain

1.3.

List two examples of promising products that have failed and briefly describe the reasons for it. a. Electric Automobile – In the early development of automobiles, about 1900, electric automobiles were a significant proportion of those made. However, gas engine technology far outstripped battery technology, and gasoline was cheap, and pollution was not considered, so by 1920, no electric automobiles were manufactured in the US. The interest in electrical automobiles is on the rise in the last 10 years. b. New Coke – The Coca-Cola Company replaced its original formula and brand “Coke” with a sweeter “New Coke”. It failed because Coca-Cola did not adequately research the taste in other than small sips at a time, and did not consider the taste preferences and emotional attachment of its most loyal customers to the original Coke formula.

1.4.

Examine the 1998 case study of Breakfast Mates from Kellogg. Identify the reasons for the product to be withdrawn. Reasons for the Product’s Withdrawal: 1. Warm milk: The product was advertised as ‘aseptically pack-aged and did not need refrigeration’. Aseptic processing is the process by which a sterile (aseptic) product (typically food or pharmaceutical) is packaged in a sterile container in a way that maintains sterility. However, consumers did not like the idea of warm milk 2. Cool milk: In order to accommodate for the consumer’s preference for cool milk, Kellogg’s eventually decided to place Cereal Mates in refrigerators to imply that consumers should have the milk cold. According to Robert McMath, president of New Product Works has has the following quotation which led to more confusion. ‘This decision inevitably caused a problem in that Cereal Mates was not in a location where you would generally expect to find breakfast cereal. The expense of trying to re-educate the consumer to look for cereal in the dairy case proved too enormous – way beyond, apparently, what Kellogg’s wanted to spend on selling the new line,’ 3. Advertising: Kellogg complicated matters further with the advertising campaign for Cereal Mates. The TV advertisements featured young kids helping themselves to the product, while their parents were still in bed. However, the packaging of the product was not child-friendly 4. Taste: Since the milk was warm, it did not taste good. 5. Price: Cereal Mates was considered too expensive by many consumers.

1.5.

What role does research play in product design? Indicate four sources of research and the desired information that you can expect from each source. Research is the key factor in the design and successful market launch of the product. The companies that spend a higher percentage of revenue on research have a good possibility of keeping up with the market forces worldwide.

Four sources of research are: 1. Internet 3. Patents

2. Reference books, journals, Standards and trade catalogs 4. Use of simulation tools

1. Internet: This relatively new-research tool has proven to be very effective. Internet can facilitate and provide information on a range of competitive products, research publications. The Internet facilitates companies to conduct research and release new designs much faster. With the Internet connection becoming available in more and more countries, the Internet based technology provides new opportunity. For market research on new products, the resources available from the Internet are unlimited. The technology can help the product to get to the market as quickly as possible and explore the best possible alternatives. The advances in software and hardware have made it possible to animate prototypes and create design alternatives, adding a whole new dimension of utility to the practice. The Internet can be utilized to contact suppliers, vendors and contractors. The Internet provides an extremely inexpensive and widely distributed format for distributing and soliciting product information and feedback. Distributing Internet based models via local networks, wide-area networks, or the Internet is very easy If the research is focused on customers, the use of Internet tools in early focusgroup sessions can yield effective feedback from potential customers, leading to higher market acceptance for the ultimate product. Traditional communication and collaboration often result in significant expenses from travel, personnel relocations, and telecommunications. Internet communication addresses most of these needs by enabling real-time linking of multiple sites in one virtual product; the result is a far more efficient use of time than traditional meetings. Access via the World Wide Web is simple and intuitive with the help of standard browsers available today. Tools The most popular search tools for finding information on the Internet include Web search engines, meta search engines, Web directories, and specialty search services. A Web search engine uses software known as a Web crawler to follow the hyperlinks connecting the pages on the World Wide Web. The information on these Web pages is indexed and stored by the search engine. To access this information, a user enters keywords in a search form and the search engine queries its algorithms, which take into consideration the location and frequency of keywords on a Web page, along with the quality and number of external hyperlinks pointing at the Web page. A Meta search engine enables users to enter a search query once and it runs against multiple search engines simultaneously, creating a list of aggregated search results. Since no single search engine covers the entire web, a meta search 3 © 2016 Cengage Learning®. May not be scanned, copied or duplicated, or posted to a publicly accessible website, in whole or in part.

engine can produce a more comprehensive search of the web. Most meta search engines automatically eliminate duplicate search results. However, meta search engines have a significant limitation because the most popular search engines, such as Google, are not included because of legal restrictions. A Web directory organizes subjects in a hierarchical fashion that lets users investigate the breadth of a specific topic and drill down to find relevant links and content. Web directories can be assembled automatically by algorithms or handcrafted. Human-edited Web directories have the distinct advantage of higher quality and reliability, while those produced by algorithms can offer more comprehensive coverage. The scope of Web directories are generally broad, such as DOZ, Yahoo! and The WWW Virtual Library, covering a wide range of subjects, while others focus on specific topics. Specialty search tools enable users to find information that conventional search engines and meta search engines cannot access because the content is stored in databases. In fact, the vast majority of information on the web is stored in databases that require users to go to a specific site and access it through a search form. Often, the content is generated dynamically. As a consequence, Web crawlers are unable to index this information. In a sense, this content is "hidden" from search engines, leading to the term invisible or deep Web. Specialty search tools have evolved to provide users with the means to quickly and easily find deep Web content. These specialty tools rely on advanced bot and intelligent agent technologies to search the deep Web and automatically generate specialty Web directories, such as the Virtual Private Library.

Advantage of using Internet for product related research: •

Shortening of the product definition phase involving the customer, marketing and design engineering.

•

Provides instantaneous access to knowledge and experience from different locations and disciplines during design and development stage to achieve high quality results quickly.

•

Exploring and building on ideas in the product implementation stage involving trade-off decisions between manufacturing, tooling and design engineering.

•

Improved design coordination with remote and non-remote partners.

Disadvantages: •

Internet security

•

Bandwidth 4

•

Exposed proprietary information

There are other research search mechanisms such as Google including Research at Google; Google Research Blog; Think with Google; Google Research Programs; Google Scholar; Google Research on Twitter; Google Research Scientist 2. Reference books, journals, Standards and trade catalogs: In the early stages of research, many reference books will be useful as they provide analytical techniques and abstract ideas. Published literature includes scientific journals, conference proceedings, trade magazines, government reports, and new product reports. The state of the art information is available from scientific journals. Many good ideas are published in trade journals, which are usually oriented towards a specific discipline. However, there are some trade journals that are targeted at product designers. Handbooks cataloging technical information can also be very useful reference as research tool. Examples of reference standards are: SME Handbook of product design, Standards Handbook of Mechanical Engineers etc. Electronic database searches are another research tool to gather information from the published literature. The database can be accessed through on-line sources or in the form of CD-ROM storage devices 3. Patents: The patent literature is a good source of information. Patents are the sources of readily available sources of information that contains drawings and explanations of how many products work. The patents are also useful to check what concepts are already protected and must be avoided for certain period. Since there are a few millions of patents, a patent search narrows the area of interest. A patent search on a specific topic is done in three steps. 1. Identify the class and/or subclass of the area of interest. 2. Find the numbers of the specific patents that have been filed in the specific class that has been identified. 3. For a specific patent number, the information is available from the patent itself or from the official gazette announcement. 4. Use of simulation tools: Interactive product simulation can assist the product designers in conducting more efficient research. Use of Interactive product simulation procedures assists the research and development of department’s efforts. They can provide earlier access 5 © 2016 Cengage Learning®. May not be scanned, copied or duplicated, or posted to a publicly accessible website, in whole or in part.

to prototypes, faster updates than with physical models, enterprise distribution of information in an easy-to-understand format. They can support existing processes, and provide long-term value that extends beyond the finalization of product designs. In the design and detailing phase of product development, during which the primary need is to conduct frequent design reviews, Internet based simulation tools provide a means of integrating work from many different people and processes for group review and feedback. Instant on-line model changes on 3D models allow design optimization and lower manufacturing costs through immediate understanding of impact and implications of design alternatives. As users can add real-time animations to the virtual product and edit them to indicate part paths and sequences as well as check for collision and clearances, cross-disciplinary collaborative design reviews can quickly evaluate individual ideas in the context of overall product assembly, maintenance and usability. The use of interactive tools in early product research can yield more-effective feedback from potential customers, leading to higher market acceptance for the ultimate product. 1.6.

With the help of sketches, show the basic concepts that can be used in the development of a product. What strategies would you use to have an effective design as speedily as possible?

Product Considered: Three Dimensional Vision Sensor (3D Sensor Development and Validation for Robotics and Unmanned Vehicle Applications. The sensor will be a part of the mobile Robot which has the capability to recognize objects within six feet) Objectives: The objectives of product design strategy should be to create a product with the basic objectives of achieving the desired functions with quality and greatest impact to the organization. The design of the product has a major impact on the cost. • Make sure that the project goals are well defined and everyone understands what is to be committed in achieving them. • Team goals are as important as individual goals. The environment should be comfortable for team action. Variety of viewpoints are encouraged. Team members should communicate regularly; diversity of opinions should be encouraged. • The product related decisions are made by consensus and supported by team members. • Follow a predetermined agenda with time estimates. Focus on ideas, not personalities. Background: The need for three dimensional sensing can be applied to various markets and has scores of applications including unmanned ground vehicles or mobile robots. Three dimensional technologies allows the capabilities such as mapping out a room or given area and scanning 6 © 2016 Cengage Learning®. May not be scanned, copied or duplicated, or posted to a publicly accessible website, in whole or in part.

for an object such as a bomb or a person, to report back to the military and act accordingly to the situation. A great advancement is in the safety for ground troops and be able to recognize things that the human eye may not see at first glance. Unmanned vehicles have been deployed in several defense and security applications to provide information about unknown, unstructured environments with minimal risk to human life. These vehicles instrumented with sensors are capable of avoiding obstacles to navigate in an unknown environment, reporting concerns in different scenarios such as a battlefield, civilian security, disaster management, or in a patrol/surveillance mission. In such missions, a 3D environment map of the surveyed area of interest is useful feedback for organizing future action and deployment of army resources in a much more efficient manner. State-of-the-art unmanned ground vehicles are capable of understanding and adapting to arbitrary road terrain for navigation. The robotic mobility platforms mounted with sensors detect and report security concerns for subsequent action. Often, the information based on the localization of the unmanned vehicle is not sufficient for deploying army resources. In such a scenario, a three dimensional (3D) map of the area that the ground vehicle has surveyed in its trajectory would provide a good spatial knowledge for directing resources in an efficient manner Navigation sensors for robots - such as lasers, radar, flash lidar, high-definition lidar and stereovision cameras - often are extremely expensive and perform poorly under the harsh terrain, lighting, precipitation and abrasion conditions met outdoors. Two-dimensional sensors such as planar range-finding lasers work well with robots indoors. However, in less predictable outdoor spaces, robots require 3D sensing to handle organic obstacles and cliffs. Most 3D sensors, such as high-definition flash lidars, are power-hungry and expensive, limiting their applicability. There is a definite need for a reliable, low cost, energy efficient 3D sensor for robotic navigation purposes. Basic Design Concepts and Principles of Operation: The design methodology consists of the development of a laser based 3D sensor with unique illumination and positioning of sensors.

Fig. 1. Telescopic robot with the mounted laser sources and sensors

On the top of that tube have to be mounted seven identical sensors where one of them must be located along the tube and to be tightened to it rigidly. The other six sensors with the combination of first one must be used for creation the entire 3D image of object’s frontal and top sides. These six sensors have to be located on the small platform, adjusted on the top of the detector C (Fig. 1.) R

S C γ

Fig. 2. Location of the sensors on the top of the telescopic tube

Fig. 3. Location of sensors by the right side (R) and left side (L) detector holders

Sensor Design

Divergent light source (visible or infrared) is used with circular exit of the source surrounded by the sensors/photodetectors. The shape of the sensors also is considered as a circular one, which must be tangent to the cylindrical surface of the light source and the sensors’ cylindrical holder (Fig. 4.)

Fig. 4. Location of the laser source and 12 Sensors/Photodetectors 8 © 2016 Cengage Learning®. May not be scanned, copied or duplicated, or posted to a publicly accessible website, in whole or in part.

Here the vertexes of the central angles α coincides with the center of the circles and that angle indicates the angular occupation of each sensor. If the radius of the light source is R than the radius of the sensors holder will be R + 2r where r is the radius of the sensor. The efficiency of each detecting system might be determined as the ratio of the total area, occupied by the given ceria of sensors and the area between two circles that is the circle of the light source and detectors holder. Hence, the efficiency of detecting system might be found through this formula.

n ⋅π ⋅ r 2 n r π sin α E= = ⋅ = ⋅ π ⋅ (R + 2 ⋅ r )2 − π ⋅ R 2 4 (R + r ) 4 α , where n =

(1)

π r sin α = . α is the number of detectors and R+r

On the base of formula (2) let us calculate the efficiency with the several values of angle

α:

Table 1. 1)

then n = 4 ,

r ≈ 2.414 ⋅ R ,

E ≈ 0.707

then n = 6 ,

r ≈ R,

E ≈ 0.750

then n = 8 ,

r ≈ 0.62 ⋅ R ,

E ≈ 0.765

then n = 12 ,

r ≈ 0.35 ⋅ R

E ≈ 0.778

then n = 16

r ≈ 0.24 ⋅ R

E ≈ 0.780

if α = 45

2) if α = 30

3) if α = 22 .5 4) if α = 15 5)

if α = 11 .25

From these values, we can calculate and improve efficiency.

∆E = Eα =450 − Eα =600 ≈ 0.058 ∆E = Eα =300 − Eα =450 ≈ 0.043 ∆E = Eα =22.50 − Eα =300 ≈ 0.015 ∆E = Eα =150 − Eα =22.50 ≈ 0.013

(3)

∆E = Eα =11.50 − Eα =150 ≈ 0.002 It can be concluded that increasing the number of sensors leads to the decreasing of diameters of the sensors and in result of that increasing the efficiency of detection system. 9 © 2016 Cengage Learning®. May not be scanned, copied or duplicated, or posted to a publicly accessible website, in whole or in part.

Timeline Task

Months 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Methodology Experiment and analysis Validation and testbed Report

Fig. 5. Conceptual sketches and prototype

1.7.

Explain how you would select a team to undertake the product design for a multicomponent product. Product design process is of complex and interdisciplinary nature. Carrying out a project on product design requires gathering a team of people with diverse expertise. It is important that the group dynamics of participants should be of right caliber. The methodology used by the product team would determine the quality of final product and its innovativeness and competitiveness. A good team leader is essential to coordinate the team members effectively so that the group can be kept focused. In selecting a product design team, various factors to be considered are: • Composition of team members • Creation of an environment for design discussions • Management of the team • Methodology and approach Team Chemistry: The team must have clearly defined goals: the rules of the game must be set for budgets, staffing, and responsibilities. The team should begin with a small, manageable problem. The disciplines that are related to the product should be included. The team member must develop an atmosphere that is conducive to free thinking. Most importantly, the team must have strong leadership. Teams generally make better decisions than individuals, especially in situations that are relatively broad and far-reaching in scope (e.g., strategic planning). Because of the diversity in background, experience and skills of the team members, they are more likely to consider a wider range of alternatives to solving problems and be more creative in their solutions. The very nature of team dynamics and consensus approaches to problem-solving means that teams are likely to take longer time to make their decisions. When dealing with sensitive issues, team has more potential power than any one of the individuals. Team Selection: Next to the selection of the project, the single most important task is to choose the right players to serve on the team. As with any type of team, having the right combination of individual skills, attitudes and leadership will have a dramatic impact on the outcome of a project. It is also very important to have a good understanding of how teams should, and can work together in meeting their goals. Teams are composed of highly motivated individuals from various areas of the company who may never have worked together. Regardless of whether concurrent engineering is used to develop a new product or process, or modify an existing one, some start-up problems must be anticipated. If people in the various functional departments are comfortable with traditional design approaches, the switch to teamwork may be difficult. In the traditional approach, each department has a welldefined piece of action. Each function adds its value as the project is passed from 11

department to department, often with minimal interaction. Problems naturally arise, often resulting in some level of controversy. Genuine communication is not likely to occur under these conditions. For most employees of manufacturing companies, people from other departments are like strangers. Only rarely have they been required to share ideas or interact with each other during the early phases of a project. Leaders of multifunctional or cross-functional teams are faced with the challenge of optimizing team performance. For leaders to have a reasonable chance of success, any team project must be preceded by adequate managerial preparation. An underlying foundation in the concept of teamwork must be developed within the organization prior to commissioning any team. Team Leader: Picking the right team leader is absolutely critical to a project’s success. The leader needs to have a combination of knowledge and qualities that will bring out the best in the team. Some of the qualities to look for are listed below: • • • • • • •

Respected technical specialist in one functional area Open to change. Strong desires to contribute toward positive change Willingness to listen to ideas of others and to evaluate those ideas objectively; Good level of creativity; Effective oral communication; Assertiveness and persistence; Willingness and desire to work with others in problem solving.

Once members have been recruited, various amounts of team training should be considered. This, of course, will depend on the magnitude of the project and the experience of the leader and members in team solutions. Depending on the size and resources of the organization, the team leader could perform the selected training, or external consultants, an internal education department, or other qualified personnel could perform the training. Special training in team dynamics, cost reduction, or value engineering techniques only can improve the probability and degree of team success. 1.8.

Draw the functional diagram of an entire product. With examples, illustrate the difference between constraints and engineering specifications.

Utility knife

Function Diagram of Utility knife A constraint is a limitation, within which the system must operate. The system may be constrained to such factors as cost, safety, compatibility with other products, and use of specific electronic and mechanical parts as other devices, interfaces with other instruments and test equipment, and development schedule. The engineering specifications are detailed parameters describing how the system should work. For example, a requirement may state that the system should fit into a pocket,

whereas a specification would give the exact size and weight of the device. For example, suppose we wish to build a motor controller. 1.9.

From the perspective of engineering design, what are the differences and similarities between a system and a product?

A system is an arrangement of physical components connected or related in such a manner as to form and/ or act as an entire unit. System can be controlled and modified. A product is the result of creation an idea where the final output will be in the form of a device or gadget. The product could be a physical entity or software algorithm satisfying the needs. The characteristics of a system are: 1. It has distinct parts and parts involve a broad range of physical phenomenon. 2. The parts have observable attributes. 3. Parts are designed by different locations and by different designers. 4. The parts operate interactively. The products and/or components are used to create a system. Designing a product involves one in a constant decision-making process, which includes problem solving in a sequential fashion, and analysis of the constraints at each step. Designing a product is providing a set of rules for reorganizing the elements of creation toward some greater purpose, known as “design intent.” The process of creating a product is very much influenced by the process of designing, as well as the overall product cost. The cost of a product grows from conception, through the stages of technical research, design, development, market testing, use, maturity, until finally, its disposal. An organization has greatest control over a product at the early stages of its creation, when the market, its factory cost, operational cost and life cycle are determined. At this stage, a product’s status can be unstable as the organization tries to optimize the distinctiveness of the product for greater market acceptance. Naturally, a product’s features determine its performance and cost. The speed of a product’s development process, market testing, and manufacturing, are important factors in a product’s life cycle. Industrial designers view design as a product. The solution of a design problem may take several forms. It may be a particular device or a product, such as an automobile, submarine or a space shuttle. The solutions for a design problem could be a process such as a technique for preserving food, or a new procedure for cutting metals. It could also be a procedure or a set of action plans. Although various professions define it differently, in general, design is some answer to a problem, an answer that has visible form or shape, or function. There is a powerful trend in product design toward material substitution, in using new, synthetically designed materials which have the highly desirable characteristics of toughness, lightness, durability, and flexibility. These technological advances are spurred by higher rates of productivity and, therefore, higher return rates on investment. In all these cases, the new technology exerts a more serious impact on the environment than the older one if we are not careful. Thus, the major cause of environmental crises has been these technological “improvements,” which have originated from a faulty design, failing to take the environment into account, in the quest for narrowly defined efficiencies. There should 14 © 2016 Cengage Learning®. May not be scanned, copied or duplicated, or posted to a publicly accessible website, in whole or in part.

be concern at the corporate level for the larger consequences of design can be understood and is being excused on the basis of economic exigencies. By neglecting such safety factors in design, we end up borrowing on the future, running an environmental repair and clean up. Rapid developments are currently taking place in certain research and development fields will have tremendous effects on product design. The changes we have witnessed in the electronic industry in the last thirty years, from the vacuum tube to the present day computer chip, are just a glimpse of what is in store for the future. Wide spectrums of information technologies, biotechnologies, along with other new materials are influencing the market significantly.

1.10.

Using web-based research, identify five corporations and their product lines. In what way do these products support each corporation’s strategy?

• • • • •

Five corporations are Pratt & Whitney Jacobs vehicle systems Wiremold Company ABB Trumpf Inc.

Pratt & Whitney Pratt & Whitney is a leader in the design, manufacture and support of engines for commercial, military and general aviation aircraft, space propulsion and power systems. Pratt & Whitney is focused on continuously improving products and processes to deliver the performance and reliability the customers expect. It is an ISO9001-certified company. Commercial Aviation Large Commercial Engines JT8D JT9D PW2000 PW4000-100" PW4000-112" V2500 GP7000 Parts Pratt & Whitney Canada Engines PT6A - Large JT15D PT6B Parts

PT6A - Small PW300 PT6C

Military Aviation F100 F117 PW4000 JT8D-219

PW4000-94" PW6000

PW100 PW500 PW200

PW800 PT6T/T400 PW900

F119 Parts

F135

FT8 ST6L-72 ST5

ST30 ST6L-79 Brush Seals

Space & Missile Propulsion RL10 RD180 Orbus 21D

MK-72 Booster

ST6L-90 ST6L-81

ST40 ST18

Space Shuttle Turbo pumps Booster Separation Motors

THAAD National Missile Defense (NMD) System

Pratt and Whitney is also involved in maintenance services, spare parts, field services, support systems Jacobs’s vehicle systems As the world's leading manufacturer of engine brakes, Jacobs continues to push design, manufacturing, and performance standards beyond accepted limits. As Jacobs pursues incremental improvements, each hurdle represents the next standard. Each achievement becomes the basis of yet another. Quite simply, defying limits is the energy and spirit of Jacobs. No other manufacturer can match our products' track record & proven reliability. Since 1961, over 2 million Jake Brake retarders have been specified & installed and proven in over 1 trillion miles of driving. Their engine brakes are used in Caterpillar C-10, C-12 & 3176/B Engines Caterpillar 3306 Engines, Caterpillar 3406B/C/E Engines Cummins N14 Engines Wiremold Company The Wiremold Company, founded in 1900 and headquartered in West Hartford, Conn., is a leading manufacturer of wire and cable management systems, power and data quality products, and data/communications connectivity systems. The Wiremold Company has embarked upon an aggressive program of quality improvement and product introduction using the “Kaizen” philosophy. The Wiremold Company is developing and introducing new products faster than ever before. And strategic acquisitions of companies such as Walker Systems, Interlink Technologies, Brooks Electronics, Shape Electronics, and Sentinel Lighting have added new solutions that meet today’s challenges. This company mainly concentrates on power, data transfer devices, and wiring systems like

WallSource Box, Nonmetallic Raceway, Metal Raceway, AnySize Raceway, Aluminum Raceway, Prewired Raceway, Plugmold. ABB (Asea Brown Boveri Ltd.) ABB's strategy is to offer more value for customers while building a leaner organization. ABB is a global leader in power and automation technologies that enable utility and industry customers to improve performance while lowering environmental impact. ABB is moving all of its offerings to a common architecture, to deliver Industrial IT-enabled products and services that allow customers to optimize their operations and link up in real time with their suppliers and customers. The result is a leap in efficiency, quality and competitiveness. The products are in wide categories like Utilities, Process Industries, Manufacturing and Consumer Industries, Oil, Gas and Petrochemicals, - Power Technology Products, Automation Technology Products, and Financial Services. TRUMPF Inc. TRUMPF Inc. is the North American subsidiary of TRUMPF GmbH +Co. KG. based near Stuttgart, Germany. With more than 566 employees, TRUMPF Inc. is the largest subsidiary within the TRUMPF Group. TRUMPF Inc. is dedicated to serving the fabricating machinery, OEM laser and laser marking needs of the American, Canadian and Mexican markets and is the largest manufacturer of fabricating machinery in the United States. The TRUMPF Group of companies has subsidiaries in 23 countries and with about 5,600 employees generates sales in excess of $1.1 billion. The TRUMPF Group is a world leader in sheet metal fabrication machinery and industrial lasers. The products are: • Machine Tools: TRUMPF offers computer controlled machine tools for flexible sheet metal and material processing. • Laser Technology: High powered CO2 and solid-state lasers are ideal for cutting, welding or marking applications in industrial fabrication. • Electronics: This includes dc power supplies and radio-frequency generators for laser, induction and vacuum technology. • Medical Technology: This field includes surgery tables, systems for physical therapy, and systems for high frequency and laser surgery. • Power Tools: In this field TRUMPF offers power tools for cutting, fastening and shaping.

Chapter 2 Exercises 2.1.

Conduct a complete QFD analysis on a household product of your choice such as a dishwasher, washing machine, or refrigerator. The analysis should include the voice of the customer and the product’s ranking compared to that of competitors. Briefly explain your reasoning for the selection. Product considered: Refrigerator Voice of the Customer: A. Energy efficient. Low importance. B. Aesthetically pleasing. High importance. C. Easy to clean. High importance. D. Labor saving. Medium importance. E. Reliable. High importance. F. Quiet. High importance. G. Cost. Medium importance. Requirements Energy efficient

Aesthetically pleasing

What Low electrical consumption Low cooling loss when door is open Refined handles and exterior details Finish options

Easy to clean

Exterior Interior

Labor saving

Additional options

Convenience

Reliable

Long design life

Low Cost

Warranty High Value

How High efficiency compressor Temperature barrier Design includes ergonomic considerations Stainless, wide variety of colors Built-in cabinet option Fingerprint resistant Stable shelving Spill guards to contain spill on one shelf Ice maker (cube and chip) Water dispenser Night light Controls are ergonomically designed and located Components with 15 year design life Minimize vibration or redesign components to eliminate source 15 year, parts and labor Market value for dollar spent versus absolute cost

Quiet

High efficiency compressor Sound isolation Vibration dampers Ice Maker Low noise pump, sound isolation A QFD chart with detailed market analysis and survey might capture a few more customer requirements. 2.2.

Compressor

Select a simple product of your choice (such as a can opener or umbrella) and identify the parts and objectives.

Product 1: Hand Held Cheese Slicer

Wire

Roller

Handle

Parts

Objectives Power Input, Control Cutting Guide Cutting Blade

Handle Roller Wire Product 2: Electric Kettle Parts

Objectives Main component of kettle for assembly. Used to boil small quantity of water for domestic use. Used for energizing. Made of thermoplastic elastomers and facilitates handling of kettle. These parts are interlocked with snap-fit with the base.

Base Reservoir Toggle switch Handle Grip Rear Cover and lid

2.3.

Create a figure that shows the elements of a QFD chart. Explain how a cascade of these charts can be used to cover the total design and development process. The typical product selected here is: Sports Bicycle. Before the QFD chart is drawn, the basic customer requirements are identified. Customer Requirents/Voice of the customer: • affordable, • easy to pedal, • adjustable positions, • lightweight, • aesthetically pleasing, • comfortable seat, • ability to ride on and off the road Elements of House of Quality The central body of the house of quality consists of WHATS (Customer needs), HOWS (what we control), and a matrix of relationships between the WHATS and HOWS. Figure shows the essential elements of a general house of quality. The customer requirements/needs/wants are listed horizontally and are known as WHATS. The counterpart technical characteristics are listed vertically and are known as HOWS. The interrelationship matrix (WHATS against the HOWS) is shown where horizontal and vertical axes meet. The roof of the matrix shows the correlation between the HOWS and HOWS. The bottom of the house of quality gives an indication of the technical characteristics against the technical bench marking (HOWS against the HOW MUCH). Four Phases of QFD The four phases of QFD are: • Product planning phase • Part deployment phase • Process deployment phase • Product deployment phase

Correlation Matrix

• Strong Relationship = 9 ο Medium Relationship =3 ∆ Weak Relationship = 1 Customer Requirements

Lightweight

•

Smooth ride Target values

ο X

ο •

∆

∆ X

Make a Snap Fit

Multi-suspension system

Standard components • ∆

Quick release fastener

Use of light weight material 2 5

ο •

Inexpensive Easy to pedal Adjustable positions

ο ∆ ο

∆

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House of Quality In the product planning phase, customer attributes are drawn based on surveys, interviews, observations, field contacts, focus groups, employee feedback, publications, and sales records and are converted into product characteristics. A relationship matrix between the customer requirements and the product characteristics is drawn. This matrix will have data from market evaluation that includes customer expressed importance ratings and data on competitor’s products. The matrix will have information on data on current product strengths and weaknesses, measurable targets to be achieved, and selling points. In the part deployment phase, the product characteristics are translated into component characteristics. At this stage, the characteristics of the final product are converted into part details at the component level. In the process deployment phase, the process plan for the manufacture of the component, sub-assembly, and assembly are identified as well as quality parameters. In the production deployment phase, the output from the process deployment charts provides a measure of critical product and process parameters. At this stage production operations for all critical components are identified