Catedra 4 -_diseño_de_bienes_y_servicios

Victor Alvarez Celedon, ICI

DISEÑO DE BIENES Y SERVICIOS

ADMINISTRACION DE LA PRODUCCION


QFD Process

Hay dos modelos para explicar el proceso QFD.Uno es el denominado modelo de cuatro fases (Hauser and Clausing, 1988).Y el otro es la matriz de matrices (matrix ofmatrices) desarrollado por Akao (1990).La estructura es presentada usualmente como un sistema de matrices, siendo el mas comunel de 4 fases.


QFD Process



EJEMPLO – APLICACIÓN QFDAUTOMATIC GARBAGE COMPACTOR


AUTOMATIC GARBAGE COMPACTOR

(Figura 2.3)





(Figura 2.4)



















Organizing for Product Development

Historically – distinct departmentsDuties and responsibilities are definedDifficult to foster forward thinking

Today – team approachCross functional – representatives from all disciplines or functionsConcurrent engineering – cross functional team


Manufacturability andValue Engineering

Benefits:1. Reduced complexity of products2. Additional standardization of products3. Improved functional aspects of product4. Improved job design and job safety5. Improved maintainability of the product6. Robust design


Cost Reduction of a Bracket through Value Engineering

Figure 5.5Figure 5.5


Issues for Product Development

Robust designModular designComputer-aided design (CAD)Computer-aided manufacturing (CAM)Virtual reality technologyValue analysisEnvironmentally friendly design


Robust Design

Product is designed so that small Product is designed so that small variations in production or variations in production or assembly do not adversely affect assembly do not adversely affect the productthe productTypically results in lower cost and Typically results in lower cost and higher qualityhigher quality


Modular Design

Products designed in easily segmented componentsAdds flexibility to both production and marketingImproved ability to satisfy customer requirements


Using computers to design products and prepare engineering documentationShorter development cycles, improved accuracy, lower costInformation and designs can be deployed worldwide

Computer Aided Design (CAD)


Design for Manufacturing and Assembly (DFMA)

Solve manufacturing problems during the design stage

3-D Object ModelingSmall prototype development

International data exchange through STEP

Extensions of CAD


Computer-Aided Manufacturing (CAM)

Utilizing specialized computers Utilizing specialized computers and program to control and program to control manufacturing equipmentmanufacturing equipmentOften driven by the CAD systemOften driven by the CAD system


1. Product quality2. Shorter design time3. Production cost reductions4. Database availability5. New range of capabilities

Benefits of CAD/CAM


Virtual Reality Technology

Computer technology used to develop an interactive, 3-D model of a product from the basic CAD dataAllows people to ‘see’ the finished design before a physical model is builtVery effective in large-scale designs such as plant layout


Value Analysis

Focuses on design improvement during productionSeeks improvements leading either to a better product or a product which can be produced more economically


Ethics and Environmentally Friendly Designs

It is possible to enhance productivity, It is possible to enhance productivity, drive down costs, and preserve drive down costs, and preserve resourcesresources

The Ethical ApproachThe Ethical Approach

1.1. View product design from a systems View product design from a systems perspectiveperspective

2.2. Consider the entire life cycle of the Consider the entire life cycle of the productproduct


Goals for Ethical and Environmentally Friendly

Designs1.1. Develop safe and more environmentally Develop safe and more environmentally

sound productssound products2.2. Minimize waste of raw materials and energyMinimize waste of raw materials and energy3.3. Reduce environmental liabilitiesReduce environmental liabilities4.4. Increase costIncrease cost--effectiveness of complying effectiveness of complying

with environmental regulationswith environmental regulations5.5. Be recognized as a good corporate citizenBe recognized as a good corporate citizen


Guidelines for Environmentally Friendly Designs

1. Make products recyclable2. Use recycled materials3. Use less harmful ingredients4. Use lighter components5. Use less energy6. Use less material


Legal and Industry Standards

For Design For Design ……

Federal Drug AdministrationFederal Drug AdministrationConsumer Products Safety CommissionConsumer Products Safety CommissionNational Highway Safety AdministrationNational Highway Safety AdministrationChildrenChildren’’s Product Safety Acts Product Safety Act



For Manufacture/Assembly For Manufacture/Assembly ……

Occupational Safety and Health Occupational Safety and Health AdministrationAdministrationEnvironmental Protection AgencyEnvironmental Protection AgencyProfessional ergonomic standardsProfessional ergonomic standardsState and local laws dealing with State and local laws dealing with employment standards, discrimination, etc.employment standards, discrimination, etc.



For Disassembly/Disposal For Disassembly/Disposal ……

Vehicle Recycling PartnershipVehicle Recycling PartnershipIncreasingly rigid laws worldwideIncreasingly rigid laws worldwide


Acquiring TechnologyBy Purchasing a FirmBy Purchasing a Firm

Speeds developmentSpeeds developmentIssues concern the fit between the acquired Issues concern the fit between the acquired organization and product and the hostorganization and product and the host

Through Joint VenturesThrough Joint VenturesBoth organizations learnBoth organizations learnRisks are sharedRisks are shared

Through AlliancesThrough AlliancesCooperative agreements between Cooperative agreements between independent organizationsindependent organizations


Defining The Product

First definition is in terms of First definition is in terms of functionsfunctionsRigorous specifications are Rigorous specifications are developed during the design phasedeveloped during the design phaseManufactured products will have an Manufactured products will have an engineering drawingengineering drawingBill of material (BOM) lists the Bill of material (BOM) lists the components of a productcomponents of a product


Engineering drawingShows dimensions, tolerances, and materialsShows codes for Group Technology

Bill of Material Lists components, quantities and where usedShows product structure

Product Documents


Monterey Jack Cheese(a) (a) U.S. grade AAU.S. grade AA. Monterey cheese shall conform to the . Monterey cheese shall conform to the

following requirements:following requirements:(1) (1) FlavorFlavor. Is fine and highly pleasing, free from undesirable . Is fine and highly pleasing, free from undesirable

flavors and odors. May possess a very slight acid or feed flavors and odors. May possess a very slight acid or feed flavor.flavor.

(2) (2) Body and textureBody and texture. A plug drawn from the cheese shall be . A plug drawn from the cheese shall be reasonably firm. It shall have numerous small mechanical reasonably firm. It shall have numerous small mechanical openings evenly distributed throughout the plug. It shall not openings evenly distributed throughout the plug. It shall not possess sweet holes, yeast holes, or other gas holes.possess sweet holes, yeast holes, or other gas holes.

(3) (3) ColorColor. Shall have a natural, uniform, bright and attractive . Shall have a natural, uniform, bright and attractive appearance.appearance.

(4) (4) Finish and appearance Finish and appearance -- bandaged and paraffinbandaged and paraffin--dippeddipped. . The rind shall be sound, firm, and smooth providing a good The rind shall be sound, firm, and smooth providing a good protection to the cheese.protection to the cheese.

Code of Federal Regulation, Parts 53 to 109,. Revised as of Jan. 1, 1985, General Service Administration


Engineering Drawings



Bills of MaterialPanel WeldmentPanel Weldment

NUMBERNUMBER DESCRIPTIONDESCRIPTION QTYQTY

A 60A 60--7171 PANEL WELDMPANEL WELDM’’TT 11

A 60A 60--77 LOWER ROLLER ASSM.LOWER ROLLER ASSM. 11R 60R 60--1717 ROLLERROLLER 11R 60R 60--428428 PINPIN 11P 60P 60--22 LOCKNUTLOCKNUT 11

A 60A 60--7272 GUIDE ASSM. REARGUIDE ASSM. REAR 11R 60R 60--5757--11 SUPPORT ANGLESUPPORT ANGLE 11A 60A 60--44 ROLLER ASSM.ROLLER ASSM. 110202--5050--11501150 BOLTBOLT 11

A 60A 60--7373 GUIDE ASSM. FRONTGUIDE ASSM. FRONT 11A 60A 60--7474 SUPPORT WELDMSUPPORT WELDM’’TT 11R 60R 60--9999 WEAR PLATEWEAR PLATE 110202--5050--11501150 BOLTBOLT 11 Figure 5.9Figure 5.9


Bills of MaterialBBQ Bacon CheeseburgerBBQ Bacon Cheeseburger

DescriptionDescription QtyQty

BunBun 11Hamburger pattyHamburger patty 8 oz.8 oz.Cheddar cheeseCheddar cheese 2 slices2 slicesBaconBacon 2 strips2 stripsBBQ onionsBBQ onions 1/2 cup1/2 cupHickory BBQ sauceHickory BBQ sauce 1 oz.1 oz.Burger setBurger set

LettuceLettuce 1 leaf1 leafTomatoTomato 1 slice1 sliceRed onionRed onion 4 rings4 ringsPicklePickle 1 slice1 slice

French friesFrench fries 5 oz.5 oz.Seasoned saltSeasoned salt 1 tsp.1 tsp.1111--inch plateinch plate 11HRC flagHRC flag 11 Figure 5.9Figure 5.9


Parts grouped into families with similar characteristicsCoding system describes processing and physical characteristicsPart families can be produced in dedicated manufacturing cells

Group Technology


Group Technology Scheme


(a) Ungrouped Parts(b) Grouped Cylindrical Parts (families of parts)

Grooved Slotted Threaded Drilled Machined


1. Improved design2. Reduced raw material and purchases3. Simplified production planning and

control4. Improved layout, routing, and machine

loading5. Reduced tooling setup time, work-in-

process, and production time

Group Technology Benefits


Documents for Production

Assembly drawingAssembly chartRoute sheetWork orderEngineering change notices (ECNs)


Assembly Drawing

Shows exploded Shows exploded view of productview of productDetails relative Details relative locations to locations to show how to show how to assemble the assemble the productproduct

Figure 5.11 (a)Figure 5.11 (a)


Assembly Chart

1

2

3

4

5

6

7

8

9

10

11

R 209 AngleR 209 Angle


Bolts w/nuts (2)Bolts w/nuts (2)



Bolt w/nutBolt w/nut

R 404 RollerR 404 Roller

Lock washerLock washer

Part number tagPart number tag

Box w/packing materialBox w/packing material

Bolts w/nuts (2)Bolts w/nuts (2)

SA1

SA2

A1

A2

A3

A4

A5

LeftLeftbracketbracket

assemblyassembly

RightRightbracketbracket

assemblyassembly

PokaPoka--yoke yoke inspectioninspection

Figure 5.11 (b)Figure 5.11 (b)

Identifies the point Identifies the point of production of production where where components flow components flow into into subassemblies subassemblies and ultimately into and ultimately into the final productthe final product


Route Sheet

Lists the operations and times required Lists the operations and times required to produce a componentto produce a component

Setup OperationProcess Machine Operations Time Time/Unit

1 Auto Insert 2 Insert Component 1.5 .4Set 56

2 Manual Insert Component .5 2.3Insert 1 Set 12C

3 Wave Solder Solder all 1.5 4.1components to board

4 Test 4 Circuit integrity .25 .5test 4GY


Work Order

Instructions to produce a given quantity Instructions to produce a given quantity of a particular item, usually to a scheduleof a particular item, usually to a schedule

Work OrderItem Quantity Start Date Due Date

Production DeliveryDept Location

157C 125 5/2/06 5/4/06

F32 Dept K11


Engineering Change Notice (ECN)

A correction or modification to a A correction or modification to a productproduct’’s definition or s definition or documentationdocumentation

Engineering drawingsEngineering drawingsBill of materialBill of material

Quite common with long product life cycles, long manufacturing lead times, or

rapidly changing technologies


Configuration Management

The need to manage ECNs has led The need to manage ECNs has led to the development of configuration to the development of configuration management systemsmanagement systemsA productA product’’s planned and changing s planned and changing components are accurately components are accurately identified and control and identified and control and accountability for change are accountability for change are identified and maintainedidentified and maintained


BACKUP

EJEMPLO QFD


QFD House of Quality

What the Customer

WantsRelationship

Matrix

TechnicalAttributes and

Evaluation

How to SatisfyCustomer Wants

Interrelationships

Ana

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House of Quality Example

Your team has been charged with Your team has been charged with designing a new camera for Great designing a new camera for Great Cameras, Inc.Cameras, Inc.The first action is The first action is to construct a to construct a House of QualityHouse of Quality



CustomerCustomerimportanceimportance

ratingrating(5 = highest)(5 = highest)

Lightweight 3Easy to use 4Reliable 5Easy to hold steady 2No double exposures 1

What the What the customer customer

wantswants

What the Customer

Wants

RelationshipMatrix


Evaluation


Interrelationships

Ana

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House of Quality ExampleWhat the Customer

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RelationshipMatrix


Evaluation


Interrelationships

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Low

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Lightweight 3Easy to use 4Reliable 5Easy to hold steady 2No double exposures 1


Wants

RelationshipMatrix


Evaluation


Interrelationships

Ana

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High relationshipHigh relationshipMedium relationshipMedium relationshipLow relationshipLow relationship

Relationship matrixRelationship matrix



Wants

RelationshipMatrix


Evaluation


Interrelationships

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Relationships Relationships between the between the things we can dothings we can do



Weighted Weighted ratingrating

What the Customer

Wants

RelationshipMatrix


Evaluation


Interrelationships

Ana

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Lightweight 3Easy to use 4Reliable 5Easy to hold steady 2No double exposures 1Our importance ratings 22 9 27 27 32 25



Com

pany

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Com

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G PG PF GG PP P

Lightweight 3Easy to use 4Reliable 5Easy to hold steady 2No double exposures 1Our importance ratings 22 5

How well do How well do competing products competing products meet customer wantsmeet customer wants

What the Customer

Wants

RelationshipMatrix


Evaluation


Interrelationships

Ana

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Com

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Wants

RelationshipMatrix


Evaluation


Interrelationships

Ana

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Technical attributes

Technical evaluation

Company A 0.7 60% yes 1 ok GCompany B 0.6 50% yes 2 ok FUs 0.5 75% yes 2 ok G

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Completed Completed House of House of QualityQuality


House of Quality Sequence

Des

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House 2

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Design characteristics

House 1

Spec

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Production process

House 3 Pr

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Quality plan

House 4

Deploying resources through the Deploying resources through the organization in response to organization in response to customer requirementscustomer requirements
