Design for manufacturability : how to use concurrent engineering to rapidly develop low-cost, high-quality products for lean production, second edition / David M. Anderson.

Format:

Book

Author/Creator:

Anderson, David M. (Engineer), author.

Language:

English

Subjects (All):

Lean manufacturing.

Concurrent engineering.

Physical Description:

1 online resource (xlviii, 499 pages) : illustrations

Edition:

Second edition.

Place of Publication:

New York, NY : Routledge, Taylor & Francis, 2020.

Summary:

"This book shows how to use concurrent engineering teams to design products for all aspects of manufacturing with the lowest cost, the highest quality, and the quickest time to stable production. Extending the concepts of design for manufacturability to an advanced product development model, the book explains how to simultaneously make major improvements in all these product development goals, while enabling effective implementation of Lean Production and quality programs. Illustrating how to make the most of lessons learned from previous projects, the book proposes numerous improvements to current product development practices, education, and management. It outlines effective procedures to standardize parts and materials, save time and money with off-the-shelf parts, and implement a standardization program. It also spells out how to work with the purchasing department early on to select parts and materials that maximize quality and availability while minimizing part lead-times and ensuring desired functionality. This updated second edition includes completely new sections on: Scalability -- shows how to design products to easily scale up production to any need expansion quickly. This is essential for hot products to capture their full market potential (e.g., for instance for solar power to be able to rapidly replace greenhouse-gas generating power sources world-wide when the need is realized. Manufacturable Research -- a unique section that, for the first time, shows research labs many "low-hanging-fruit" techniques that can easily be done in research efforts to ensure research results will be result in manufacturable and scalable products. Commercialization -- another unique methodology to show how to preserve the "crown jewels" of un-manufacturable research or patents and redesign the rest for manufacturability. How to design half-cost products"-- Provided by publisher.

Contents:

Cover

Half Title

Title Page

Copyright Page

Dedication

Table of Contents

List of Figures

Figure 1.1 When Costs are Determined

Figure 1.2 Hidden Costs and Consequences of Cheap Parts

Figure 1.3 Cost of Engineering Changes Over Time

Figure 1.4 The Decision Tree

Figure 2.1 Team Participation: Traditional vs. Advanced Models

Figure 2.2 Customer Input Form

Figure 2.3 Customer Importance vs. Competitive Grade

Figure 2.4 QFD Executive Overview

Figure 2.5 QFD "House Of Quality" Chart

Figure 3.1 Tradition vs. Front-Loaded Timelines

Figure 3.2 Increasing Revenue with Early Introductions and Upgrades

Figure 4.1 Kanban Part Resupply

Figure 4.2 Flexible Fixture

Figure 5.1 Examples of Part Type Listing Orders

Figure 5.2 Pareto Chart of Existing Part Usage

Figure 5.3 Standardization of Expensive Parts

Figure 5.4 Cost Trade-Offs for Part Consolidations

Figure 5.5 Decisions for ASICS

Figure 5.6 Searching for Ranges of Parts

Figure 6.1 Common Cost Reduction Scenario

Figure 6.2 Typical Cost Breakdown

Figure 6.3 Selling Price Breakdown

Figure 6.4 Part Cost Percentage Throughout Outsourced Supply Chain

Figure 6.5 Programs that Reduce Specific Costs

Figure 7.1 Cost Distortion Downward Spiral

Figure 7.2 Changes in Cost After Implementing ABC

Figure 8.1 Alignment using Round and Diamond Pins

Figure 9.1 Improvement Design for Easier and Better Machining

Figure 9.2 Cost as a Function of Process

Figure 10.1 Quality Issue Frequency vs. Severity

Figure 10.2 Quality as a Function of Part Count for Average Part Quality Levels

Figure 10.3 Reliability Phases

Figure 11.1 Pre-Seminar Survey Results

Figure 11.2 Incorporating DFM into the NPD Process

Figure 11.3 Key DFM Tasks, Results, and Tools

Figure A.1 Pareto's Law for Products

Figure A.2 Cost Breakdown

Figure A.3 Cost Distribution in Dollars

Figure A.4 Results after Rationalization

Figure A.5 Redirecting Focus to Cash Cows

Figure A.6 Rationalization Procedure

Figure A.7 Prioritized Profitability: Typical Cost vs. Total Cost

Preface for the Second Edition

Preface for Students

Author

Section I: Design Methodology

Chapter 1 Design for Manufacturability

1.1 Manufacturing before DFM

1.1.1 What DFM is Not

1.1.2 Comments from Company DFM Surveys

1.2 Myths and Realities of Product Development

1.3 Costs, When They Are Determined

1.3.1 Toyota on When Cost is Determined

1.3.2 Ultra-Low-Cost Product Development

1.4 Designing for Low Cost

1.4.1 Design for Cost Approaches

1.4.1.1 Cost-Based Pricing

1.4.1.2 Price-Based Costing (Target Costing)

1.4.1.3 Cost Targets Should Determine Strategy

1.4.2 Cost Metrics and Their Effect on Results

1.4.3 How to Design Very Low Cost Products

1.4.4 Cost Reduction by Change Order

Notes:

"A Productivity Press Book".

OCLC-licensed vendor bibliographic record.

OCLC:

1141034009