-​ Liability issues, ethical

considerations, sustainability
PRODUCT DESIGN
issues, costs and profits

REASONS TO DESIGN OR REDESIGN LEGAL CONSIDERATIONS

●​ The driving forces for product and - Product Liabillity
service design or redesign are market ●​ The responsibility a
opportunities or threats: manufacturer has for any
injuries or damages caused by a
-​ Economic faulty product
-​ Social and Demographic ●​ Some of the contaminant costs
-​ Political, Liability, or Legal
-​ Competitive - Litigation
-​ Cost or Availability - Legal and insurance costs
-​ Technological - Settlement costs
- Costly product recalls
●​ Is there a demand for it? - Reputation effects
-​ Market size
-​ Demand profile NORMATIVE BEHAVIOR
- Produce designs that are consistent
●​ Can we do it? with the goals of the organization – e.g.,
Do not compromise on quality, or cut
Manufacturability corners, even in areas that are not
-​ The capability of an apparent to the customer
organization to produce an item - Give customers the value they expect
at an acceptable profit - Make health and safety a concern
●​ Do not place employees,
Serviceability customers, or third parties at
-​ The capability of an risk because of faulty products
organization to provide a and services
service at an acceptable cost or
profit SUSTAINABILITY
- Using resources in ways that do not
●​ What level of quality is appropriate? harm ecological systems that support
-​ Customer expectations human existence
-​ Competitor quality
-​ Fit with current offering

●​ Does it make sense from an economic

standpoint?
 ●​ Key aspects of designing for ●​ Is the function
sustainability necessary
-​ Life cycle assessment ●​ Can the function of two
-​ Reduction of costs and or more parts be
materials used performed by a single
-​ Re-using parts of part?
returned products ●​ Can a part be
-​ Recycling simplified?
●​ Could product
LIFE CYCLE ASSESSMENT specifications be
- The assessment of the environmental relaxed?
impact of a product or service ●​ Could standard parts
throughout its useful life be substituted for
- Focuses on factors such as non-standard parts?
●​ Global warming
●​ Smog formation ●​ Re-use: Remanufacturing
●​ Oxygen depletion
●​ Solid waste generation Remanufacturing
- LCA procedures are part of the ISO -​ Refurbishing used products by
14000 environmental management replacing worn-out or defective
procedures components
●​ Can be performed by
REDUCE, REUSE, RECYCLE the original
manufacturer or
●​ Reduce: Costs and Materials another company
-​ Design for disassembly (DFD)
Value analysis ●​ Designing a product to
-​ Examination of the function of that used products can
parts and materials in an effort be easily taken apart
to reduce the cost and/or
improve the performance of a
product
-​ Common questions used in
value analysis

●​ Could a less expensive

part of material be
used?
 ●​ Recycle STANDARDIZATION
- Extent to which there is an absence of
Recycling variety in a product, service, or process
-​ Recovering materials for future
use Advantages of Standirdazation
●​ Applies to 1.​ Fewer parts to deal with in
manufactured parts inventory & manufacturing
●​ Also applies to 2.​ Reduced training costs and time
materials used during 3.​ More routine purchasing,
production handling and inspection
-​ Why recycle? procedures
●​ Cost savings 4.​ Orders fillable from inventory
●​ Environmental concerns 5.​ Opportunities for long
●​ Environmental production runs and automation
regulations 6.​ Need for fewer parts justifies
-​ Design for recycling (DFR) increased expenditures on
●​ Product design that perfecting designs and
takes into account the improving quality control
ability to disassemble a procedures
used product to recover
the recyclable parts Disadvantages of Standardization
1.​ Designs may be frozen with too
OTHER CONSIDERATIONS many imperfections remaining
●​ Product of service life cycles 2.​ High cost of design changes
●​ Standardization increases resistance to
●​ Product or service reliability improvements
●​ Product or service robustness 3.​ Decreased variety results in
less consumer appeal

DESIGNING FOR MASS CUSTOMIZATION

●​ Mass Customization
-​ A strategy of producing
basically standardized goods or
services, but incorporating
some degree of customization
in the final product or service
-​ Facilitating techniques
 ●​ Delayed differentiation RELIABILITY
●​ Modular design - The ability of a product, part, or
system to perform its intended function
●​ Delayed Differentiation under a prescribed set of conditions
-​ The process of producing, but
not quite completing, a product ●​ Failure
or service until customer -​ Situation in which a
preferences are known product, part, or system
-​ It is a postponement tactic does not perform as
●​ Produce a piece of intended
furniture, but not stain
it; the customer ●​ Normal operating conditions
chooses the stain -​ The set of conditions
under which an item’s
●​ Modular Design reliability is specified
-​ A form of standardization in
which component parts are ROBUST DESIGN
grouped into modules that are
easily replaced or interchanged -​ A design that results in products or
services that can function over a broad
●​ Advantages range of conditions
-​ Easier diagnosis and -​ Pertains to product as well as process
remedy of failures design
-​ Easier repair and
replacement
-​ Simplification of
manufacturing and
assembly

●​ Disadvantages
DEGREE OF NEWNESS
-​ Limited number of
possible product
Product or service design changes:
configurations
- Modification of an existing product or
-​ Limited ability to repair
service
a faulty module; the
- Expansion of an existing product line
entire module must
or service offering
often be scrapped
- Clone of a competitor’s product or
service
- New product or service
 ●​ Competitor based
- The degree of changes affects the - By studying how a competitor
newness of the product or service to the operated and its products and
market and to the organization services, many useful ideas can
●​ Risks and benefits? be generated
- Reverse engineering
PHASES IN DESIGN AND DEVELOPMENT
●​ Dismantling and
1. Idea generation inspecting a
2. Feasibility analysis competitor’s product to
3. Product specifications discover product
4. Process specifications improvements
5. Prototype development
6. Design review ●​ Research based
7. Market test - Research and Development
8. Product introduction (R&D)
9. Follow-up evaluation - Organized efforts to increase
scientific knowledge or product
IDEA GENERATION innovation

1. Supply-chain based - Basic research

2. Competitor based ●​ Has the objective of
3. Research based advancing the state of
knowledge about a
●​ Supply-chain based subject without any
- Ideas can come from near-term expectation
anywhere in the supply chain: of commercial
applications
-​ Customers
-​ Suppliers - Applied research
-​ Distributors ●​ Has the objective of
-​ Employees achieving commercial
-​ Maintenance and repair applications
personnel
- Development
●​ Converts the results of
applied research into
useful commercial
applications.
Concurrent Engineering
-​ Bringing engineering design and
manufacturing personnel together early
in the design phase

●​ Also may involve marketing and

purchasing personnel
●​ Views of suppliers and
customers may also be sought

PRODUCT REQUIREMENTS
- Designers must take into account
production capabilities:
●​ Equipment
●​ Skills
●​ Types of materials
●​ Schedules
●​ Technologies

Manufacturability
- Ease of fabrication and/or assembly
- It has important implications for
●​ Cost
●​ Productivity
●​ Quality