TUM Library

"A Productivity Press Book".

"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.

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

OCLC-licensed vendor bibliographic record.