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In this chapter, the following content will be discussed: Robust design, modular design, computer-aided design (CAD), computer-aided manufacturing (CAM), virtual reality technology, value analysis ethics and environmentally friendly design,…
LECTURE LSM733-PRODUCTION OPERATIONS MANAGEMENT By: OSMAN BIN SAIF Summary of last Session ỵ MS PROJECTAn Introduction ỵ Global Company Profile: Regal Marine ỵ Goods and Services Selection ỵ þ Product Strategy Options Support Competitive Advantage þ Product Life Cycles ỵ Life Cycle and Strategy ỵ Product-by-Value Analysis Agenda for this Session ỵ Issues for Product Design ỵ Robust Design ỵ Modular Design ỵ Computer-Aided Design (CAD) ỵ Computer-Aided Manufacturing (CAM) ỵ Virtual Reality Technology ỵ Value Analysis þ Ethics and Environmentally Friendly Design Agenda for this Session (Contd.) ỵ ỵ Time-Based Competition ỵ Purchasing Technology by Acquiring a Firm ỵ Joint Ventures ỵ Alliances Defining a Product ỵ Make-or-Buy Decisions ỵ Group Technology Agenda for this Session (Contd.) ỵ Documents For Production ỵ ỵ Service Design ỵ ỵ ỵ Product Life-Cycle Management (PLM) Documents for Services Application of Decision Trees to Product Design Transition to Production Issues for Product Development ỵ Robust design ỵ Modular design ỵ Computer-aided design (CAD) ỵ Computer-aided manufacturing (CAM) þ Virtual reality technology þ Value analysis þ Environmentally friendly design Robust Design ỵ ỵ Product is designed so that small variations in production or assembly not adversely affect the product Typically results in lower cost and higher quality Modular Design ỵ ỵ ỵ Products designed in easily segmented components Adds flexibility to both production and marketing Improved ability to satisfy customer requirements Computer Aided Design (CAD) ỵ ỵ ỵ Using computers to design products and prepare engineering documentation Shorter development cycles, improved accuracy, lower cost Information and designs can be deployed worldwide Extensions of CAD ỵ Design for Manufacturing and Assembly (DFMA) ỵ ỵ 3-D Object Modeling ỵ ỵ ỵ Solve manufacturing problems during the design stage Small prototype development CAD through the internet International data 10 Moments of Truth ỵ ỵ ỵ ỵ Concept created by Jan Carlzon of Scandinavian Airways Critical moments between the customer and the organization that determine customer satisfaction There may be many of these moments These are opportunities to gain or lose business 43 Moments-of-Truth Computer Company Hotline Experience Enhancers Standard Expectations Experience Detractors I had to call more than once to get through A recording spoke to me rather than a person While on hold, I get silence,and wonder if I am disconnected The technician sounded like he was reading a form of routine questions Only one local number needs to be dialed I never get a busy signal I get a human being to answer my call quickly and he or she is pleasant and responsive to my problem A timely resolution to my problem is offered The technician was sincerely concerned and apologetic about my problem He asked intelligent questions that allowed me to feel confident in his abilities The technician offered various times to have work done to suit my schedule Ways to avoid future problems were suggested The technician is able to explain to me what I can expect to happen next The technician sounded uninterested I felt the technician rushed me Figure 5.13 44 Documents for Services ỵ ỵ ỵ High levels of customer interaction necessitates different documentation Often explicit job instructions for moments-of-truth Scripts and storyboards are other techniques 45 Application of Decision Trees to Product Design ỵ Particularly useful when there are a series of decisions and outcomes which lead to other decisions and outcomes 46 Application of Decision Trees to Product Design Procedures ỵ ỵ ỵ Include all possible alternatives and states of nature - including “doing nothing” Enter payoffs at end of branch Determine the expected value of each branch and “prune” the tree to find the alternative with the best expected value 47 Decision Tree Example (.4) Purchase CAD High sales (.6) Low sales Hire and train engineers (.4) High sales (.6) Do nothing Low sales 48 Figure 5.14 Decision Tree Example (.4) Purchase CAD High sales (.6) Low sales Hire and train engineers $2,500,000 - 1,000,000 - 500,000 $1,000,000 $800,000 - 320,000 - 500,000 - $20,000 Revenue Mfg cost ($40 x 25,000) CAD cost Net Revenue Mfg cost ($40 x 8,000) CAD cost Net loss (.4) High sales EMV (purchase CAD system) = (.4)($1,000,000) + (.6)(- $20,000) (.6) Do nothing Low sales 49 Figure 5.14 Decision Tree Example (.4) Purchase CAD $388,000 High sales (.6) Low sales Hire and train engineers $2,500,000 - 1,000,000 - 500,000 $1,000,000 $800,000 - 320,000 - 500,000 - $20,000 Revenue Mfg cost ($40 x 25,000) CAD cost Net Revenue Mfg cost ($40 x 8,000) CAD cost Net loss (.4) High sales EMV (purchase CAD system) = (.4)($1,000,000) + (.6)(- $20,000) = $388,000 (.6) Do nothing Low sales 50 Figure 5.14 Decision Tree Example (.4) Purchase CAD $388,000 High sales (.6) Low sales Hire and train engineers $365,000 (.4) High sales (.6) Do nothing $0 Low sales $2,500,000 - 1,000,000 - 500,000 $1,000,000 $800,000 - 320,000 - 500,000 - $20,000 $2,500,000 - 1,250,000 - 375,000 $875,000 $800,000 - 400,000 - 375,000 $25,000 $0 Net Revenue Mfg cost ($40 x 25,000) CAD cost Net Revenue Mfg cost ($40 x 8,000) CAD cost Net loss Revenue Mfg cost ($50 x 25,000) Hire and train cost Net Revenue Mfg cost ($50 x 8,000) Hire and train cost Net 51 Figure 5.14 Transition to Production ỵ þ Know when to move to production þ Product development can be viewed as evolutionary and never complete ỵ Product must move from design to production in a timely manner Most products have a trial production period to insure producibility þ Develop tooling, quality control, training þ Ensures successful production 52 Transition to Production ỵ Responsibility must also transition as the product moves through its life cycle ỵ ỵ Line management takes over from design Three common approaches to managing transition ỵ Project managers ỵ Product development teams ỵ Integrate product development and manufacturing organizations 53 Summary of this Session þ Issues for Product Design þ Robust Design þ Modular Design ỵ Computer-Aided Design (CAD) ỵ Computer-Aided Manufacturing (CAM) ỵ Virtual Reality Technology ỵ Value Analysis ỵ Ethics and Environmentally Friendly 54 Design Summary of this Session (Contd.) ỵ ỵ Time-Based Competition ỵ Purchasing Technology by Acquiring a Firm ỵ Joint Ventures ỵ Alliances Defining a Product ỵ Make-or-Buy Decisions þ Group Technology 55 Summary of this Session (Contd.) þ Documents For Production ỵ ỵ Service Design ỵ ỵ ỵ Product Life-Cycle Management (PLM) Documents for Services Application of Decision Trees to Product Design Transition to Production 56 THANK YOU 57 ... 60 -7 1 PANEL WELDM’T A 60 -7 R 6 0- 17 R 6 0-4 28 P 6 0-2 LOWER ROLLER ASSM ROLLER PIN LOCKNUT 1 1 A 60 -7 2 R 6 0- 5 7- 1 A 6 0-4 0 2-5 0-1 150 GUIDE ASSM REAR SUPPORT ANGLE ROLLER ASSM BOLT 1 1 A 60 -7 3 A 60 -7 4 ... nothing $0 Low sales $2,500,000 - 1,000,000 - 500,000 $1,000,000 $800,000 - 320,000 - 500,000 - $20,000 $2,500,000 - 1,250,000 - 375 ,000 $ 875 ,000 $800,000 - 400,000 - 375 ,000 $25,000 $0 Net Revenue... CAD High sales (.6) Low sales Hire and train engineers $2,500,000 - 1,000,000 - 500,000 $1,000,000 $800,000 - 320,000 - 500,000 - $20,000 Revenue Mfg cost ($40 x 25,000) CAD cost Net Revenue Mfg