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Why Study Product and Service Design Reliability
To always stay competitive
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Product Design is a process which:
- •Specifies materials
- • Determines dimensions and tolerances
- • Defines appearance
- • Sets performance standards
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Demand for product design
- Market size
- Demand profile
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The capabilityof an organization to produce an item at an acceptable profit
Manufacturability
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The capability of an organization to provide a service at an acceptable cost or profit
Serviceability
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What is designed in a product or service?
A concept-the understanding of the nature, use and value of the service or product
A package-the group of 'component' products and services that provide those benefits defined in the concept
A process-the way in which the component products and services will be created and delivered
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Stages of Product Design
- Concept generation
- Concept screening
- Preliminary design
- Evaluation and improvement
- Prototyping and final design
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What Does Product and Service Design Do?
- OTranslate customer wants and needs into product and service requirements
- ORefine existing products and services
- ODevelop new products and services
- OFormulate quality goals
- OFormulate cost targets
- OConstruct and test prototypes
- ODocument specifications
- OTranslate product and service specifications into process specifications
- OInvolve inter-functional collaboration
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Reasons to Design or Re-Design
- - Economic
- - Social and Demographic
- - Political, Liability, or Legal
- - Competitive
- - Cost or Availability
- - Technological
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Supply Chain
- Raw materials
- Supplier
- Manufacturer
- Distributer
- Retailer
- Consumer
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Ideas can come from anywhere in the Supply Chain
Supply-Chain Based Ideas
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By studying how a competitor operates and its products and services, many useful ideas can be generated
Competitor-Based Ideas
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Dismantling and inspecting a competitor's product to discover product improvements
Reverse engineering
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Organized efforts to increase scientific knowledge or product innovation
Researched Based Ideas
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Product or Service Life Stages
- Introduction
- Growth
- Maturity
- Decline
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The extent to which there is an absence of variety in product, service or process.
Standardization Design
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Advantages of Standardization
- 1. Fewer parts to deal with in inventory & manufacturing
- 2. Reduced training costs and time
- 3. More routine purchasing, handling and inspection procedures
- 4. Orders fillable from inventory
- 5. Opportunities for long production runs and automation
- 6. Need for fewer parts justifies increased expenditures on perfecting designs and improving quality control procedures
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Disadvantages of Standardization
- 1. Designs may be frozen with too many imperfections remaining.
- 2. High cost of design changes increases resistance to improvements
- 3. Decreased variety results in less consumer appeal.
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A strategy of producing basically standardized goods or services but incorporating some degree of customization in the final product or service.
Mass customization design
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Facilitating techniques
- Delayed differentiation
- Modular design
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-The process of producing, but not quite completing, a product or service until customer preferences are known
- It is a postponement tactic
• Produce a piece of furniture, but do not stain it; the customer chooses the stain
Delayed Differentiation
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A form of standardization in which components parts are grouped into modules that are easily replaced or interchanged.
Modular design
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A design that results in products or services that can function over a broad range of conditions
Robust design
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OBringing engineering design and manufacturing personnel together early in the design phase
OThe purpose is to achieve product designs that reflect customer wants as well as manufacturing capabilities
Concurrent Engineering
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OProduct design using computer graphics
OEnables developers to perform simulations that aid in the design analysis and commercialization of new products
Computer-Aided Design (CAD)
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A process which specifies what the customer is to experience:
• Physical Benefits - physiques
• Sensual Benefits - good feeling
• Psychological Benefits - entertainment
• Physiological Benefits - health
• Service Standards
Service design
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OThe ability of a product, part or system to perform its intended function under a prescribed set of conditions
Reliability
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Importance of Reliability
•Customer Satisfaction: Reliable products and services lead to happier customers.
•Brand Reputation: A reputation for reliability can differentiate your business in the market.
•Cost Savings: Reducing failures and recalls can save significant resources.
•Legal and Regulatory Compliance: Many industries have strict reliability standards.
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The Reliability Engineering Process
•Design Phase: Consider reliability from the very beginning of product/service development.
•Testing and Validation: Rigorous testing and validation processes are essential.
•Continuous Improvement: Ongoing monitoring and improvement are key to long-term reliability.
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Reliability Metrics
•Failure Rate: The rate at which products or services fail over time.
•Mean Time Between Failures (MTBF): The average time between failures.
•Mean Time to Repair (MTTR): The average time it takes to restore a product or service after a failure.
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Reliability and Testing Methods
•HALT (Highly Accelerated Life Testing): Expose products to extreme conditions to uncover weaknesses.
•HASS (Highly Accelerated Stress Screening): Identify and eliminate latent defects during production.
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