Successfully reported this slideshow.
Your SlideShare is downloading. ×

Why Integrating Manufacturing Into Design Process is Critical

Ad

7-Jun-21
Copyright
–
Do
not
duplicate
or
distribute
without
written
permission
from
Design
1st
Inc.
1
.

Ad

7-Jun-21
Copyright
–
Do
not
duplicate
or
distribute
without
written
permission
from
Design
1st
Inc.
2
.

Ad

7-Jun-21
Copyright
–
Do
not
duplicate
or
distribute
without
written
permission
from
Design
1st
Inc.
3 Manufacturing in the...

Ad

Ad

Ad

Ad

Ad

Ad

Ad

Ad

Ad

Ad

Ad

Ad

Ad

Ad

Ad

Ad

Ad

Ad

Ad

Ad

Ad

Ad

Ad

Ad

Ad

Ad

Ad

Check these out next

1 of 30 Ad
1 of 30 Ad

More Related Content

Slideshows for you (19)

Why Integrating Manufacturing Into Design Process is Critical

  1. 1. 7-Jun-21 Copyright – Do not duplicate or distribute without written permission from Design 1st Inc. 1 .
  2. 2. 7-Jun-21 Copyright – Do not duplicate or distribute without written permission from Design 1st Inc. 2 .
  3. 3. 7-Jun-21 Copyright – Do not duplicate or distribute without written permission from Design 1st Inc. 3 Manufacturing in the Design Process AGENDA Designing Without Manufacturing: The Problem You Don’t Know You Have 2 minutes on Kevin Bailey & Design 1st – Our Expertise in Hardware Statistics on Hardware Product Failures Our DFM Risk Identification Tools Concept Design Stage Importance When Manufacturing expertise is not included in the early Concept Design Team Iterative Design Cycling Summary
  4. 4. 7-Jun-21 Copyright – Do not duplicate or distribute without written permission from Design 1st Inc. 4 THE SOBERING REALITY - 70% of Hardware Startups Will Fail
  5. 5. 7-Jun-21 Copyright – Do not duplicate or distribute without written permission from Design 1st Inc. 5 DESIGN AND MANUFACTURING – A NECESSARY MARRIAGE When developing hardware, product skeletons are not a matter of IF, but a matter of when. Including manufacturing expertise early can save lots of headache and money down the line.
  6. 6. 7-Jun-21 Copyright – Do not duplicate or distribute without written permission from Design 1st Inc. 6 FINDING SUCCESS AND AVOIDING ‘DEATH BY PRODUCT FAILURE’ 1. Understand the overall Project Risk 1. Know your team’s strengths and weaknesses 1. Insert DFM (design for manufacturing) reviews for critical components at the right time. 1. Encourage STAGE CYCLING and risk experimentation to find and eliminate problem components and design features that are not required to deliver customer value. 1. Avoid REDO CYCLING using proactive reviews, and address sourcing risks as early as possible. We’ve developed the below process over 30 years:
  7. 7. 7-Jun-21 Copyright – Do not duplicate or distribute without written permission from Design 1st Inc. 7 Kevin Bailey & Design 1st: Over 3 decades of Hardware Expertise 1984 Mechanical Engineer Grad Digital Telephony Boom Outside Plant Equipment Designer 1988 Nortel Norstar Key system Design team Network equipment design 1992 Global Corporate Design Nokia Cellphone team Daimler Benz German Car phone team 1995 100-person Global Design team First smartphone in production 10 years before the iPhone introduction
  8. 8. 7-Jun-21 Copyright – Do not duplicate or distribute without written permission from Design 1st Inc. 8 Starting Design 1st Design 1st 1996 - 2005 Helped Belair Networks innovate a line of outdoor wireless mesh network products Developed trendy consumer electronics for Brookstone USA. Solidified lasting manufacturing relationships in Shen Zhen City, Hong Kong
  9. 9. 7-Jun-21 Copyright – Do not duplicate or distribute without written permission from Design 1st Inc. 9 Design 1st Today Design 1st …2021 30 people 70% USA clients - Design (ID, UX, Human Factors) - Engineering (ME, EE, FW) Over 1000 products designed Wide variety of clients and industries Christie Digital Cinema Theater Projectors
  10. 10. 7-Jun-21 Copyright – Do not duplicate or distribute without written permission from Design 1st Inc. 10 Integrating Manufacturing Early in the Design Process 2021: Global Clients. Global 2021: Global Clients. Global Network of Manufacturing Partners. We understand what works, and why it works.
  11. 11. 7-Jun-21 Copyright – Do not duplicate or distribute without written permission from Design 1st Inc. 11 Manufacturing in the Design Process Design 1st 2020 Successes: Our Expertise in Practice
  12. 12. 7-Jun-21 Copyright – Do not duplicate or distribute without written permission from Design 1st Inc. 12 Manufacturing in the Design Process Asking the right questions at the right time leads to better solutions. Not asking the right questions leads to... THE IMPORTANCE OF UNDERSTANDING COMPLEXITY AND RISK
  13. 13. 7-Jun-21 Copyright – Do not duplicate or distribute without written permission from Design 1st Inc. 13 HARDWARE DESIGN FAILURES Zano Drones: Crowdfunding Failure Raised $2.3M Only 4% of 15K orders shipped One year later company filed for bankruptcy “Unforeseen tolerance issues when moving to production” Peloton Treadmill May 5th, 2021 recall of Treadmill due to roller design Launched 2020, 125K sold (pet unit $2500 - $4300) 70+ incidents of children, pets, objects get stuck under roller 1 Child died, Pelton taking $165M revenue loss AIRIA Smart Scent Launch in 2019 at CES 2019 Recall May 2021 due to power supply failure P&G startup hub company Both products went to full mass production, recall of all products. Early-stage design reviews could have prevented all of these.
  14. 14. 7-Jun-21 Copyright – Do not duplicate or distribute without written permission from Design 1st Inc. 14 UNDERSTANDING RISK: HERE’S WHERE TO START There are two risk categories design projects fall into. ● Modifying an existing design ● A new product design In either case, it’s essential to think about manufacturing early in the design process.
  15. 15. 7-Jun-21 Copyright – Do not duplicate or distribute without written permission from Design 1st Inc. 15 HARDWARE PROJECTS – MORE DETAIL ON COMPLEXITY RISK Modification Design - Incremental design that can be done by current manufacturer e.g., product cost reductions, product refresh, feature additions You may have an existing design-engineering team already familiar with the product. Adjustments to known parts, a sub-assembly or existing component modification. May already be suppliers and manufacturing in place, a quality processes in place. Risks are contained to several new elements being added or changed. Each change may be complicated but the degree of uncertainty is contained. New Product Design - taking ideas and turning them into product New Design New suppliers, new manufacturer New processes/materials New design team New Business team Much higher chance of one mistake leading to design failure
  16. 16. 7-Jun-21 Copyright – Do not duplicate or distribute without written permission from Design 1st Inc. 16 Integrating Manufacturing Early in the Design Process Modifying an Existing Design Helping an outdoor monitor maker update their product. New Product Design Helping a new product get to market.
  17. 17. 7-Jun-21 Copyright – Do not duplicate or distribute without written permission from Design 1st Inc. 17 Once you’ve identified the risk category, you’ll need tools to examine the different aspects of that risk.
  18. 18. 7-Jun-21 Copyright – Do not duplicate or distribute without written permission from Design 1st Inc. 18 A PRACTICAL TOOL FOR ESTIMATING LABOR EFFORT From simpler design development - fewer parts, no electronics, no wireless, copying other product, adding features… To the most complex ‘greenfield designs’ - many new parts/suppliers, no reference product, new user group, no customer data…
  19. 19. 7-Jun-21 Copyright – Do not duplicate or distribute without written permission from Design 1st Inc. 19 Another Tool to Look at Project Complexity Risk Total # of parts in the Assembly # of Fully Custom parts to design # customized off the shelf parts (COTS) Other Complexity Risks > system products, accessories, moving parts.. Simple Medium Complex # parts # custom # COTS Other EFFORT $$ / time to market Development Predictability Matrix Use it as a barometer for ‘Manufacturing Review Required’ signal in early stage design.
  20. 20. 7-Jun-21 Copyright – Do not duplicate or distribute without written permission from Design 1st Inc. 20 Integrating Manufacturing Early in the Design Process - Example 1 Example 1 – Lily Chiller New product Single component No electronics New manufacturer selection risk Material & Process selection risk New start-up company risk High probability of positive outcome
  21. 21. 7-Jun-21 Copyright – Do not duplicate or distribute without written permission from Design 1st Inc. 21 Integrating Manufacturing Early in the Design Process - Example 2 Example 2 – Toddler Monitor New product Custom electronics COTS = existing microprocessor + custom firmware ‘System product’ - Bluetooth risk New manufacturer selection Housing material selection Assembly process risk Good probability of positive outcome 205 parts total 5 fully custom parts 2 COTS Components ‘Other’ risks
  22. 22. 7-Jun-21 Copyright – Do not duplicate or distribute without written permission from Design 1st Inc. 22 Integrating Manufacturing Early in the Design Process - Example 3 Example 3 – Laptop Computer New product 1600 parts including electronics components selected 57 fully custom parts 6 COTS single source modules (display, battery, keypad..) 8 additional COTS components - multisource Other – new CM, new supply network COTS Example – DISPLAY MODULE
  23. 23. 7-Jun-21 Copyright – Do not duplicate or distribute without written permission from Design 1st Inc. 23 Integrating Manufacturing Early in the Design Process - Example 4 Example 4 – Drone Landing Re-Charge Garage New product 270 parts/modules 24 COTS sub-assemblies, 5 sole sourced 67 fully custom parts Customized software code Network connected for remote operation COTS Example - STRUCTURAL HOUSING SELECTION
  24. 24. 7-Jun-21 Copyright – Do not duplicate or distribute without written permission from Design 1st Inc. 24 Integrating Manufacturing Early in the Design Process - But, when? CONCEPT DESIGN STAGE This stage is critical to select the major components of the design and identify the supplier source options. Red flags for moving Manufacturing DFM to design stage include: *Customized off the shelf parts (COTS) and sub-assemblies *Single or narrowly sourced components that involve reliance on third party suppliers (this would ideally be removed if not essential) DE Detailed Engineering PT Prototype and Test CD Concept Design MA Manufacturing DFM MA Manufacturing Transfer
  25. 25. 7-Jun-21 Copyright – Do not duplicate or distribute without written permission from Design 1st Inc. 25 Integrating Manufacturing Early in the Design Process EXPERIENCE Over time designers learn engineering and the manufacturing risks of their decisions. Engineers learn how to think like designers and to appreciate manufacturing process and variability and choose design solutions that minimize risk without sacrificing product features. EXPERIENCE DIVERSITY Design teams that work on the same type of products get very good at high quality product and specific risk identification (and avoidance). In my experience, this environment is too rigid for free flow idea innovation and exploration. New product configurations and useful new features come from ignoring the conventional wisdom and in the process of creative exploration, uncovering new opportunity. Once the magic is found there is usually a way to design the new features with manufacturing in mind and at high quality level. PROFESSIONALS Product design teams with diverse experience provide concept exploration techniques that have design-engineering, manufacturing and supply feasibility infused in the process to explore and refine. Business teams are finding it easier to start hardware development ventures finding expert teams that integrate designers, engineers and manufacturing specialists and have been working together on many projects. These teams understand all three worlds and the balance of risk and opportunity for predictable positive outcomes.
  26. 26. 7-Jun-21 Copyright – Do not duplicate or distribute without written permission from Design 1st Inc. 26 MANUFACTURING SPECIALISTS IN THE DESIGN CONCEPT STAGE There are 1000’s of decisions to make in every product development Around 10 decisions are critical to avoid product failure. Early DFM can help navigate these especially important decisions. Design For Manufacture (DFM) reviews should touch on 3 main areas: 1. The Part Supply Risks – identify critical components 2. The Major Parts Design Risks – parts that affect other parts if changed 3.The General Manufacturing risks – wide ranging parts and assembly review
  27. 27. 7-Jun-21 Copyright – Do not duplicate or distribute without written permission from Design 1st Inc. 27 USE HELPFUL STAGE CYCLING – FOR KNOWN HIGHER RISKS CD DE PT MONTH 1 MONTH 2 MONTH 3 MONTH 4 MONTH 5 MONTH 6 MONTH 7 MONTH 8 MONTH 9 MONTH 10 CD CD-RnD DE Suppliers Identification, Regulatory Questions, Component Identification Tooling & Samples Build MONTH 11 MONTH 12 Production Runs Product Design and Development Process DE-RnD MA MA MA PT STAGE CYCLING STAGE CYCLING STAGE CYCLING
  28. 28. 7-Jun-21 Copyright – Do not duplicate or distribute without written permission from Design 1st Inc. 28 AVOID COSTLY REDO CYCLING CD DE PT MONTH 1 MONTH 2 MONTH 3 MONTH 4 MONTH 5 MONTH 6 MONTH 7 MONTH 8 MONTH 9 MONTH 10 CD CD-RnD DE Suppliers Identification, Regulatory Questions, Component Identification Tooling & Samples Build MONTH 11 MONTH 12 Production Runs DE-RnD MA MA MA PT DESIGN REDO CYCLING
  29. 29. 7-Jun-21 Copyright – Do not duplicate or distribute without written permission from Design 1st Inc. 29 Integrating Manufacturing Early in the Design Process Summary 1. Know your new product complexity level and identify the higher risk elements 2. Know your design team’s expertise and weaknesses 3. Find the best time and expertise to insert into early stage DFM reviews 4. Encourage STAGE CYCLING and risk experimentation 5. Avoid the REDO CYCLING 6. Get to market with the help of experienced Design-Engineering-Manufacturing teams
  30. 30. 7-Jun-21 Copyright – Do not duplicate or distribute without written permission from Design 1st Inc. 30 .

×