Provides basics of Product and Process Design Management

1. Dr. Pradeep Desai
Basics of Product and Process Design Management
Technology and Innovation

2. Contents
1 Product Design
2 Objectives of Product Design
3 Features of a Good Product Design
4 Concepts of Product Design
5 Steps of Product Design
6 Product Design Management
7 4-Pillars of Design Management
8 Value & Role of Design Management
9 Process Design
10 Process Development for Process Design
11 Steps for Process Design
12 Objectives of Process Design
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3. Product Design
• Product design is conceptualization of an idea about a
product and transformation of the idea into a reality.
• To transform the idea into reality a specification about
the product is prepared. This specification is prepared
by considering different constraints such as
production process, customer expectation, etc.
• In product design stage every aspects of the product
are analyzed. Also final decision regarding the product
is taken on the basis of the analysis. This decision can
be any aspect related to the product. E.g. dimension
and tolerances, type of material for every components
etc.
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4. Objectives of Product Design
• To ensure growth of the organization.
• To utilize the surplus capacity of the organization, such as
physical facility, man power, etc.
• To utilize the surplus fund of the organization.
• To meet new requirement of the customers.
• To increase company’s market share and to target new
market segment.
• To ensure complete product range in company’s portfolio.
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5. Features of a Good Product Design
Quality: The product must satisfy customer’s stated and
unstated needs.
Standardization: The product should be designed in such
a fashion so that most of the components are
standardized and easily available in the market.
Maintainability: The product must perform for a
designated period with a minimum and defined
maintenance. Adequate provision for maintenance should
be kept in the product.
Cost effectiveness: The product must be cost effective.
The must be manufactured in the most cost effective
environment.
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6. Concepts of Product Design
Research & development:
• Basic research is a search for new knowledge. It does not have
any immediate application, but based on the basic research new
product can be developed in future.
• Applied research has objective of developing commercial products.
Reverse engineering:
• Reverse engineering is the process of carefully dismantling a
product, understanding its design and developing a product which
is better than the existing one.
CAD-CAM:
By using 3D modeling software system, designers develop a
computerized model of a new product and analyze its design
parameters. After computer aided design (CAD), computer aided
manufacturing (CAM) system produce the product by using CNC
facility.
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7. Steps of Product Design
1. Synthesis: Try to develop different alternatives
2. Sketching: Draw sketches in exact scale for different alternatives
3. Analysis: Analysis different alternatives with respect to operability,
maintainability, inspection, assembling and dismantling issues, cost
parameters, production methods, etc.
4. Selection: Select the best alternative
5. Basic engineering: Prepare layout in exact scale, calculate strength of
components, select proper cost effective material.
6. Detail design: Prepare detail engineering drawing for each component
7. Prototype: If option is there, then prepare prototype and test it
8. Manufacturing: If prototype is not made, then follow manufacturing
steps and solve manufacturing problems and assembly problems, if any.
9. Operation: collect feedback during actual operation of the new
product. If any problem exists, try to provide design based solution.
Also, implement lessons in the future design.
10. Product development: If any modification can be done, implement
the same in the next generation product.
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8. Product Design Management
• Product Design Management is a multidisciplinary
management methodology that benefits product
design and innovation for business growth, as part of
the company strategy.
• Business side of design- Used to develop and maintain
a business environment in which an organization can
achieve its strategic goals through design.
• It includes:
– Strategy and planning
– Information and communication, link to R&D and branding
– Project management
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9. Project Management- Helps to achieve project goals within:
Time, Scope, Budget and Quality.
Design- A specification of an object, intended to accomplish
goals in a particular environment, satisfying a set of
requirements and subject to constraints.
Strategy- A high level plan to achieve one or more goals
under conditions of uncertainty.
Supply Chain Techniques-
Role of Design in the Supply Chain:
– Demand Generation
– Influencing manufacturing processes, cost, quality and lead time
– Effect on transportation, quality, quantity, production schedule and
production technologies
4-Pillars of Design Management
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10. Value of Design Management-
• Innovation in internal business processes
• Learning and growing opportunity
• Customer and brand: strategic positioning
• Financial- Explicit and measurable value for company
reputation and market performance
Roles of Design Management-
• Align design strategy with corporate /brand strategy
• Manage quality and consistency of design outcomes
• Enhance user experience, create new solutions,
differentiate from rivals
Value & Role of Design Management
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11. • At the time of designing a product, preliminary
consideration is given to the capacity of the firm to
manufacture the product
• Process planning is concerned with planning the conversion
or transformation processes needed to convert the materials
into finished products
• Process and Operations design provide information on what
is required to effectively utilize the existing equipment and
to determine what new equipment and machinery would be
required
Product
Design
Process
planning
Process
Design
Operations
Design
Process Design

12. Process Design
Process design is taking the product development and
breaking it down into parts, which in turn helps the actual
manufacturing process.
• It ensures that there is smooth and continuous
relationship between required output and all the
intermediate process.
• Process design is a diagram representing a sequence of
activities. It typically shows events, actions and links or
connection points, in the sequence from end to end.

13. Process Development for Process
Design
• Process Requirement: The 1st step is to collect and gather
information to give structure with the end objective. That is to
make process requirement document highlighting various stages,
risk and stakeholders for production. This will include assessment of
available technology, raw material requirement, factory/plant layout
and demand forecast.
• Team Building: Once the process requirements are finalized, for
each objective, a team is finalized based on skill level and
experience. Function of the team is to get familiarize with the whole
process.
• Planning and Implementation: Process planning team will
develop module; policies and procedure require for production,
which are after required approval internal as well as external is
implemented.
• Audit: A regular audit is carried out to ensure that process thus
implemented is in line and delivering value to customers.
• End of Life: Over a course of time there may be enhancement of
the product or product may get discontinued in these
circumstances, process thus develop is discontinued.

15. Objectives of Process Design
Operations performance objectives translate directly to process
design objectives. Because processes are managed at a very
operational level, process design also needs to consider a more
micro and detailed set of objectives. These are largely concerned
with flow through the process.
Process flow performance is described by:
• Throughput rate- the rate at which units emerge from the
process i.e. the number of units passing through the process
per unit of time.
• Throughput time- the average elapsed time taken for inputs
to move through the process and become outputs.
• Work in progress- the number of units in the process as an
average over a period of time.
• Utilization- the proportion of available time that the resources
within the process are performing useful work.
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