2. INTRODUCTION
• Definition
• A process of the end to end creation of goods that solve a specific problem for
the user.
• Aspects of product Design
• Design for Function
• Design for Making
• Design for Selling
• Classification of Product Design
• New Product Development
• Modification of Existing Products.
4. 1. Problem assessment: After having identified the problem in terms of a new
product/enhanced product, it is better to write-down the problem in clear
terms.
2. Design specification : Requirements of the product are to be listed out.
Such requirements will fix the boundaries to design the product.
3. Idea generation: At this stage, a group of experts will generate ideas about
the design of the product. Some of the ideas may be funny. But, the team
leader should not curb the ideas
4. Screening and evaluation of ideas: Rank the ideas generated in descending
order of the importance and select idea from the top list for design purpose
5. Business analysis : It is an in-depth study of the estimated economic
feasibility of the product. The expected cost and revenues may be
estimated in macro terms.
Steps of Product Design:
5. 6. Concept design: A rough design of product is to be worked out in terms of
components of product , shape , size. 3 -dimensional product is constructed for
comparison.
7.Detailed design: Measurements are determined by functional requirements.
3 dimensional prototype is developed.
8. Production of prototype and testing: Prototype is sent to laboratory to test
the performance
9. Manufacturing: The design engineer in consultation with the process
planning engineer design manufacturing system.
10. Commercialization/product launch: In case of MNC, launch take place
simultaneously in atleast one city or in the most promising city by taking future
sales into account.
6. Process Selection
Process selection decisions determine the type of product process to be
used and the appropriate span of that process
Process Classification - Decisions
7.
8. • Interpretation of part print analysis, symbols
• Gathering the fundamental details of product design
• Recommending design changes
• Selection of proper machinery with allied tooling
• Study the effect of engineering changes upon existing tooling
• Tooling Data
• Sequence of operations
• Decide the inspection equipments in order to meet the desired quality
Responsibilities of process planning engineer
9. Steps in Process Planning
• Part Blueprint Analysis: Review the part print to
grasp the desired outcome.
• Engineering Collaboration: Offer recommendations
or consult product engineers for design refinements.
• Operation Enumeration: Identify essential
operations aligned with the drawing or
specifications.
• Methodology Selection: Optimize manufacturing
approach and tooling for efficiency and cost-
effectiveness.
• Operation Sequencing: Strategically arrange
operations for seamless workflow.
• Quality Assurance: Define necessary gauging for
process integrity and product quality.
10. ❖ The process of bringing a new product to customers involves product
development and process development.
❖ Product development creates the new product, while process development
creates the production method.
❖ Process design combines science, mechanics, and automation to design
equipment for production, validated before full-scale use.
❖ The process development will undergo the following phases:
PROCESS DESIGN
● Process research
● Pilot development
● Capacity consideration
● Commercial plant transfer
● Enhanced capacity using optimization
11. PROCESS RESEARCH
Let the product be the casting of gear blanks for making
gears which are used to rotate the kilns in cement plants
or sugar plants.So, one should do a research about the
operations involved in making the castings of the gear
blanks. The following operations are involved in making
the gear blanks:
● Preparation of green sand to make mould
● Preparation of patterns
● Making pit mould
● Preparation of molten metal
● Pouring the molten metal into the mould
● Doing fettling operation to remove the foreign
particles on the casting
● Doing gouging operation to fill external cavities
on the surface of the casting
● Doing annealing operation of the casting to
release the internal stress and strain developed
during the casting processl.
The objective of the process design is to design and
develop each of the above processes and stand validate
before using them to make the gear blanks.
For each of these processes, the following tasks are to be
carried
● State the purpose
● Establish the means of achieving the purpose
● Checking the quality if applicabl
12. PILOT DEVELOPMENT
• Pilot development in operations management typically involves implementing a small-scale
version of a new process, system, or technology to test its effectiveness before full-scale
implementation.
CAPACITY CONSIDERATION
• Capacity considerations in operations management involve assessing and managing the ability
of a system, process, or organization to produce goods or services to meet demand effectively.
• Key factors are forecasting demand, understanding production capabilities, balancing capacity
with demand fluctuations, optimizing resource allocation, and implementing strategies .
COMMERCIAL PLAN TRANSFER
• After having convinced about the integrated functioning of processes using the pilot
development phase, the process design may be transfer to commercial plant Where the
regular production can take place.
ENHANCED CAPACITY
• Once the plant starts producing the product, over ah period of time, the performance of the
operations of the process, will be available for the integrated function of the plant.
• Based on such data, one can make an attempt to optimize the process design in the plant, to
increase the capacity. One may use some model/process improvement based on the available
data.
