Product Engineering and Manufacturing

by Schmidt, Linda C.; Zhang, Guangming; Herrmann, Jeffery W.; Dieter, George E.; Cunniff, Patrick F.

• ISBN13: 9780970067562
• ISBN10: 0970067569
• Edition: 2nd
• Format: Hardcover
• Copyright: 2002-04-01
• Publisher: Frank Amato Pubns

Table of Contents

About the Authors	iii
Forward	xi
Preface	xiii
Introduction
Linda C. Schmidt
Introduction	1	(1)
Winning Products	2	(1)
Engineers and the Product Development Process	3	(3)
Teamwork	6	(1)
Objectives of this Textbook	7	(4)
Exercises	8	(1)
References	9	(2)
A Product Development Process
Linda C. Schmidt
Introduction	11	(1)
Product Development Process: Mechanical Design	11	(3)
The Nine-Step PDP Process in Brief	14	(12)
Project Planning	26	(3)
A Toolkit for the Product Development Process	29	(1)
Summary	29	(4)
Exercises and References	31	(2)
Development Teams
James W. Dally
Introduction	33	(1)
A Balanced Team Structure in a Functional Organization	34	(2)
Development Planning	36	(1)
Staffing	36	(1)
Team Leaders	37	(1)
Team Member Responsibilities	37	(1)
Team Member Traits	38	(2)
Evolution of a Development Team	40	(1)
A Team Contract	41	(1)
Effective Team Meetings	42	(2)
Preparing for Meetings	44	(2)
Positive and Negative Team Behavior	46	(1)
Summary	47	(6)
Exercises	49	(2)
References	51	(2)
Benchmarking
Linda C. Schmidt
Introduction	53	(1)
Benchmarking is Comparing	54	(3)
Benchmarking: Benefits and Barriers	57	(1)
Competitive-Performance Benchmarking	58	(1)
Tools for Competitive Performance Benchmarking	59	(2)
Developing Tests for Competitive Performance Benchmarking	61	(2)
Summary	63	(2)
Exercises and References	64	(1)
Manufacturing Processes
George E. Dieter
Introduction	65	(1)
Engineering Materials	65	(5)
Classification of Manufacturing Processes	70	(3)
Metal Processes	73	(11)
Polymer Processing	84	(5)
Equipment, Tooling and Fixtures	89	(1)
Selection of Manufacturing Processes	90	(4)
Cost of Manufacture	94	(5)
Summary	99	(2)
Exercises	99	(1)
References	100	(1)
Design for ``X''
George E. Dieter
Jeffery. W. Herrmann
Introduction	101	(1)
What is ``X''?	101	(2)
Design for Manufacture and Assembly (DFMA)	103	(3)
Failure Mode and Effects Analysis	106	(4)
Design for Production	110	(3)
Design for Maintenance	113	(1)
Design for Sustainability	114	(3)
Design for the Environment (DFE)	117	(1)
Summary	118	(3)
Exercises	119	(1)
References	120	(1)
Meeting the Customers Needs
Patrick F. Cunniff
Introduction	121	(2)
The House of Quality	123	(4)
Case Study: Palm-Grip Random Orbit Sander	127	(6)
Case Study: A Drywall Screwdriver	133	(3)
Summary	136	(3)
References and Exercises	137	(2)
Functional Decomposition
Linda C. Schmidt
Introduction	139	(1)
Screwdriver Example of Functional Decomposition	139	(4)
Functional Decomposition---a Description Process	143	(2)
Functional Decomposition Process	145	(6)
When is Functional Decomposition Appropriate?	151	(1)
Summary	152	(5)
Exercises	153	(2)
References	155	(2)
Concept Generation and Selection
Linda C. Schmidt
Introduction	157	(1)
Constraints, Criteria, and Difficulties in Concept Generation	158	(2)
Common Concept Generation Methods	160	(2)
Formal Concept Generation Methods	162	(6)
Selecting the Superior Design Concept	168	(7)
Summary	175	(2)
Exercises	175	(1)
References	176	(1)
Product Architecture
Linda C. Schmidt
Introduction	177	(1)
What is Product Architecture?	178	(1)
Integral and Modular Product Architectures	178	(1)
Modularity in Product Architecture	179	(2)
Product Architecture Design	181	(2)
Implications of Product Architecture Design	183	(3)
Summary	186	(3)
Exercises	186	(1)
References	187	(2)
Economics of Product Development
Patrick F. Cunniff
Introduction	189	(1)
Time Value of Money	189	(7)
Equivalent Cost Comparisons	196	(4)
Breakeven Analysis	200	(1)
A Product Profit Model	201	(2)
Trade-Off Exercises	203	(1)
Summary	204	(9)
Exercises	204	(2)
References	206	(1)
Profit Model Tables	207	(6)
Design for Quality
George E. Dieter
Guangming Zhang
Introduction	213	(1)
What is Quality?	214	(1)
Achieving Quality Products	215	(2)
Continuous Quality Improvements	217	(8)
Six-Sigma Quality Management Systems	225	(3)
Taguchi Loss Function	228	(3)
Robust Design	231	(5)
Summary	236	(3)
Exercises	237	(1)
References	238	(1)
Engineering Statistics in Manufacturing
Guangming. Zhang
Introduction	239	(1)
Process Variations	239	(2)
Characterization of Data	241	(7)
Probability Distributions	248	(13)
The Student t-Distribution	261	(7)
Comparison of Means	268	(1)
Summary	269	(8)
Statistical Tables	270	(3)
Exercises	273	(3)
References	276	(1)
Statistical Process Control
Guangming Zhang
Introduction	277	(1)
Assessment of Process Capability	277	(5)
Process Capability Indices	282	(2)
X Bar Control Charts	284	(7)
R Control Charts	291	(3)
s Control Charts	294	(3)
Summary	297	(4)
Exercises	298	(1)
References	299	(2)
Dimensions and Tolerances
Guangming Zhang
Patrick F. Cunniff
Introduction	301	(1)
General Principals for Dimensioning	302	(6)
Methods of Tolerancing	308	(7)
A Statistical Approach for Determining Assembly Tolerances	315	(6)
Geometric Tolerances	321	(4)
Summary	325	(6)
Exercises	326	(3)
References	329	(2)
Production Management
Jeffery W. Herrmann
Introduction	331	(1)
A Brief History of Manufacturing in America	331	(1)
A Typical Manufacturing Firm	332	(1)
Manufacturing Objectives	333	(1)
Types of Manufacturing Systems	334	(2)
Process Planning	336	(1)
Production Planning and Scheduling	337	(2)
Summary	339	(6)
Exercises	340	(1)
References	341	(4)
APPENDICIES
Appendix A Technical Reports and Information Searches
James W. Dally
A.1 Introduction	345	(1)
A.2 Approach and Organization	346	(3)
A.3 Know Your Readers and Your Objective	349	(1)
A.4 The Technical Writing Process	350	(1)
A.5 Revising, Editing and Proofreading	351	(2)
A.6 Word Processing Software	353	(1)
A.7 Searching for Information	354	(2)
A.8 Electronic Libraries on the World Wide Web	356	(5)
A.9 Summary	361	(1)
Exercises	362	(1)
References	363	(2)
Appendix B Design Briefings
James W. Dally
B.1 Introduction	365	(1)
B.2 Speeches, Presentations and Discussions	365	(2)
B.3 Preparing for the Briefing	367	(2)
B.4 Presentation Structure	369	(5)
B.5 Types of Visual Aids	374	(1)
B.6 Delivery of the Presentation	375	(3)
B.7 Summary	378	(1)
Exercises and References	379	(2)
Appendix C Quality Management Systems
Guangming Zhang
C.1 Introduction	381	(1)
C.2 TQM with Deming's 14 Points	381	(5)
C.3 The Malcolm Baldridge National Quality Award	386	(4)
C.4 ISO 9000 Registration	390	(3)
C.5 Summary	393	(1)
References	393	(2)
Index	395