Integrated Product and Process Design and Development

by Magrab, Edward B.

• ISBN13: 9780849384837
• ISBN10: 0849384834
• Format: Hardcover
• Copyright: 1997-07-01
• Publisher: CRC Pr I Llc

Summary

This book presents both a complete development of the integrated product and process design and development (IP2D2) method and a large number of successful techniques and checklists that can be used to conceptualize, design, and rapidly produce competitively priced products. The book has been extensively class tested and used as a text in senior/graduate-level Mechanical Engineering Design courses. It creates an attitude toward design that encourages creativity and innovation while considering customer requirements and satisfaction, quality, reliability, manufacturing methods, material selection, assembly, economics, the environment, and scheduling.

Table of Contents

1. PRODUCT DEVELOPMENT INTO THE 21(st) CENTURY	1	(28)
1.1 Some Definitions	1	(3)
1.2 Manufacturing in the 21(st) Century	4	(3)
1.3 Time as a Competitive Advantage	7	(1)
1.4 Benchmarking	8	(4)
1.5 Partnering with Suppliers	12	(3)
1.6 Mass Customization - The Next Paradigm?	15	(1)
1.7 Quality	16	(9)
1.7.1 What is Quality?	16	(4)
1.7.2 Malcolm Baldrige National Quality Award	20	(3)
1.7.3 Continuous Improvement	23	(1)
1.7.4 ISO 9000	24	(1)
1.8 Foundations of Manufacturing	25	(4)
2. THE INTEGRATED PRODUCT AND PROCESS DESIGN AND DEVELOPMENT TEAM METHOD	29	(18)
2.1 Introduction	29	(2)
2.2 The IP(2)D(2) Team and Its Agenda	31	(6)
2.3 Dynamic and Static Product Status	37	(1)
2.4 Company Strategy and IP(2)D(2)	37	(2)
2.5 Technology's Role in IP(2)D(2)	39	(1)
2.6 IP(2)D(2) Team Interactions	40	(7)
2.6.1 Creative Methods	40	(4)
2.6.2 Team Interactions	44	(3)
3. PRODUCT COST ANALYSIS	47	(18)
3.1 Introduction	47	(1)
3.2 Factors that Determine a Product's Cost	48	(6)
3.3 Cost Models	54	(11)
3.3.1 Introduction	54	(1)
3.3.2 Hewlett-Packard's Return Map	54	(1)
3.3.3 Product Profit Model (Design-to-Cost)	55	(10)
4. PRODUCT FUNCTIONAL REQUIREMENTS AND DECOMPOSITION	65	(24)
4.1 Principles of Design	65	(7)
4.1.1 Introduction	65	(3)
4.1.2 Axiomatic Approach and Functional Decomposition	68	(2)
4.1.3 Mathematical Representation of Axiom 1	70	(1)
4.1.4 Function Analysis	71	(1)
4.2 Examples of the Use of the Axiomatic Method	72	(17)
4.2.1 Introduction	72	(3)
4.2.2 Example 1 - Carton Taping System	75	(2)
4.2.3 Example 2 - Intelligent V-Bending Machine	77	(3)
4.2.4 Example 3 - High-Speed In-Press Transfer Mechanism	80	(1)
4.2.5 Example 4 - Drywall Taping System	81	(2)
4.2.6 Example 5 - Steel Frame Joining Tool	83	(6)
5. TRANSLATING CUSTOMER REQUIREMENTS INTO PRODUCTS	89	(20)
5.1 Voice of the Customer	89	(5)
5.2 Quality Function Deployment (QFD)	94	(8)
5.2.1 Introduction	94	(1)
5.2.2 QFD and the House of Quality	95	(7)
5.3 Product Design Specification	102	(7)
6. PRODUCT CONCEPTS AND EMBODIMENTS	109	(32)
6.1 Introduction	109	(5)
6.2 Concept Generation	114	(13)
6.2.1 Introduction	114	(5)
6.2.2 The Search for Solutions	119	(8)
6.3 Product Configuration (Architecture)	127	(2)
6.4 Concept Evaluation and Selection	129	(7)
6.5 Product Embodiments	136	(5)
7. DESIGN FOR ASSEMBLY AND DISASSEMBLY	141	(11)
7.1 Introduction	141	(2)
7.2 Design for Assembly	143	(8)
7.2.1 Why Assemble?	143	(1)
7.2.2 Assembly Principles and Guidelines	143	(8)
7.3 Design for Disassembly (Dismantling) - DFD	151	(4)
7.3.1 Introduction	151	(1)
7.3.2 DFD Guidelines and the Effects on the Design for Assembly	152	(3)
8. MATERIAL SELECTION	155	(39)
8.1 Introduction	155	(6)
8.2 Ferrous Alloys	161	(5)
8.2.1 Plain Carbon Steels	161	(1)
8.2.2 Alloy Steels	162	(2)
8.2.3 Cast Irons	164	(2)
8.3 Nonferrous Alloys	166	(9)
8.3.1 Light Alloys	166	(4)
8.3.2 Heavy Alloys	170	(4)
8.3.3 Refractory Metals	174	(1)
8.4 Special Purpose Alloys	175	(3)
8.5 Plastics	178	(10)
8.5.1 Introduction	178	(2)
8.5.2 Thermoplastics - Partially Crystalline	180	(2)
8.5.3 Thermoplastics - Amorphous	182	(2)
8.5.4 Thermosets - Hoghly Crosslinked	184	(2)
8.5.5 Thermosets - Lightly Crosslinked	186	(2)
8.6 Ceramics	188	(1)
8.7 Composites	189	(2)
9. MANUFACTURING PROCESSES AND DESIGN	191	(48)
9.1 Introduction	191	(7)
9.2 Casting - Permanent Mold	198	(7)
9.2.1 Pressure Die Casting	198	(2)
9.2.2 Centrifugal Casting	200	(1)
9.2.3 Compression Molding	201	(2)
9.2.4 Injection Molding	203	(2)
9.3 Casting - Permanent Pattern	205	(5)
9.3.1 Sand Casting	205	(2)
9.3.2 Shell Mold Casting	207	(3)
9.4 Casting - Expendable Pattern	210	(1)
9.4.1 Investment Casting	210	(1)
9.5 Cutting - Mechanical Machining	211	(7)
9.5.1 Single Point Cutting	211	(2)
9.5.2 Milling (Multiple Point Cutting)	213	(2)
9.5.3 Grinding	215	(3)
9.6 Cutting - Electromachining	218	(2)
9.6.1 Electric Discharge Machining (EDM)	218	(2)
9.7 Forming - Sheet	220	(3)
9.7.1 Blow Molding	220	(1)
9.7.2 Sheet Metal Working	221	(2)
9.8 Forming - Bulk	223	(9)
9.8.1 Forging	223	(3)
9.8.2 Rolling	226	(2)
9.8.3 Extrusion	228	(4)
9.9 Powder Processing	232	(4)
9.9.1 Powder Metallurgy	232	(4)
9.10 Rapid Prototyping (Stereolithography)	236	(3)
10. DESIGN FOR `X'	239	(28)
10.1 Reliability	239	(6)
10.1.1 Introduction	239	(2)
10.1.2 Failure Identification Techniques	241	(4)
10.2 Poka-Yoke	245	(4)
10.3 Design for Maintainability (Serviceability)	249	(1)
10.4 Design for the Environment	250	(4)
10.5 Product Safety, Liability and Design	254	(4)
10.6 Ergonomics (Usability)	258	(1)
10.7 Design for Aesthetics	259	(1)
10.8 Design for Packaging	260	(1)
10.9 Material Handling	260	(2)
10.10 Design for Production (Time-to-Market)	262	(5)
11. PRODUCT AND PROCESS IMPROVEMENT	267
11.1 Introduction	267	(1)
11.2 What Is Experimental Design?	268	(4)
11.3 Guidelines for Designing Experiments	272	(2)
11.4 Factorial Analysis	274	(14)
11.4.1 Analysis of Variance (ANOVA)	274	(1)
11.4.2 Single Factor Experiment	275	(2)
11.4.3 Factorial Experiments	277	(2)
11.4.4 Factorial Experiments with One Replicate	279	(1)
11.4.5 2(k) Factorial Analysis	280	(3)
11.4.6 2(k) Factorial Analysis with One Replicate	283	(4)
11.4.7 2(k) Fractional Factorial Analysis	287	(1)
11.5 Example of the Use of the Analysis of Variance	288	(11)
11.5.1 Example 1 - Manufacture of Stiff Composite Beams	288	(2)
11.5.2 Example 2 - Optimum Performance of an Air-Driven Vacuum Cleaner	290	(4)
11.5.3 Example 3 - Operating Conditions for a Solder Deposition Machine	294	(3)
11.5.4 Example 4 - Optimization of a Spray Drying Process	297	(2)
11.6 The Taguchi Method	299