Chapter 3 Product Design and Process Selection

Question 1

service design

Answer 1

is the process of establishing all the characteristics of the service, including physical, sensual, and psychological benefits.

Question 2

What are the steps for Product Design Process?

Answer 2

1. Idea Development
2. Product Screening
3. Preliminary Design and testing
4. Final design

Question 3

manufacturability

Answer 3

the ease with which the product can be made

Question 4

Product Design Process step: Idea Development

Answer 4

Someone thinks of a need and a product/service design to satisfy it; customers, marketing, engineering, competitors, benchmarking, reverse engineering.

Question 5

reverse engineering

Answer 5

buy a competitor’s new product and study its design features. Using a process called reverse engineering, a company’s engineers carefully disassemble the product and analyze its parts and features.

Question 6

Product Design Process step: Product screening

Answer 6

Every business needs a formal/structured evaluation process; fit with facility and labor skills, size of market, contribution margin, break-even analysis, return on sales.

Question 7

Product Design Process step: Preliminary design and testing

Answer 7

Technical specifications are developed, prototypes built, testing starts.

Question 8

Product Design Process step: final design

Answer 8

Based on test results, facility, equipment, material, and labor skills defined, suppliers identified .

Question 9

Early supplier involvement (ESI)

Answer 9

involving suppliers in the early stages of product design.

Question 10

Factors Impacting Product Design, Design for manufacturing (DFM):

Answer 10

is a series of guidelines that we should follow to produce a product easily and profitably.

Question 11

Factors Impacting Product Design, Design for manufacturing (DFM),
focuses on 2 issues:

Answer 11

design specification, design standardization

Question 12

DFM, Design simplification

Answer 12

reducing the number of parts and features of the product whenever possible. A simpler product is easier to make, costs less, and gives higher quality.

Question 13

DFM, Design standardization:

Answer 13

refers to the use of common and interchangeable parts. By using interchangeable parts, we can make a greater variety of products with less inventory and significantly lower cost and provide greater flexibility.

Question 14

DFM guidelines:

Answer 14

1. minimize parts
2. design parts of different products
3. use modular design
4. avoid tools
5. simplify operations

Question 15

Factors in - Product life cycle:

Answer 15

A series of stages that products pass through in their lifetime, characterized by changing product demands over time.

Question 16

stages of Product lifecycle:

Answer 16

1 introduction.

2. Growth
3. Maturity
4. decline

Question 17

concurrent engineering:

Answer 17

is an approach that brings many people together in the early phase of product design in order to simultaneously design the product and the process.

Question 18

remanufacturing:

Answer 18

The concept of using components of old products in the production of new ones. Common with: computers, televisions, automobiles

Question 19

Types of processes are:

Answer 19

intermittent operations and repetitive operations

Question 20

type of process, Intermittent operations:

Answer 20

Processes used to produce a variety of products with different processing requirements in lower volumes (such as a healthcare facility)

Question 21

type of process, repetitive operation:

Answer 21

Processes used to produce one or a few standardized products in high volume (such as a cafeteria or car wash).

Question 22

Differences between Intermittent and Repetitive Operations, Product variety:

Answer 22

Intermittent Operations - great

Repetitive Operations - small

Question 23

Differences between Intermittent and Repetitive Operations, Degree of Standardization

Answer 23

Intermittent ops - low

repetitive ops - high

Question 24

Differences between Intermittent and Repetitive Operations, organization of resources:

Answer 24

Intermittent ops - grouped by function

repetitive ops - Line flow to accommodate processing needs

Question 25

Differences between Intermittent and Repetitive Operations, path of products through facility:

Answer 25

intermittent ops - In a varied pattern, depending on product needs repetitive ops - line flow

Question 26

Differences between Intermittent and Repetitive Operations, factor driving production:

Answer 26

intermittent ops - customer orders | repetitive ops - Forecast of future demands

Question 27

Differences between Intermittent and Repetitive Operations, critical resource:

Answer 27

intermittent ops - Labor-intensive operation (worker skills important) repetitive ops - Capital-intensive operation (equipment automation, technology important)

Question 28

Differences between Intermittent and Repetitive Operations, type of equipment:

Answer 28

intermittent ops - General-purpose | repetitive ops - specialized

Question 29

Differences between Intermittent and Repetitive Operations, degree of automation:

Answer 29

intermittent ops - low | repetitive ops - high

Question 30

Differences between Intermittent and Repetitive Operations, throughput time:

Answer 30

intermittent ops - longer | repetitive ops - shorter

Question 31

Differences between Intermittent and Repetitive Operations, work-in process inventory:

Answer 31

intermittent ops - more | repetitive ops - less

Question 32

Product design considerations must include the ____

Answer 32

process.

Question 33

main differences between intermittent and repetitive ops are ....

Answer 33

1) the amount of product volume produced, and | 2) the degree of product standardization.

Question 34

process types (within intermittent and repetitive ops)

Answer 34

project process batch process line process continuous process

Question 35

intermittent ops, project process:

Answer 35

make a one-at-a-time product exactly to customer specifications.

Question 36

intermittent ops, batch process:

Answer 36

small quantity of product in groups or batches based on customer orders or specifications

Question 37

repetitive ops, line process:

Answer 37

large volume of a standardized product

Question 38

repetitive ops, continuous process:

Answer 38

very high volumes of a fully standardized | product

Question 39

designing processes, process design tools include ______ and ____

Answer 39

Process flow analysis | Process flowchart

Question 40

designing processes, Process flow analysis:

Answer 40

A technique used for evaluating a process in terms of the sequence of steps from inputs to outputs with the goal of improving its design.

Question 41

designing processes, Process flowchart:

Answer 41

A chart showing the sequence of steps in producing the product or service.

Question 42

designing process terminology, Bottleneck:

Answer 42

Longest task in the process.

Question 43

design processes, Design considerations include: _____, _____, and _____

Answer 43

Make-to-stock strategy Assemble-to-order strategy Make-to-order strategy

Question 44

designing processes (strategies), Make-to-stock strategy:

Answer 44

Produces standard products and services for immediate sale or delivery.

Question 45

designing processes (strategies), Assemble-to-order:

Answer 45

strategy Produces standard components that can be combined to customer specifications.

Question 46

designing processes (strategies), Make-to-order strategy:

Answer 46

Produces products to customer specifications after an order has been received.

Question 47

process performance metrics, Throughput time:

Answer 47

Average amount of time product takes to move through the system

Question 48

A measure of wasted time in the system (process performance metrics) (what is the formula to find what?)

Answer 48

Process velocity = throughput time / value-added time

Question 49

A measure of how well a company uses its resources (process performance metrics) (what is the formula to find what?)

Answer 49

Productivity = output/input

Question 50

The proportion of time a resource is actually used (process performance metrics) (what is the formula to find what?)

Answer 50

Utilization = time a resource used/ time a resource available

Question 51

Measures performance relative to a standard (process performance metrics) (what is the formula to find what?)

Answer 51

Efficiency = actual output/ standard input

Question 52

Process performance metrics:

Answer 52

Measurements of different process characteristics that tell how a process is performing.

Question 53

TRUE OR FALSE Linking Product Design, Decisions concerning product design and process selection are not linked and can be made independently of one another.

Answer 53

False, correct answer below: Decisions concerning product design and process selection are directly linked and cannot be made independently of one another.

Question 54

Product Design Decisions: Intermittent Operations

Answer 54

Product design - Early stage of product life cycle Competitive priorities - Delivery, flexibility, and quality Facility layout - Resources grouped by function Product strategy - Make-to-order/assemble-to- order Vertical integration - Low

Question 55

Product Design Decisions: Repetitive Ops

Answer 55

Product design - Later stage of product life cycle Competitive priorities - Cost and quality Facility layout - Resources arranged in a line Product strategy -Make-to-stock Vertical integration -High

Question 56

TRUE OR FALSE | Linking Product Design and Process Selection, Type of operation is directly related to product and service strategy.

Answer 56

TRUE!

Question 57

3 basic strategies (Product and service strategies):

Answer 57

- Make-to-stock: in anticipation of demand - Assemble-to-order: built from standard components on order - Make-to-order: produce to customer specification at time of order

Question 58

Linking Product Design and Process Selection: Degree of Vertical Integration

Answer 58

Vertical integration refers to the degree to which a firm performs processes — from raw material to sales. (Think whether outsourcing is best for the company) In summary, vertical integration is typically a better strategic decision for repetitive operations. For intermittent operations it is generally a poor strategic choice.

Question 59

Technology Decisions, Information technology (IT):

Answer 59

is technology that enables storage, processing, and communication of information within and between firms.

Question 60

Technology Decisions, enterprise resource planning (ERP)

Answer 60

These are large software programs used for planning and coordinating all resources throughout the entire enterprise. They allow data sharing and communication within and outside of the firm, enabling collaborative decision making.

Question 61

Technology Decisions, Global positioning systems (GPS) A type of wireless technology that uses satellite transmission to communicate exact locations. How has it impacted process and product design?

Answer 61

GPS has even found its use in advertising. Geo-advertising uses GPS to target and push advertising to devices in specific geographic areas. For example, in 2018 the jeans company True Religion needed to promote new products at its retail stores. Using geo-advertising the company sent customized e-mails to customers in areas in which the brand had a high concentration of stores and was able to drive up in-store traffic.

Question 62

Technology Decisions, Radio frequency identification (RFID):

Answer 62

A wireless technology that uses memory chips equipped with radio antennas attached to objects used to transmit streams of data.

Question 63

Technology Decisions, Radio frequency identification (RFID), how has RFID impacted in the process and product design?

Answer 63

For example, RFID can be used to identify any product movement, reveal a missing product’s location, or have a shipment of products “announce” its arrival. Empty store shelves can signal that it is time for replenishment using RFID, or low inventories can signal the vendor that it is time to ship more products. RFID can also be used in the service environment, enabling innovative applications in locating and tracking people and assets. (wally world used it to track freshness of their produce out front)

Question 64

Technology Decisions, automation:

Answer 64

Using machinery to perform work without human operators.

Question 65

Technology Decisions, automated material handling: (what types)

Answer 65

automated guided vehicle (AGV), a small battery-driven truck that moves materials from one location to the other. The AGV is not operated by a human and takes its directions from either an onboard or central computer. automated storage and retrieval systems (AS/RSs), which are basically automated warehouses.

Question 66

Technology Decisions, Flexible manufacturing system (FMS):

Answer 66

A type of automated system that combines the flexibility of intermittent operations with the efficiency of repetitive operations.

Question 67

Technology Decisions, robotics, Numerically controlled (NC) machine;

Answer 67

A machine controlled by a computer that can perform a variety of tasks.

Question 68

Technology Decisions, E-manufacturing:

Answer 68

Today’s Web-based environment has created numerous opportunities for business collaboration. This includes collaboration in product and process design, where customers, buyers, and designers can share information and jointly make decisions in real time.

Question 69

Technology Decisions, e-manufacturing, computer system's that aid in e-manufacturing

Answer 69

Computer-aided design (CAD) A system that uses computer graphics to design new products. Computer-integrated manufacturing (CIM) A term used to describe the integration of product design, process planning, and manufacturing using an integrated computer system. The purpose of CIM is to improve how quickly the company can respond to customer needs in terms of product design and availability, as well as quality and productivity, and to improve overall efficiency. 3D Printing 3D Printing is three-dimensional printing technology that deposits materials like plastics and metals in thick layers one atop the other with the process gradually building up one layer at a time until the object is produced.