Step 6.1

Draft preliminary bill of materials.

Primary findings

Models

Design manufacturing integration is positively associated with NPD project efficiency, if product design and manufacturing personnel act in truly cooperative ways, overall project efficiency should increase.
Survey of 137 completed NPD projects. The degree of design and manufacturing integration significantly differed across the project groups in the expected direction.
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Methods

By using templates, the time required for new product development is drastically reduced. At the same time incorporating computer-aided process planning into the system gives the designer a better understanding of the cost implications of the modified design with respect to manufacturing. The major challenge in implementing of such system is that any changes in the manufacturing facility have to be incorporated in the process plans stored. This can be a tedious job but can be overcome by using hybrid process planning approach instead of variant based approach.
Author experience
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Consider durability and product quality of materials from suppliers
Survey.
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Process planning task involves the development of a set of work instructions used for part transformation from its initial to final form. In the proposed system, the process plan module provides detailed information and description of manufacturing processes and machine tools required. The information includes: list of required machines; specific cutting energy for the work material; standard set-up and tear down times; number of tools required; and cost per hour of operation. A search heuristic is developed for the selection of appropriate process plan. If a process plan is not found in the database, a new process plan will be generated based on the defined design features, dimensions and required tolerance for finished product. The information from the developed process plan is used to calculate the manufacturing time and cost.
Author developed template
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Product fabrication is the means by which shape, size, and other intended physical properties are imparted to a device or product. The critical criteria include selecting appropriate materials to enable the device to satisfy its function, and to ensure that manufacturing costs are minimized in terms of equipment, power, labor, overhead and rework costs.
Authors experience in industrial engineering, physical medicine and rehabilitation, and as Editor-in-Chief of the International Journal of Industrial Engineering.
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Measures

Prototype web-based system, called WeBID, permitting manufacturers to assess their NPD requirements and match them against a variety of suppliers. The system has application at each stage where suppliers interface.
Case Study. Design and testing of prototype tool for assessing capabilities of various suppliers to identify best match.
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Tips

All products are formed of some materials or combination of materials. The choice of materials depends on numerous factors such as intended function, workability (ease of manufacturing), and cost.
Authors experience in industrial engineering, physical medicine and rehabilitation, and as Editor-in-Chief of the International Journal of Industrial Engineering.
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Be flexible with product pricing at launch.
Survey.
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Guidelines for materials selection: — It is best to group materials related to principal shape generating processes used in discrete parts manufacture; - For initial material searches look at material categories rather than specific materials which is sufficient for early process/material decision-making. — For each process, it is best to have a super material that offers the best attainable properties of all materials in that category. Material trade-offs within the process can be made at a later date. — As detailed part specifications become available, one can eliminate the excess process and materials options. The final choice is usually one optimal material and the most compatible process. — Minimize material costs by using available mill forms, standard stock shapes gauges, grades and formulations whenever possible. Consider using pre-finished materials and match materials to functions.
Authors experience in industrial engineering, physical medicine and rehabilitation, and as Editor-in-Chief of the International Journal of Industrial Engineering.
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Secondary findings

Methods

Markets, prices and costings are interwoven with the creation of supplier-user networks, in the development of product-service systems.
Source: McAloone & Andreasen, (2006). In: Grunert, K.G. et al (2008)

Suppliers can contribute to the NDP process at multiple points in various ways including: 1) Developing specifications; 2) Identifying interchangeable parts; 3) Planning part standardization and simplification; 4) Suggesting part substitution; 5) Excluding parts with known problems.
Source: In: Humphreys, P., Huang, G., Cadden, T. (2005)

Use of methods such as design for manufacturing (DFM) to encourage the integration of product and process design decisions has been associated with lower product costs and better conformance quality.
Source: Youssef (1994), Swink (2002), Sanchez and Perez, (2003). In: Swink, M., Talluri, S., & Pandejpong, T. (2006)

Develop materials plan.

Primary findings

Models

Design manufacturing integration is positively associated with NPD project efficiency, if product design and manufacturing personnel act in truly cooperative ways, overall project efficiency should increase.
Survey of 137 completed NPD projects. The degree of design and manufacturing integration significantly differed across the project groups in the expected direction.
(View full citation)

Methods

By using templates, the time required for new product development is drastically reduced. At the same time incorporating computer-aided process planning into the system gives the designer a better understanding of the cost implications of the modified design with respect to manufacturing. The major challenge in implementing of such system is that any changes in the manufacturing facility have to be incorporated in the process plans stored. This can be a tedious job but can be overcome by using hybrid process planning approach instead of variant based approach.
Author experience
(View full citation)

Process planning task involves the development of a set of work instructions used for part transformation from its initial to final form. In the proposed system, the process plan module provides detailed information and description of manufacturing processes and machine tools required. The information includes: list of required machines; specific cutting energy for the work material; standard set-up and tear down times; number of tools required; and cost per hour of operation. A search heuristic is developed for the selection of appropriate process plan. If a process plan is not found in the database, a new process plan will be generated based on the defined design features, dimensions and required tolerance for finished product. The information from the developed process plan is used to calculate the manufacturing time and cost.
Author developed template
(View full citation)

Tips

Be flexible with managing resources to have higher levels of success with product development execution.
Survey of 120 development projects from 57 firms. Hierarchical regression was significant, beta = .179 at p<=.1
(View full citation)

Secondary findings

Methods

Use of methods such as design for manufacturing (DFM) to encourage the integration of product and process design decisions has been associated with lower product costs and better conformance quality.
Source: Youssef (1994), Swink (2002), Sanchez and Perez, (2003). In: Swink, M., Talluri, S., & Pandejpong, T. (2006)