1st Edition

Effective Transition from Design to Production

By David F. Ciambrone Copyright 2008
    272 Pages 119 B/W Illustrations
    by Auerbach Publications

    Taking a new product from the design stage to large-scale production in a profitable, efficient manner can challenge the processes of even the most advanced companies. Lapses in these processes drive up the cost of new products, and hinder their launch into the marketplace. Effective Transition from Design to Production provides an expeditious roadmap that considers every phase of production. It identifies customer requirements, discusses product concept, and covers master scheduling and risk analysis, as well as design considerations, prototypes, and tooling essentials. Among other things, it also explains how to identify and augment facility requirements, initiate production ramp up, evaluate packaging, and institute defect control.

    Takes an Integrative Approach that Allows Managers to Understand the Big Picture

    As the author introduces and explains each stage, he also offers guidance as to when to involve outside parties including potential providers of raw materials and subcontractors who may take part in the production and assembly process. He presents the seven stages of the production process— system design, detailed design, manufacturing planning, production readiness, low rate initial production, and production—in sequential order, examining how each one leads to the other. This allows readers to not only grasp the basic concepts crucial for success at each stage, but also to visualize the big picture so that they can anticipate problems, eliminate inefficiency, and make informed managerial decisions.

    Introduction
    Proposal/Contract
    General Discussion
    Proposal Support
    Identify Customer Requirements
    Determine Product Concept
    Determine Commonality
    Request for Deviations from Customer Requirements
    Risk Analysis/Risk Mitigation
    Design to Cost
    Master Schedule
    Determine Production Philosophy and Location
    Simulation Analysis for Producibility
    Simulation Analysis for Factory
    Assembly Tooling Forecasts – Assess Assembly Tooling Requirements
    New or Modified Production Equipment
    System/Conceptual Design
    Conduct Prelimary Design to Cost Analysis
    Assembly Process Methodology
    Develop Tooling Concepts
    Develop Manufacturing Plan/Flow
    Identify New Manufacturing Technologies
    Determine Product-Packaging Requirements
    Develop Prototype Assembly Tooling
    Conduct Facilities and Analysis
    Determine Logistical Support Requirements
    Determine Capital Equipment Requirements
    Determine Test Philosophy
    Determine Quality Assurance Requirements
    Identify Human Resource Requirements
    Meetings
    Detailed Design
    New Production Process Development
    Assembly/Process Methodology
    Design to Cost
    Conduct Parts Obsolescence Study
    Design for Production
    Design for Manufacturing and Assembly (DFMA)/Design for the Environment (DFE)
    Conduct Cross-Functional Design Reviews
    Bill of Material – Create Detailed Indentured Bill of Material
    Assembly Simulation
    Select Subcontractors/Vendors/Selection Process
    Determine Exit Criteria for Design Output to Manufacturing
    Create Detailed Manufacturing Plan/Flow
    Lean Factory Design/Balanced Flow
    Develop Configuration Management Plan
    Documentation Media Method
    Conduct Product Design Documentation Release
    Prepare Test Integration Plan
    Create Test Hardware and Software
    Manufacturing Planning & Processes/Prototype Development/Test Development
    Transition New Production Processes
    Determine Facility Requirements
    Finalize Assembly Methodology
    Determine Tool Design and Fabrication Requirements
    Ergonomics
    Transition to a Contract Manufacturing Facility
    Vendor Implementation
    Write Software Programs for Manufacturing Equipment
    Assembly Tooling
    Finalize New Production Processes
    Conduct Line Balancing Analysis
    Metrics
    Determine Inventory System Based on Contractual Type
    Staffing Plan
    Tool Control
    Finalize Manufacturing Plan/Flow
    Conduct Prototype Documentation Planning
    Determine Capital Requirements
    Create Inventory System
    Finalize Production Plan
    Conduct a Preliminary Production Readiness Review
    Test Integration
    Manufacturing Plan Checklists
    Production Readiness
    Production Readiness
    Implement Line Stock
    Configuration Management
    Create Change Control Board
    Tooling Verification
    Support Transition to Production Process
    Create Prototype Routing and Planning
    Develop Change Control Board Protocol
    Conduct Prototype Kitting
    Coordinate Configuration Management with Vendors
    Develop Quality Assurance Requirements/Buy-Off
    Train Production Staff
    Build Prototype
    Low Rate Initial Production (LRIP)
    Introduction to LRIP
    Obtain and Implement Production Tooling
    Update Tooling Documentation
    Calibration and Maintenance
    Update Drawing Documentation
    Update Planning Documentation
    Implement Kitting Plans
    Update Test Fixtures and Software for Production Hardware
    Staffing Plan Finalized
    Build First Article
    Create a Master Schedule
    Documentation Changes
    First Article Buy-Off
    Begin Low Rate Initial Production
    Production Ramp-Up
    Production
    Build Production Units – Ramp Up to Full Production
    Other Areas for Concern
    Data Loss
    Bathtub Issues
    Defect Control
    The Hidden Factory
    The Experience Level of Manufacturing and Producibility Engineering Personnel
    Appendix A Quality Functional Deployment
    Appendix B Six Sigma Tools
    Appendix C Design for Manufacturing
    Appendix D Vendor Assessment Forms
    Appendix E Production Readiness Check Sheets / Evaluation Forms
    Appendix F Design for the Environmental Guide
    References

    Biography

    David F. Ciambrone