Effective Transition from Design to Production: 1st Edition (Hardback) book cover

Effective Transition from Design to Production

1st Edition

By David F. Ciambrone

Auerbach Publications

272 pages | 119 B/W Illus.

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Hardback: 9781420046861
pub: 2007-10-04
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pub: 2007-10-04
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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.

Table of Contents



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


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


Transition to a Contract Manufacturing Facility

Vendor Implementation

Write Software Programs for Manufacturing Equipment

Assembly Tooling

Finalize New Production Processes

Conduct Line Balancing Analysis


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


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


Subject Categories

BISAC Subject Codes/Headings:
BUSINESS & ECONOMICS / Quality Control
BUSINESS & ECONOMICS / Industries / Manufacturing Industries
TECHNOLOGY & ENGINEERING / Industrial Design / General