1st Edition

Effective Transition from Design to Production




ISBN 9781420046861
Published October 4, 2007 by Auerbach Publications
272 Pages 119 B/W Illustrations

USD $125.00

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Book Description

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

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

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