C215- Chapter 3

Question 1

What is Product Design?

Answer 1

• Process of deciding all unique characteristics/features of a product

-Defines a product’s characteristics, such as its appearance, materials, dimensions, tolerances, and performance standards.

Example: When Apple releases new iPhone specs.

Question 2

What is Service Designs ?

Answer 2

• Process of establishing all characteristics of the service

Service Design → Focuses on intangible experiences (things you can’t physically touch). The design involves how the service is delivered, customer interactions, speed, atmosphere, and reliability.

Example: Designing how a restaurant serves customers, how a bank handles clients, or how an airline manages boarding.

Question 3

What are the 4 steps in Product Design?

Answer 3

1. Idea Development : product idea developed
2. Product Screening : consider operations, marketing, financial requirements
3. Preliminary Design & Testing : product prototype built, tested and refined
4. Final Design: final product specifications completed

Question 4

2 Process Design Tools

Answer 4

1. Process Flowchart : Used for viewing the sequence of steps involved in producing a product and the flow through the process, helping identify potential problem areas.
2. Process Flow Analysis : technique for evaluating a process in terms of sequence from input to output to improve design

Question 5

What is a Make-to-Stock strategy?

Answer 5

• Making products ahead of time to ensure availability upon demand.
  -Products are made in advance and kept in stock, waiting for customers to buy.

Example: Bottled water in a store.
Example: A standard cheese pizza is prepared in advance as it is the most popular and often ordered.

MTS = ready before order

Question 6

What is a Make-to-Order strategy?

Answer 6

→ Nothing is made until the customer orders, then the product is built from scratch.

Making products as they are ordered based on specific customer requests, allowing for choices in crusts and toppings.

MTO = made completely after orde

Question 7

What is an Assemble-to-Order strategy?

Answer 7

Parts are ready in stock, and the final product is assembled only after the customer orders

Example: A pizza shop keeps dough, sauce, and toppings ready, but only makes the pizza when you order.

ATO = parts ready, final assembly after order

Question 8

Intermittent Operations

Answer 8

• Intermittent: Used to produce a variety of products with different processing requirements in lower volumes.
  Example: An auto body shop or healthcare facility.
• High Variety, Low standardization, grouped by function, customer orders, worker skill important, low degree of automation, longer throughout time, more work-in-progress inventory

Question 9

Intermittent Operation : 2 types of processes

Answer 9

1) Project Process : Used to make one-of-a-kind products exactly to customer specifications, with high customization and low product volume. Used for unique, one-time work. Every project is different, often large and customized.

Example: Construction or custom tailoring, Building a bridge or designing a new hospital.

2) Batch Process : Used to produce small quantities of products in groups based on customer orders or specifications, also known as job shops. Used for making small groups (batches) of similar products at once, then switching to another batch.

Example: bakery making 100 muffins, then later baking 50 loaves of bread.

Question 10

Repetitive Operations

Answer 10

-Repetitive : Used to produce one or a few standardized products in high volume, often involving mass production and automation.

• Mass production, capital intensive, volume produced on forecast of future demand, high standardization, low variety, high equipment skills

Question 11

Repetitive Operations - 2 Types of Processes

Answer 11

1. Line Process : Products are made in a step-by-step sequence on an assembly line. Each unit moves from one station to the next.
   Example: Making cars on an assembly line.
2. Continuous Process : Production never stops and runs 24/7, usually for liquids, gases, or chemicals. It’s not about individual units but a steady flow.

Question 12

What are Process Performance Metrics?

Answer 12

Measurements of different process characteristics that indicate how a process is performing and changing over time.

1.Throughput Time
2. Process Velocity
3. Productivity
4. Utilization
5. Efficiency

Question 13

1. Throughput Time?

Answer 13

Average amount of time a product takes to move through the system.

• lower throughput time allows more products to move through.
• Goal: Reduce throughput time.

Question 14

2. Process Velocity?

Answer 14

A metric that measures how much wasted time exists in a process.

Formula : throughput time/ value-added time -

Question 15

3. Productivity?

Answer 15

How well a company uses its resources
-Formula : output/input

Question 16

4. Utilization

Answer 16

The proportion of time a resource is actually used
- (Time resource is used) / (Time resource is available)

Question 17

5.Efficiency

Answer 17

Measures performance relative to a standard

• (actual output) / (standard output)

Question 18

What are Technology Decisions in Product Design (3)?

Answer 18

Includes
1.information technology
2. automation
3. e-manufacturing.

Question 19

What is a Goods Designs ?

Answer 19

Goods Design → Focuses on tangible products (things you can touch and see). The design involves physical features like shape, size, materials, durability, and packaging.

Example: Designing a phone, shoes, or a car.

Question 20

Product Design Steps - Idea Development 3 Sources

Answer 20

1. Customers
2. Competitors : benchmarking, reverse engineering
3. Suppliers : ESI (early supplier involvement)

Question 21

Product Design Steps - Product Screening Considerations

Answer 21

• Every business needs formal/structured evaluation process
• Consider : facility/labor skills, size of market, contribution margins, break-even analysis, return on sales

Question 22

Product Design Steps - Preliminary Design & Testing

Answer 22

• Technical specifications are developed, prototypes built, testing starts

Question 23

Product Design Steps - Final Design

Answer 23

• Based on test results, facility, equipment, material, labor skills, suppliers

Question 24

4 Factors Impacting Product Design

Answer 24

1. Design for Manufacture (DFM): guidelines to produce a product easily and profitably
   - simplification, standardization, modular designs, avoid tools, simplifying operations
2. Product Life Cycle: series of stages that products pass through characterized by changing product demands over time
   - Introduction, growth, maturity, decline
3. Concurrent Engineering: all teams (designers, engineers, marketers, manufacturers) work together at the same time.
4. Remanufacturing: using components of old products in production of newer ones
   - cost and environmental benefits

Question 25

3 Designing Process Strategies

Answer 25

1. Make-to-stock : produces standard products/services for immediate sale or delivery 2. Assemble-to-order : Produces standard components that can be combined to customer specifications 3. Make-to-order: produces products to customer specifications after order has been received