Integrated Product and Process Design and Development,9780849384837

Integrated Product and Process Design and Development

by
ISBN13: 9780849384837
ISBN10: 0849384834
Format: Hardcover
Pub. Date: 1997-07-01
Publisher(s): CRC Pr I Llc
List Price: $124.95

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Summary

This book presents both a complete development of the integrated product and process design and development (IP2D2) method and a large number of successful techniques and checklists that can be used to conceptualize, design, and rapidly produce competitively priced products. The book has been extensively class tested and used as a text in senior/graduate-level Mechanical Engineering Design courses. It creates an attitude toward design that encourages creativity and innovation while considering customer requirements and satisfaction, quality, reliability, manufacturing methods, material selection, assembly, economics, the environment, and scheduling.

Table of Contents

1. PRODUCT DEVELOPMENT INTO THE 21(st) CENTURY
1(28)
1.1 Some Definitions
1(3)
1.2 Manufacturing in the 21(st) Century
4(3)
1.3 Time as a Competitive Advantage
7(1)
1.4 Benchmarking
8(4)
1.5 Partnering with Suppliers
12(3)
1.6 Mass Customization - The Next Paradigm?
15(1)
1.7 Quality
16(9)
1.7.1 What is Quality?
16(4)
1.7.2 Malcolm Baldrige National Quality Award
20(3)
1.7.3 Continuous Improvement
23(1)
1.7.4 ISO 9000
24(1)
1.8 Foundations of Manufacturing
25(4)
2. THE INTEGRATED PRODUCT AND PROCESS DESIGN AND DEVELOPMENT TEAM METHOD
29(18)
2.1 Introduction
29(2)
2.2 The IP(2)D(2) Team and Its Agenda
31(6)
2.3 Dynamic and Static Product Status
37(1)
2.4 Company Strategy and IP(2)D(2)
37(2)
2.5 Technology's Role in IP(2)D(2)
39(1)
2.6 IP(2)D(2) Team Interactions
40(7)
2.6.1 Creative Methods
40(4)
2.6.2 Team Interactions
44(3)
3. PRODUCT COST ANALYSIS
47(18)
3.1 Introduction
47(1)
3.2 Factors that Determine a Product's Cost
48(6)
3.3 Cost Models
54(11)
3.3.1 Introduction
54(1)
3.3.2 Hewlett-Packard's Return Map
54(1)
3.3.3 Product Profit Model (Design-to-Cost)
55(10)
4. PRODUCT FUNCTIONAL REQUIREMENTS AND DECOMPOSITION
65(24)
4.1 Principles of Design
65(7)
4.1.1 Introduction
65(3)
4.1.2 Axiomatic Approach and Functional Decomposition
68(2)
4.1.3 Mathematical Representation of Axiom 1
70(1)
4.1.4 Function Analysis
71(1)
4.2 Examples of the Use of the Axiomatic Method
72(17)
4.2.1 Introduction
72(3)
4.2.2 Example 1 - Carton Taping System
75(2)
4.2.3 Example 2 - Intelligent V-Bending Machine
77(3)
4.2.4 Example 3 - High-Speed In-Press Transfer Mechanism
80(1)
4.2.5 Example 4 - Drywall Taping System
81(2)
4.2.6 Example 5 - Steel Frame Joining Tool
83(6)
5. TRANSLATING CUSTOMER REQUIREMENTS INTO PRODUCTS
89(20)
5.1 Voice of the Customer
89(5)
5.2 Quality Function Deployment (QFD)
94(8)
5.2.1 Introduction
94(1)
5.2.2 QFD and the House of Quality
95(7)
5.3 Product Design Specification
102(7)
6. PRODUCT CONCEPTS AND EMBODIMENTS
109(32)
6.1 Introduction
109(5)
6.2 Concept Generation
114(13)
6.2.1 Introduction
114(5)
6.2.2 The Search for Solutions
119(8)
6.3 Product Configuration (Architecture)
127(2)
6.4 Concept Evaluation and Selection
129(7)
6.5 Product Embodiments
136(5)
7. DESIGN FOR ASSEMBLY AND DISASSEMBLY
141(11)
7.1 Introduction
141(2)
7.2 Design for Assembly
143(8)
7.2.1 Why Assemble?
143(1)
7.2.2 Assembly Principles and Guidelines
143(8)
7.3 Design for Disassembly (Dismantling) - DFD
151(4)
7.3.1 Introduction
151(1)
7.3.2 DFD Guidelines and the Effects on the Design for Assembly
152(3)
8. MATERIAL SELECTION
155(39)
8.1 Introduction
155(6)
8.2 Ferrous Alloys
161(5)
8.2.1 Plain Carbon Steels
161(1)
8.2.2 Alloy Steels
162(2)
8.2.3 Cast Irons
164(2)
8.3 Nonferrous Alloys
166(9)
8.3.1 Light Alloys
166(4)
8.3.2 Heavy Alloys
170(4)
8.3.3 Refractory Metals
174(1)
8.4 Special Purpose Alloys
175(3)
8.5 Plastics
178(10)
8.5.1 Introduction
178(2)
8.5.2 Thermoplastics - Partially Crystalline
180(2)
8.5.3 Thermoplastics - Amorphous
182(2)
8.5.4 Thermosets - Hoghly Crosslinked
184(2)
8.5.5 Thermosets - Lightly Crosslinked
186(2)
8.6 Ceramics
188(1)
8.7 Composites
189(2)
9. MANUFACTURING PROCESSES AND DESIGN
191(48)
9.1 Introduction
191(7)
9.2 Casting - Permanent Mold
198(7)
9.2.1 Pressure Die Casting
198(2)
9.2.2 Centrifugal Casting
200(1)
9.2.3 Compression Molding
201(2)
9.2.4 Injection Molding
203(2)
9.3 Casting - Permanent Pattern
205(5)
9.3.1 Sand Casting
205(2)
9.3.2 Shell Mold Casting
207(3)
9.4 Casting - Expendable Pattern
210(1)
9.4.1 Investment Casting
210(1)
9.5 Cutting - Mechanical Machining
211(7)
9.5.1 Single Point Cutting
211(2)
9.5.2 Milling (Multiple Point Cutting)
213(2)
9.5.3 Grinding
215(3)
9.6 Cutting - Electromachining
218(2)
9.6.1 Electric Discharge Machining (EDM)
218(2)
9.7 Forming - Sheet
220(3)
9.7.1 Blow Molding
220(1)
9.7.2 Sheet Metal Working
221(2)
9.8 Forming - Bulk
223(9)
9.8.1 Forging
223(3)
9.8.2 Rolling
226(2)
9.8.3 Extrusion
228(4)
9.9 Powder Processing
232(4)
9.9.1 Powder Metallurgy
232(4)
9.10 Rapid Prototyping (Stereolithography)
236(3)
10. DESIGN FOR `X'
239(28)
10.1 Reliability
239(6)
10.1.1 Introduction
239(2)
10.1.2 Failure Identification Techniques
241(4)
10.2 Poka-Yoke
245(4)
10.3 Design for Maintainability (Serviceability)
249(1)
10.4 Design for the Environment
250(4)
10.5 Product Safety, Liability and Design
254(4)
10.6 Ergonomics (Usability)
258(1)
10.7 Design for Aesthetics
259(1)
10.8 Design for Packaging
260(1)
10.9 Material Handling
260(2)
10.10 Design for Production (Time-to-Market)
262(5)
11. PRODUCT AND PROCESS IMPROVEMENT
267
11.1 Introduction
267(1)
11.2 What Is Experimental Design?
268(4)
11.3 Guidelines for Designing Experiments
272(2)
11.4 Factorial Analysis
274(14)
11.4.1 Analysis of Variance (ANOVA)
274(1)
11.4.2 Single Factor Experiment
275(2)
11.4.3 Factorial Experiments
277(2)
11.4.4 Factorial Experiments with One Replicate
279(1)
11.4.5 2(k) Factorial Analysis
280(3)
11.4.6 2(k) Factorial Analysis with One Replicate
283(4)
11.4.7 2(k) Fractional Factorial Analysis
287(1)
11.5 Example of the Use of the Analysis of Variance
288(11)
11.5.1 Example 1 - Manufacture of Stiff Composite Beams
288(2)
11.5.2 Example 2 - Optimum Performance of an Air-Driven Vacuum Cleaner
290(4)
11.5.3 Example 3 - Operating Conditions for a Solder Deposition Machine
294(3)
11.5.4 Example 4 - Optimization of a Spray Drying Process
297(2)
11.6 The Taguchi Method
299

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