Cover
Product Design and Development
Dedication
About the Authors
Preface
Acknowledgments
Brief Contents
Contents
Chapter 1: Introduction
Characteristics of Successful Product Development
Who Designs and Develops Products?
Duration and Cost of Product Development
The Challenges of Product Development
Approach of This Book
Structured Methods
Industrial Examples
Organizational Realities
Roadmap of the Book
References and Bibliography
Exercises
Thought Question
Chapter 2: Product Development Process and Organization
The Product Development Process
Concept Development: The Front-End Process
Adapting the Generic Product Development Process
Technology-Push Products
Platform Products
Process-Intensive Products
Customized Products
High-Risk Products
Quick-Build Products
Digital Products
Product-Service Systems
Complex Systems
Product Development Process Flows
The Tyco Product Development Process
Product Development Organizations
Organizations Are Formed by Establishing Links among Individuals
Organizational Links May Be Aligned with Functions, Projects, or Both
Choosing an Organizational Structure
Distributed Product Development Teams
The Tyco Product Development Organization
Summary
References and Bibliography
Exercises
Thought Questions
Chapter 3: Opportunity Identification
What Is an Opportunity?
Types of Opportunities
Tournament Structure of Opportunity Identification
Effective Opportunity Tournaments
Opportunity Identification Process
Step 1: Establish a Charter
Step 2: Generate and Sense Many Opportunities
Techniques for Generating Opportunities
Step 3: Screen Opportunities
Step 4: Develop Promising Opportunities
Step 5: Select Exceptional Opportunities
Step 6: Reflect on the Results and the Process
Summary
References and Bibliography
Exercises
Thought Questions
Chapter 4: Product Planning
The Product Planning Process
Four Types of Product Development Projects
The Process
Step 1: Identify Opportunities
Step 2: Evaluate and Prioritize Projects
Competitive Strategy
Market Segmentation
Technological Trajectories
Product Platform Planning
Technology Roadmapping
Evaluating Fundamentally New Product Opportunities
Balancing the Portfolio
Step 3: Allocate Resources and Plan Timing
Resource Allocation
Project Timing
The Product Plan
Step 4: Complete Pre-Project Planning
Mission Statements
Assumptions and Constraints
Staffing and Other Pre-Project Planning Activities
Step 5: Reflect on the Results and the Process
Summary
References and Bibliography
Exercises
Thought Questions
Chapter 5: Identifying Customer Needs
The Importance of Latent Needs
The Process of Identifying Customer Needs
Step 1: Gather Raw Data from Customers
Choosing Customers
The Art of Eliciting Customer Needs Data
Documenting Interactions with Customers
Step 2: Interpret Raw Data in Terms of Customer Needs
Step 3: Organize the Needs into a Hierarchy
Step 4: Establish the Relative Importance of the Needs
Step 5: Reflect on the Results and the Process
Summary
References and Bibliography
Exercises
Thought Questions
Chapter 6: Product Specifications
What Are Specifications?
When Are Specifications Established?
Establishing Target Specifications
Step 1: Prepare the List of Metrics
Step 2: Collect Competitive Benchmarking Information
Step 3: Set Ideal and Marginally Acceptable Target Values
Step 4: Reflect on the Results and the Process
Setting the Final Specifications
Step 1: Develop Technical Models of the Product
Step 2: Develop a Cost Model of the Product
Step 3: Refine the Specifications, Making Trade-Offs Where Necessary
Step 4: Flow Down the Specifications as Appropriate
Step 5: Reflect on the Results and the Process
Summary
References and Bibliography
Exercises
Thought Questions
Appendix: Target Costing
Chapter 7: Concept Generation
The Activity of Concept Generation
Structured Approaches Reduce the Likelihood of Costly Problems
A Five-Step Method
Step 1: Clarify the Problem
Decompose a Complex Problem into Simpler Subproblems
Focus Initial Efforts on the Critical Subproblems
Step 2: Search Externally
Interview Lead Users
Consult Experts
Search Patents
Search Published Literature
Benchmark-Related Products
Step 3: Search Internally
Both Individual and Group Sessions Can Be Useful
Hints for Generating Solution Concepts
Step 4: Explore Systematically
Concept Classification Tree
Concept Combination Table
Managing the Exploration Process
Step 5: Reflect on the Solutions and the Process
Summary
References and Bibliography
Exercises
Thought Questions
Chapter 8: Concept Selection
Concept Selection Is an Integral Part of the Product Development Process
All Teams Use Some Method for Choosing a Concept
A Structured Method Offers Several Benefits
Overview of Methodology
Concept Screening
Step 1: Prepare the Selection Matrix
Step 2: Rate the Concepts
Step 3: Rank the Concepts
Step 4: Combine and Improve the Concepts
Step 5: Select One or More Concepts
Step 6: Reflect on the Results and the Process
Concept Scoring
Step 1: Prepare the Selection Matrix
Step 2: Rate the Concepts
Step 3: Rank the Concepts
Step 4: Combine and Improve the Concepts
Step 5: Select One or More Concepts
Step 6: Reflect on the Results and the Process
Caveats
Summary
References and Bibliography
Exercises
Thought Questions
Appendix A: Concept-Screening Matrix Example
Appendix B: Concept-Scoring Matrix Example
Chapter 9: Concept Testing
Step 1: Define the Purpose of the Concept Test
Step 2: Choose a Survey Population
Step 3: Choose a Survey Format
Step 4: Communicate the Concept
Matching the Survey Format with the Means of Communicating the Concept
Issues in Communicating the Concept
Step 5: Measure Customer Response
Step 6: Interpret the Results
Step 7: Reflect on the Results and the Process
Summary
References and Bibliography
Exercises
Thought Questions
Appendix: Estimating Market Sizes
Chapter 10: Product Architecture
What Is Product Architecture?
Types of Modularity
When Is the Product Architecture Defined?
Implications of the Architecture
Product Change
Product Variety
Component Standardization
Product Performance
Manufacturability
Product Development Management
Establishing the Architecture
Step 1: Create a Schematic of the Product
Step 2: Cluster the Elements of the Schematic
Step 3: Create a Rough Geometric Layout
Step 4: Identify the Fundamental and Incidental Interactions
Delayed Differentiation
Platform Planning
Differentiation Plan
Commonality Plan
Managing the Trade-Off between Differentiation and Commonality
Related System-Level Design Issues
Defining Secondary Systems
Establishing the Architecture of the Chunks
Creating Detailed Interface Specifications
Summary
References and Bibliography
Exercises
Thought Questions
Chapter 11: Industrial Design
What Is Industrial Design?
Assessing the Need for Industrial Design
Expenditures for Industrial Design
How Important Is Industrial Design to a Product?
User Experience Needs
Aesthetic Needs
The Impact of Industrial Design
Is Industrial Design Worth the Investment?
How Does Industrial Design Establish a Corporate Identity?
The Industrial Design Process
1. Investigation of Customer Needs
2. Conceptualization
3. Preliminary Refinement
4. Further Refinement and Final Concept Selection
5. Control Drawings or Models
6. Coordination with Engineering, Manufacturing, and External Vendors
Management of the Industrial Design Process
Timing of Industrial Design Involvement
Assessing the Quality of Industrial Design
1. Usability
2. Emotional Appeal
3. Ability to Maintain and Repair the Product
4. Appropriate Use of Resources
5. Product Differentiation
Summary
References and Bibliography
Exercises
Thought Questions
Chapter 12: Design for Environment
What Is Design for Environment?
Two Life Cycles
Environmental Impacts
History of Design for Environment
Herman Millerβs Journey toward Design for Environment
The Design for Environment Process?
Step 1: Set the DFE Agenda: Drivers, Goals, and Team
Identify the Internal and External Drivers of DFE
Set the DFE Goals
Set Up the DFE Team
Step 2: Identify Potential Environmental Impacts
Step 3: Select DFE Guidelines
Step 4: Apply the DFE Guidelines to the Initial Product Design
Step 5: Assess the Environmental Impacts
Compare the Environmental Impacts to DFE Goals
Step 6: Refine the Product Design to Reduce or Eliminate the Environmental Impacts
Step 7: Reflect on the DFE Process and Results
Summary
References and Bibliography
Exercises
Thought Questions
Chapter 13: Design for Manufacturing and Supply Chain
Design for Manufacturing and Supply Chain Defined
DFM Requires a Cross-Functional Team
DFM Is Performed throughout the Development Process
Overview of the DFM Method
Step 1: Consider the Strategic Sourcing Decisions
Step 2: Estimate the Manufacturing Costs
Cost of Goods
Fixed Costs versus Variable Costs
The Bill of Materials
Estimating the Costs of Standard Components
Estimating the Costs of Custom Components
Estimating the Costs of Assembly
Estimating the Overhead Costs
Step 3: Reduce the Costs of Components
Understand the Process Constraints and Cost Drivers
Redesign Components to Eliminate Processing Steps
Choose the Appropriate Economic Scale for the Part Process
Standardize Components
Adhere to βBlack Boxβ Component Procurement
Step 4: Reduce the Costs of Assembly
Integrate Parts
Maximize Ease of Assembly
Consider Customer Assembly
Step 5: Reduce the Costs of Supporting Production
Minimize Systemic Complexity
Error Proofing
Step 6: Reduce the Costs of Logistics
Here are some guidelines for minimizing volume
Step 7: Consider the Impact of DFM Decisions on Other Factors
The Impact of DFM on Development Time
The Impact of DFM on Development Cost
The Impact of DFM on Product Quality
The Impact of DFM on the Larger Enterprise
Results
Summary
References and Bibliography
Exercises
Thought Questions
Appendix A: Materials Costs
Appendix B: Component Manufacturing Costs
Appendix C: Assembly Costs
Appendix D: Cost Structures
Chapter 14: Prototyping
Understanding Prototypes
Types of Prototypes
What Are Prototypes Used For?
Principles of Prototyping
Analytical Prototypes Are Generally More Flexible Than Physical Prototypes
Physical Prototypes Are Required to Detect Unanticipated Phenomena
A Prototype May Reduce the Risk of Costly Iterations
A Prototype May Expedite Other Development Steps
A Prototype May Restructure Task Dependencies
Prototyping Technologies
CAD Modeling and Analysis
3D Printing
Planning for Prototypes
Step 1: Define the Purpose of the Prototype
Step 2: Establish the Level of Approximation of the Prototype
Step 3: Outline an Experimental Plan
Step 4: Create a Schedule for Procurement, Construction, and Testing
Planning Milestone Prototypes
Summary
References and Bibliography
Exercises
Thought Questions
Chapter 15: Robust Design
What Is Robust Design?
Design of Experiments
The Robust Design Process
Step 1: Identify Control Factors, Noise Factors, and Performance Metrics
Step 2: Formulate an Objective Function
Step 3: Develop the Experimental Plan
Experimental Designs
Testing Noise Factors
Step 4: Run the Experiment
Step 5: Conduct the Analysis
Computing the Objective Function
Computing Factor Effects by Analysis of Means
Step 6: Select and Confirm Factor Setpoints
Step 7: Reflect and Repeat
Caveats
Summary
References and Bibliography
Exercises
Thought Questions
Appendix : Orthogonal Arrays
Chapter 16: Patents and Intellectual Property
What Is Intellectual Property?
Overview of Patents
Utility Patents
Preparing a Disclosure
Step 1: Formulate a Strategy and Plan
Timing of Patent Applications
Type of Application
Scope of Application
Step 2: Study Prior Inventions
Step 3: Outline Claims
Step 4: Write the Description of the Invention
Figures
Writing the Detailed Description
Defensive Disclosure
Step 5: Refine Claims
Writing the Claims
Guidelines for Crafting Claims
Step 6: Pursue Application
Step 7: Reflect on the Results and the Process
Summary
References and Bibliography
Exercises
Thought Questions
Appendix A: Trademarks
Appendix B: Advice to Individual Inventors
Chapter 17: Service Design
Product-Service Systems
In What Ways Are Services and Products Different?
The Service Design Process
The Service Concept
Concept Development at Zipcar
The Service Process Flow Diagram
Subsequent Refinement
Downstream Development Activities in Services
Prototyping a Service
Growing Services
Continuous Improvement
Summary
References and Bibliography
Exercises
Thought Questions
Chapter 18: Product Development Economics
Elements of Economic Analysis
Quantitative Analysis
Qualitative Analysis
When Should Economic Analysis Be Performed?
Economic Analysis Process
Step 1: Build a Base-Case Financial Model
Estimate the Timing and Magnitude of Future Cash Inflows and Outflows
Compute the Net Present Value of the Cash Flows
Other Cash Flows
Supporting Go/No-Go and Major Investment Decisions
Step 2: Perform Sensitivity Analysis
Development Cost Example
Development Time Example
Understanding Uncertainties
Step 3: Use Sensitivity Analysis to Understand Trade-Offs
Potential Interactions
Trade-Off Rules
Limitations of Quantitative Analysis
Step 4: Consider the Influence of Qualitative Factors
Projects Interact with the Firm, the Market, and the Macro Environment
Carrying Out Qualitative Analysis
Summary
References and Bibliography
Exercises
Thought Questions
Appendix A: Time Value of Money and the Net Present Value Technique
Appendix B: Modeling Uncertain Cash Flows Using Net Present Value Analysis
Chapter 19: Project Management
Understanding and Representing Tasks
Sequential, Parallel, and Coupled Tasks
The Design Structure Matrix
Gantt Charts
PERT Charts
The Critical Path
Baseline Project Planning
The Contract Book
Project Task List
Team Staffing and Organization
Project Schedule
Project Budget
Project Risk Plan
Modifying the Baseline Plan
Accelerating Projects
Project Execution
Coordination Mechanisms
Assessing Project Status
Corrective Actions
Postmortem Project Evaluation
Summary
References and Bibliography
Exercises
Thought Questions
Index