03 May DESIGN for Manufacturing Engineering HW
dfM REPORT GUIDELINES
The following outline is a suggested format for the final project report for . The Background, Analysis, and Product Definition sections will depend heavily on the unique characteristics of each project. Note that while this is only a suggested format, I will be expecting to be able to find all of the major components listed below in your final report. If some of the tools are not applicable to your project, they do not need to be included in the final report. Feel free to break out of this format, but be sure to include all of the information.
1. Executive Summary (1 page max)
Writing an executive summary is not an easy task. Distilling all the work you have done on the project into a one-page summary will take some effort, but it is an important one. The executive summary will be read before the full report and will be the “first impression” of what has been done on the project. This can set the tone for how the report will be received.
The description of an effective executive summary is given below. It was taken from “Strategies for Technical Communication” by Nancy Roundy (Little, Brown, and Company, 1985). The important thing to remember is that an executive summary is complete enough in detail that the reader has a basic understanding of the results and how the results were obtained.
From “Strategies for Technical Communication” by Nancy Roundy (Little, Brown, and Company, 1985)
2. Table of Contents
3. Background – External / System Drivers – Existing Product/Process – Market/Competition – Requirements or Constraints
4. Problem Statement (1 page) (Context, why this is important/interesting)
5. Analysis and Discussion- dfM Tools and Techniques – Benchmarking
– Use-Case Scenarios – CVCA – Value Graph (How-Why)
– Voice of the Customer – Functional Analysis – QFD (Phase I) (including Customer Requirements and Engineering Metrics) – Cost-Worth Analysis – Fishbone Assembly Sequence – DFA Calculations – Failure/Service Modes and Effects Analysis – QFD (Phase II) – Variety/Complexity, Serviceability, and Recycling issues. – What insights did the tools give you?
6. Product Definition Formulate a comprehensive product definition. Focus on the issues that will make your product competitive: enhanced features, reduced cost, etc. Identify the cost drivers (e.g. assembly, components, service, variety complexity). Include Edith Wilson’s checklist applied to your project.
7. Concept Development
– summarize concept generation and selection including key sketches and figures
– include list of solution elements, morphological analysis and morph keys
8. Design Recommendation
· Product Specification (design layout, part geometry, materials, etc.) or Process Specification
· Implementation Plan (part fabrication, assembly, training, etc.)
· Life-Cycle Plan (testing, service, recycling, etc.)
9. Analysis
· comparison of proposed changes to competitors, future landscape, and initial design or process
· Cost
· Product Features
· Development Time/Risk
[requested for redesign Future project at end of semester] What will the future hold? What are the technological or otherwise developments that need to happen between now and your imagined “future”? What year will your artifact exist in?
10. Discussion
· include comments on methods: applicability/effectiveness
· for amorphous product design, what was more/less useful
11. Conclusions and Recommendations
· what advice would you have for future students for this project?
· how feasible / viable / desirable is your artifact?
12. References
NEXT:
Step 1
redesign project
or applying amorphous product design using design for manufacturing tools
You should have an idea selected for what your artifact is. For today, you will write a couple of use cases, construct a CVCA, and start a list of the features of your solution.
· List the Voice of the Customer
· Draw the CVCA
· Describe the Functional Behavior of the System
· Derive Engineering Metrics
Use sections 3.4, 3.5, and 3.6 from your reading (Beiter/MML Technical Report) to help complete these tasks. Figures 3.3 – 3.7 illustrate the steps and expected deliverables for next Tuesday.
Step 2
· Conduct QFD House 1
· Generate a morphological diagram with solution concepts
· Identify a concept leader using a Pugh selection matrix
· Create a solution element tree and hierarchy-concept view of your system using your selected concepts
Use sections 3.7 and 3.8 from your reading (Beiter/MML Technical Report) to help complete these tasks. Figures 3.8 – 3.12 illustrate the steps and expected deliverables for Thursday.
Step 3
redesign project
or applying amorphous product design using design for manufacturing tools
· Sketch your preferred solution, identifying the parts of your system
· List the parts of your preferred system
· Complete QFD House II
· Chart a Cost-Worth Diagram
Use sections 3.9 from your reading (Beiter/MML Technical Report) to help complete these tasks. Figures 3.12 and 3.13 illustrate some of the steps and expected deliverables for next Tuesday.
To make estimates for costs, use what you can figure out from today. Results from your Cost-Worth Diagram may point to necessary technological or cost advancements and opportunities for redesign.
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