Five Steps for promoting Easy to Manufacture- Product

Following are five steps :-

1.Collection & utilization of feedback information regarding present products before the start of the design.- like MP sheet.

2.Measuring needs for “ Easy of manufacturing “ by analyzing the process for present products.

3.Measuring needs for “ Easy of manufacturing” by analyzing process of new products in the stage of planning & design of products.

4.By identifying failures possibilities based on design reviews of new products.

5.By identifying failures possibilities based on trail manufacturing & test of new products.

Development Management - Product

Initial Phase Product Management :

•Between increasing Market Competition with respect to changing Customer needs,

Product Quality, Prices and Time of Delivery is most important to Efficiently Plan, Develop ,

Design & Test manufacture products that satisfy Customer needs.

• Design of Easy-to-Manufacture Products at the stage of Product Development and Design:

The Products whose production means can be easily procured, low production cost, can be produced with simple work & equipment & under safe conditions.

The Following are requirements for Easy of Manufacture-

•Easy of setting.
•Easy of clamping.
•Easy of positioning on jigs, fixtures & equipments.
•Low potential of occurrence of burrs, cutting chips.
•No rework.
•Easy of assembly.
•Easy of automation.
•Easy of measurement.

LCC - Life Cycle Costing

What is LCC :

LCC means Life Cycle Costing.
It means the the total cost required at the developed stage & is expected to arive at the design stage.
The total service life cost required from Market Research, Planning, Design, Deveopment, Trail manufacturing, Mass Production, Operation, Maintenance of any Equipment.
The LCC should be as per User/ Customer economic.
If the LCC will more, then it will be costy for the user economic. So, the LCC should be designed as per User Economic.
So, LCC is the main parameter for the Design & Development Pillar.
To Reduce this LCC, DM pillar team has to take following steps -
1) During Design & Development of New product & Equipment, DM pillar has to take help of past data in from of MP sheet.
2) During Design & Development of New product & Equipment, DM pillar has to take maximum design reviews with Customer.
3) He has to verify the Design, Drawing, Prototype samples with Customer .

Maintenance Prevention - MP

-Design activities carried out during Planning and Construction of new equipment, that carryout for –
- High degree of Reliability
- Maintainability
- Economy
- Operability
- Safety
- Flexibility
- Considering maintenance information and new technologies.

-Because of that – Reduce Maintenance expenses.
- Deterioration Losses


-MP involves at the designing stage of new equipment so that new equipment will be
-Safe
-Easy to use
-Free from failures
-Easy to maintain.
-Free from defects.
MP refers to the activities to study shortcomings of present equipment, to feedback study results to the design staff, and to enhance the Reliability of Equipment.


-Importance of MP Design :
In many cases, in new installed equipment
Either, -Smooth progress of Design
-Manufacturing
-Installment
But fail to function in stages of Operation & Initial Phase Production Control.
Accordingly, Ordinary operation can not be easily started, and only becomes workable after various efforts & revisions by operation and maintenance engineers.

Aim, Objective & Background of Development Management Pillar

-Development Management is also know as Initial Phase Control.
-Initial Phase control of Equipment as well as Equipment.
-Whatever the Kaizens done in Equipment & Product, that Information is to be goes to DM Pillar in the form of MP Sheet.
-MP Sheet contains design related changes which DM Pillar have to make changes in new machine purchase & new product development.

Aim :
Ensure basic product functions as well as achieve" easy quality
assurance” “easy manufacturing" easy automation”in the
production stage.

Prevent initial-phase equipment troubles from occurring as well as in promoting the optimal design that can balance initial cost and running cost from the equipment planning/concept stage to the mass production start-up.

Background :
- High product development lead time.
- High rejection in Development & manufacturing stage.
- Serious startup delay.
- Less delivery adherence.

Objective :
- Develop product/equipments first time right with reduced lead time.
- Reduce the product development period and realize vertical start-up
(One-shot start-up for quality production)