【北邮国院大二下】产品开发与营销知识点整理 Topic9

北邮国院大二电商在读，随课程进行整理知识点。仅整理PPT中相对重要的知识点，个人认为相对不重要的细小的知识点不列在其中。如有错误请指出。转载请注明出处

Topic 9 – Design for Manufacturing

Design for Manufacturing (DFM)

面向制造的设计

DFM is a design strategy that requires

        the expertise of multiple team members

the use of basic design rules, guidelines, and cost models

DFM是一种设计策略，需要多个团队成员的专业知识，并使用基本的设计规则、指导方针和成本模型

DFM often results in        DFM经常导致

        significant cost reduction        显著的降低成本

        improvement in product quality        产品质量提升

        the development of cross-functional expertise within the organisation

        组织内部跨职能专业知识的发展

Focus on manufacturability

Focussing on how a product can be manufactured helps the design team to find solutions to these design issues:

关注产品如何制造可以帮助设计团队找到这些设计问题的解决方案:

        Detailed design decisions can have substantial impact on product quality and cost

        详细的设计决策会对产品质量和成本产生重大影响

        Development teams face multiple, and often conflicting, goals

        开发团队面临多个，并且经常是相互冲突的目标

It is important to have metrics with which to compare alternative designs

重要的是要有比较替代设计的指标

Dramatic improvements often require substantial creative efforts early in the process

显著的改进通常需要在过程的早期进行大量的创造性工作

A well-defined method helps the decision-making process

一个定义良好的方法有助于决策过程

Manufacturing cost

Manufacturing cost has a major effect on the economic success of a product

制造成本对产品的经济成功有重大影响

An organisation wants to ensure it obtains the highest profit margin possible and therefore tries to identify the lowest manufacturing cost

一个组织想要确保获得尽可能高的利润率，因此试图确定最低的制造成本

Economically successful design is about ensuring high product quality while minimising manufacturing cost

经济上成功的设计是确保高质量的产品，同时最小化制造成本

Design for manufacturing (DFM) is one way of achieving this goal

DFM是实现这一目标的一种方法

Effective DFM practice leads to low manufacturing costs without sacrificing product quality

有效的DFM实践可以在不牺牲产品质量的前提下降低制造成本

DFM is only effective if the cross-functional team is effective

只有在跨职能团队有效的情况下，DFM才是有效的

Design for Manufacturing (DFM) and the phases

DFM begins during Phase 1 - Concept Development - when the products’ functions and specifications are being determined

DFM开始于第一阶段——概念开发-当产品的功能和规格被确定的时候

When choosing a product concept, cost is almost always one of the criteria on which the decision is made

当选择一个产品概念时，成本几乎总是做出决定的标准之一

During Phase 2 – System-level design - the team makes decisions about how to break up the product into individual components

在第二阶段(系统级设计)中，团队决定如何将产品分解为独立的组件

These decisions are largely based on the expected cost and manufacturing complexity implications

这些决策很大程度上是基于预期成本和制造复杂性的影响

Accurate cost estimates become available during Phase 3 – Detail Design

在第三阶段-详细设计阶段，可以获得准确的成本估算

At this point, many more decisions are driven by consideration of how the product will be manufactured

在这一点上，更多的决策是由如何生产产品的考虑所驱动的

Design for Manufacturing (DFM) - the 5-step process

Step 1 - Estimate the manufacturing costs        估算制造成本

Step 2 - Reduce the costs of components        降低零部件成本

Step 3 - Reduce the costs of assembly        降低装配成本

Step 4 - Reduce the costs of supporting production        降低配套生产成本

Step 5 - Consider the impact of DFM decisions on other factors        

                考虑DFM决策对其他因素的影响

图示：

Step 1 - Estimate the manufacturing costs

The manufacturing cost is the sum of all of the expenditures for the inputs of the system plus the expenditures for disposal of the wastes produced by the system

制造成本是系统投入的所有支出加上系统产生的废物的处理支出的总和

Understanding manufacturing costs-Component，Assembly，Overhead

Component costs        组件成本

Component costs, include        组件成本,包括

        standard parts from suppliers        供应商提供的标准件

                e.g. motors, switches, electronic chips etc.        例如电机、开关、电子芯片等。

        custom components from suppliers        来自供应商的定制组件

                made according to the manufacturer’s design from raw materials, such as sheet steel

                由原材料根据制造商的设计进行制造，如钢板

Assembly costs        装配成本

(labour, equipment & tooling)        (劳工、设备及工装)

Goods are generally assembled from parts        货物一般是由零件组装而成的

This process of assembly incurs labour and equipment/tooling costs

这个组装过程会产生人工和设备/模具成本

Overhead costs        管理成本（也可以翻译成间接成本，这里没有查询到具体翻译区别可以看看这个来理解overhead cost&indirect cost的区别_百度知道 (baidu.com)）

Overhead is the category used to cover all of the other costs        

管理成本是用来覆盖所有其他成本的类别

There are two types of overhead cost        管理成本有两种

        1. Support costs        支持成本

        2. Indirect allocations        间接成本

1. Support costs

These are the costs associated with materials handling, quality assurance, purchasing, shipping, receiving, etc

这些是与材料处理、质量保证、采购、运输、接收等相关的成本

These are the support systems associated with manufacture of the product

这些是与产品制造相关的支持系统

        These costs greatly depend on the product design

        这些成本很大程度上取决于产品设计

2. Indirect allocations

The costs of manufacturing that cannot be directly linked to a particular product but which must be paid for to be in business

不能直接与某一特定产品挂钩但必须为其支付的生产成本

        e.g. the salary of a security guard or the cost of building maintenance

        例如，保安人员的工资或建筑维修费用

Indirect costs are not specifically linked to the design of the product

间接成本与产品的设计没有明确的联系

they are therefore are not relevant to DFM (although they do contribute to the cost of the product)

因此它们与DFM无关(尽管它们确实对产品成本有贡献)

Estimating the costs of standard components

估计标准部件的成本

This can be done in one of two ways:        有两种方法可以做到:

        Comparing each part to a substantially similar part the firm is already producing or purchasing in comparable volume

        将每个零件与公司已经生产或购买的数量相当的相似零件进行比较

        Asking for price quotes from vendors or suppliers

        向供应商询价

The cost per unit will generally reduce if a greater number of units is purchased from a supplier

如果从供应商处购买更多的产品，单位成本通常会降低

        This should be considered when designing the product

        在设计产品时应该考虑到这一点

Standardised components can lead to the requirement for a larger number of units from the supplier and therefore a reduction in overall cost

标准化的部件可以导致供应商要求更多的部件，从而降低总体成本

Estimating the costs of custom parts

估算定制零件的成本

When the custom component is a single part, we estimate its cost by adding up the costs of

当定制组件是单个部件时，我们通过将以下的成本相加来估计其成本

        1. raw materials         原材料

        2. processing        加工

        3. tooling        工具

Where the custom component is actually an assembly of several parts, then we consider it a “product”

当定制组件实际上是几个部件的组装时，我们将其视为“产品”。

To arrive at the cost of this “product” we estimate the cost of each subcomponent, and then add assembly and overhead costs

为了得出这个“产品”的成本，我们估计了每个子组件的成本，然后加上组装和间接成本

Fixed Costs vs. Variable Costs

Fixed Costs – incurred in a predetermined amount, regardless of number of units produced (i.e. setting up the factory work area or cost of an injection mold)

固定成本-在预定数量内发生的成本，不论生产的数量(例如，设立工厂工作区或注塑模具的成本)

Variable Costs – incurred in direct proportion to the number of units produced (i.e. cost of raw materials)

可变成本-与生产的单位数成正比(即原材料成本)

Estimating the cost of assembly

估算装配成本

Manual assembly costs can be estimated by summing the estimated time of each assembly operation and multiplying by a labour rate

人工装配成本可以通过将每次装配作业的估计时间相加并乘以人工率来估算

Estimating the overhead costs

估算间接成本

This is a difficult aspect of cost estimation        这是成本估算的一个困难方面

The aim is to share the total overhead costs of the company across all of the products made by that company

其目的是在该公司生产的所有产品上分摊该公司的总间接成本

Most firms assign overhead charges by using overhead rates

大多数公司通过使用间接费用费率来分配间接费用

Overhead rates are typically applied to one or two cost drivers

管理费用费率通常适用于一两个成本动因

        Cost drivers are parameters of the product which are directly measurable

        成本动因是直接可测量的产品参数

Common cost drivers are        常见的成本驱动因素有

        the cost of any purchased materials        购买材料的费用

        the cost of assembly labour        装配工人的成本

        the number of hours of equipment time the product consumes        

        产品所消耗的设备时间的小时数

Overhead charges are added in proportion to the value of the drivers

间接费用是按动因的价值成比例增加的

Step 2 – Reduce the costs of components

For most highly engineered products, the cost of purchased components will be the most significant element of the manufacturing cost

对于大多数高度工程化的产品，采购部件的成本将是制造成本中最重要的因素

The aim is to minimise these costs as part of the design process

其目的是将这些成本作为设计过程的一部分最小化

There are 4 key aspects to consider:        有4个关键方面需要考虑:

        1. Understand the process constraints and cost drivers

        了解工艺约束和成本驱动因素

        2. Redesign components to eliminate processing steps

        重新设计组件以消除加工步骤

        3. Choose the appropriate economic scale for the part process

        选择适合零件工艺的经济规模

        4. Standardise components and processes

        使组件和过程标准化

1. Understand the process constraints and cost drivers

Design decisions can drive up costs if they are complicated to achieve in production

如果设计决策在生产中难以实现，则会推高成本

Designers should be aware of the process constraints and cost drivers early in the development process

在开发过程的早期，设计师应该意识到过程约束和成本驱动因素

For example - a designer may specify a very complex shape for a case (because it looks nice) without understanding how difficult and expensive it is to make

例如，设计师可能会为一个箱子指定一个非常复杂的形状(因为它看起来很漂亮)，但却不了解它的制作难度和成本

2. Redesign components to eliminate processing steps

A reduction in the number of steps in the production of a product will reduce costs

在产品生产过程中减少步骤会降低成本

Designers should be encouraged to design products with components that can be manufactured in the minimum number of steps

应该鼓励设计师设计出可以用最少的步骤制造的部件

For example, does each component need to be painted – will it be seen by the customer in the end product? Not painting it will remove a step

例如，每个组件都需要涂漆吗?客户在最终产品中会看到吗?不给它上漆会使它少走一步

3. Choose the appropriate economic scale for the part process

Economies of scale can be achieved in production,but the right process must be chosen for the quantities involved

规模经济可以在生产中实现，但必须根据所涉及的数量选择正确的工艺

Some processes are best suited to small scale production,other processes are best suited to large scale production

有些工艺最适合小规模生产，有些工艺最适合大规模生产

4. Standardise components and processes

Continual identification of standardisation is key to the reduction of production costs

持续的标准化识别是降低生产成本的关键

Standardised components lead to the achievement of economies of scale and a lower cost per unit from suppliers

标准化的组件导致实现规模经济和供应商的单位成本较低

They also allow an organisation to have a range of products available to the customer with minimal additional cost

它们还允许一个组织以最小的额外成本为客户提供一系列产品

Step 3 – Reduce the costs of assembly

‘Design for Assembly’ (DFA) places an emphasis on identifying ways in which assembly costs can be reduced

“面向装配的设计”(DFA)强调识别降低装配成本的方法

The key ideas of DFA are to:        DFA的关键思想是:

        1. Minimize parts count        减少零件数

        2. Maximize the ease of handling parts        最大限度地简化部件的操作

        3. Maximize the ease of inserting parts        最大限度地简化插入部件

The benefits of DFA are:        DFA的好处是:

        1. Lower labour costs        较低的劳动力成本

        2. Other indirect benefits        其他间接利益

Maximise Ease of Assembly

最大限度地简化组装（看看就行，混个眼熟到时候有话说就行）

Part is inserted from the top of the assembly        部件从组件的顶部插入

Part is self-aligning        部件是自对准

Part does not need to be oriented        部件不需要定向

Part requires only one hand for assembly        部件只需要一只手进行组装

Part requires no tools        部件不需要工具

Part is assembled in a single, linear motion        部件以单一的直线运动方式组装

Part is secured immediately upon insertion        部件在插入时立即被保护

Consider Customer Assembly

Customers will tolerate some assembly        客户会容忍一些装配

Design product so that customers can easily and assemble correctly

设计产品使客户能够轻松和正确地组装

Customers will likely ignore directions        顾客很可能会忽略指示

Step 4 – Reduce the costs of supporting production

As a result of reducing the costs of components and the costs of assembly, the team may also achieve reductions in the demands placed on the production support functions

由于降低了组件成本和装配成本，团队还可以减少对生产支持功能的需求

Examples

1. A reduction in the number of parts reduces the demands on inventory management

零件数量的减少减少了对库存管理的需求

2. A reduction in assembly content reduces the number of workers required for production, and therefore reduces the cost of supervision and Human Resource Management

装配内容的减少减少了生产所需的工人数量，从而降低了监督和人力资源管理的成本

3. Standardised components reduce the demands on engineering support and quality control

标准化的组件减少了对工程支持和质量控制的需求

Step 5 - Consider the impact of DFM decisions on other factors

Product development is not only focused on cost reductions

产品开发的重点不只是降低成本

DFM can have an impact on other aspects of product development in addition to cost reductions

除了降低成本，DFM还可以对产品开发的其他方面产生影响

The balance between cost, quality and market launch (e.g. timing) is continually being reassessed

成本、质量和市场发布(例如时间)之间的平衡不断被重新评估

The impact of DFM on development time:        DFM对开发时间的影响：

DFM has a focus on cost reduction, which usually includes the design of individual components to reduce steps in production and therefore cost

DFM的重点是降低成本，通常包括设计单个部件以减少生产步骤，从而降低成本

However, if these design decisions would increase development time and delay the release, then the priorities of the organisation will have to be considered

然而，如果这些设计决策将增加开发时间并延迟发布，那么组织的优先级将不得不被考虑

The impact of DFM on product quality:        DFM对产品质量的影响：

        Will any decision stemming from DFM affect the product’s quality?

        DFM的任何决定会影响产品的质量吗?

        The majority of improvements to the manufacturing process will usually result in an improvement to the quality of the product

        对制造过程的大多数改进通常会导致产品质量的改善

        In most cases a reduction in components that require subsequent integration and testing improves quality

        在大多数情况下，减少需要后续集成和测试的组件可以提高质量

However, this is not always the case and decisions regarding trade-offs will need to be taken in line with the organisation’s product strategies

        然而，情况并非总是如此，有关权衡的决定需要与组织的产品策略相一致

The impact of DFM on external factors        DFM对外部因素的影响

        Component reuse        组件重用性

        Life cycle costs        寿命周期成本

Summary

DFM is aimed at reducing manufacturing costs while simultaneously improving (or at least not inappropriately compromising) product quality, development time, and development cost.

DFM旨在降低制造成本，同时提高(或至少不影响)产品质量、开发时间和开发成本。