Alhamdulillah, we have finished our project in this product design development. Special thanks to our advisor, Dr Radzi Bin Haji Che Daud. Thanks also to all team member for good coorperation and commitment.May all of us get blessing from Allah SWT.....
Wednesday, 26 December 2012
project for Product Design Development
Alhamdulillah, we have finished our project in this product design development. Special thanks to our advisor, Dr Radzi Bin Haji Che Daud. Thanks also to all team member for good coorperation and commitment.May all of us get blessing from Allah SWT.....
ANSWER FOR ASSIGNMENT QUESTIONS
Question 16.2
Typical costs for the overseas subcontractor and the U.S. shoe
company that sells a name brand shoe to a retail chain might be:
Overseas subcontractor
Labor per
shoe 2.75
Materials 9.00
Shipping
and import duty 3.50
Operating
cost 3.00
Profit 1.75
Purchase
from subcontractor 20.00
Research
and development 0.25
Promotion
and advertising 4.00
Sales,
G&A 5.00
Profit 6.75
Question 16.3
This is an example of a break-even point problem. Soft tooling typically makes the part with
standard machines, universal dies and fixtures, and sometimes with tooling made
quickly from softer materials like aluminum. A process developed with soft
tooling can get under way quickly, making parts with little automation and low
tooling cost. However the life of the tools is short and the cost of making a
unit part is higher than if more time and money were spent making hard tool
steel dies using highly automated manufacturing equipment. Soft tooling works
best when the number of parts, Q , is relatively small; hard tooling works best
when the quantity of parts needed is large. The objective of this problem is to
find the break-even quantity of parts QB below which soft tooling is
the way to go, and above which using hard tooling is a better decision.
At the
break-even point, QB, the cost of using hard tooling equals the cost
of using soft tooling. The chief cost elements are:
·
the cost of tooling.
CH = $7500 CS
= $600
·
the cost of tool setup.
SH=$60 SS = $100 Parts are made in batches, b, (lots) of 500
units.
·
the cost to make one part.
CpH = $0.80 CpS = $3.40
At the break-even point,
The break-even point gives the total production at which the
hard tooling approach becomes more cost effective than soft tooling. Since the
total production is 5000 units, the best decision is to use hard tooling if the
time required to make to tools and prepare the production machines is
compatible with the product development schedule.
The units for the basic equation above are:
Question 16.4
Figure 16.1 should serve as a guide for breaking down the
costs listed in the problem statement.
Prime cost
Direct labor 950,000
Direct material 2,150,000
Direct expenses 60,000
Direct engineering 90,000
Direct engr. expenses 30,000
3,280,000 …………..…(1)
Factory expense
Plant utilities
70,000
Plant & equip. depreciation 120,000
Warehouse expense
60,000
Taxes & insurance 50,000
300,000………………….(2)
General and administrative expenses (G&A)
Plant manager and staff 180,000
Administrative salaries 120,000
Office utilities 10,000
310,000………….(3)
Manufacturing cost = (1) + (2) +(3) = 3,890,000 (4)
Sales expense =
100,000………………(5)
Total cost = (4) + (5) = 3,990,000……………(6)
This ignores corporate
overhead, which should be small for a company of this size.
The problem states that the profit margin is 0.15 or 15%.
One is tempted to multiply the total cost by 0.15 to get the profit, and add
this to cost to find the selling price.
Thursday, 20 December 2012
concept generation of portable chair
Concept generation of the Portable Chair
Concept generation is actually a phase of developing a creative thinking mind and also to develop a new product. Such creative thinking mind is developing using various methods. For instant, practical methods for enhancing creativity like brainstorming and Synectics, developed in the 20th century, are now adapted and adopted as methods for generating design concepts and ways for develop creative thinking mind. It is also a phase to generate as much ideas as possible. Some ideas may look irrelevant, but it may be the starting point for generating another brilliants ideas. Generating ideas and selecting among competing ideas are two of the most important determinants of successful design. Good detail design will never rescue a poor concept. Below is the diagram of concept generation processes.
Before the phase on creative thinking takes place, we should be able to identify the problem as well as possible. As a student, it is important to have a condusive learning environment to grasp as much knowledge as possible. Such condusive environment includes the presentation of the topic by the lecturers, the condition of the tables and chairs, the air flow circulation in the class and many other factors. It is observed that the conditions of the chairs at various kulliyyah of International Islamic University Malaysia (IIUM) are not in good conditions. Such kulliyyah are Islamic Revealed knowledge and Human Sciences (IRKHS), Ahmad Ibrahim Kulliyyah of Law (AIKOL) and Kulliyyah of Economics (EMS). Before stated the problem of the chairs, we should know how the chair look like. Below is the picture of the currently used chair in the classroom of those kulliyyah.
Figure 1 show the front view of the chair that is currently used at those kulliyyah. The frame of the chair is made up from steel and the seat is made up from wood. The leg and the body frame are welded together. Figure 3 show the chair equipped with small table. The small table is made up from wood and connected together to the holding frame. The holding frame is being inserted into the round hollow shaft called the slot.
Figure 1: Front view
Figure 2: Side View
Figure 3: front view (chair with small table)
Figure 4: Side view (chair with small table)
The design of the chair was good at that time (maybe for the past 10 years) but now lots of improvements need to be done. There are several problems that cause by that chair. Firstly, the chair is quite heavy to lift. Some may ask why we need to lift that chair. The answer is that, the number of students never be exactly the same as the amount of chairs in a class. It can be more or less, when the chairs are not enough for the students, thus it is necessary to lift another chair from another empty class. Since the frame of that chair is from steel it cause the chair to be heavy to lift from one place to another.
Secondly, the chair is not stable because the leg of the chair not properly in contact with the floor. Maybe the leg is not properly bending or because of the misalignment during the assembly or welding operation. Thirdly, the small table produce some irritating sound during opening and closing of that small table. Besides, the angle of opening of that small table is not big enough to make the small table foldable. The chair is made not for foldable and portable. Next, the holding frame is bending due to excessive load exert on the small table. Due to that reason the small table often break and have some damage. The materials selection was not good for the small table as well as the chair. Below show the pictures related to the problems of that chair. The main problems causes by that chair are:
1. The chair is quite heavy to lift.
2. The chair is not stable because the leg of the chair not properly in contact with the floor.
3. The small table produce some irritating sound during opening and closing.
4. The chair is made not for foldable and portable.
Figure 5 Maximum opening angle of the small table
Figure 6 Bending holding frame
Figure 7 Broken small table
Figure 8 Close up view of broken small table
Figure 8 Paper is used to eliminate the shaking of the small table
The design of the new chair should be able to eliminate those problems. Various methods can be used to obtain the optimal solution to the problems of that chair. We should be able to recognize that the problem exists and problems are already being recognized. Now is the step called fluency step. Fluency is actually the ability to produce a large number of alternative solutions to a problem. There are methods that can be used to obtain as many solutions as possible. Not all the solution can be accepted. At the end the optimum and the best solution achieved accepted by the consensus of the team members.
We used brainstorming method to generate as much idea as possible. It is the most common method used for generating ideas.
The used morphological method is quite relevant to select the best optimum solutions to get the best design of the new chair. Morphology means the study of shape and form. We develop the morphological chart to find the best solution to the chair’s new design. Morphological analysis is a way of creating new forms. The morphological chart is developed based on the ideas generation from the brainstorming sessions.
Morphological chart
Noted that the final new design of the chair not necessary follow the exact best solution of the morphological chart. It may come from the combination of any options of each topics and the design also may be very from the selected option.
Figure 9 General design of the new chair
The design of the chair by combining each selected option on each topic.
1. The leg and the body come from the option 1 on their respective topic.
Figure 10 First design of the chair
2. The design of the small table come from option 4 of the small table topic.
Figure 11 Second stage design of the chair
3. The design of the basket or box for books and etc. come from option 2 of its respective topic.
Figure 12 Third stage design of the chair
4. The design of drinking bottle holder comes from option 2 of its respective topic.
Figure 13 Final stage of the design of the chair
5. Finished design of the chair.
Figure 14 Different view of the chair
Noted that the design may be vary for each option selected and it’s may be as much as 20 design or even more based on the matrix of the morphological chart above.
2. They recognize that their reputation and self esteem as competent decision makers are at stake.
2. The objectives are classified as to importance. (Sort out musts and the wants)
3. Alternatives actions are developed.
4. The alternatives are evaluated against the objectives.
5. The choice of the alternatives that holds the best promises of achieving all of the objectives represent the tentative decision.
6. The tentative decision is explored for future possible adverse consequences.
7. The effects of the final decision are controlled by taking other actions to prevent possible adverse consequences from becoming problems and by making sure that the actions decided on are carried out.
Concept
selection
2.formulate the decision matrix
3.clarify the design concept
4.choose the datum concept
5.run the matrix
6.evaluate the ratings
7.establish a new datum and rerun the matrix
8.examine the selected concept for improvement opportunities
BEHAVIORAL ASPECT OF DECISION MAKING
Behavioral
psychology provides an understanding of the influences of risk taking in
individuals and teams. Making a decision is a stressful situation for most
people because there is no way to be certain about the information about the
past or predictions of the future. This psychological stress arise from at
least two sources.
1. Decision makers are concerned about the material and
social losses that will result from either course of action that is chosen.2. They recognize that their reputation and self esteem as competent decision makers are at stake.
Severe
psychological stress brought on by
decisional conflict can be major cause of errors in decision making. There are
five basic patterns by which people cope with the challenge of decision making.
1. Unconflicted adherence: Decide to continue with
current action and ignore information about risk of losses.
2. Unconflicted change: Uncritically adopt whichever
course of action is most strongly recommended.
3. Defensive avoidance: Evade conflict by
procrastinating, shifting responsibility to someone else and remaining
inattentive to corrective information.
4. Hypervigilance: Search frantically for an immediate
problem solution.
5. Vigilance: Search painstakingly for relevant
information that is assimilated in an unbiased manner and appraised carefully
before a decision made.
All these
patterns of decision making, except the last one, are defective.
The quality of a
decision does not depend on the particulars of the situation as much as it does
on the manner in which the decision-making process is carried out. We discuss
the basic ingredient in a decision and the contribution made by each. The basic
ingredient is every decision are listed in the accompanying table. That a
substitution is made for one of them
does not necessarily mean that a bad decision will be reached, but it does mean
that the foundation for the decision is weakened.
A decision usually leads to an
action. A situation requiring action can be thought of as having for aspects;
should, actual, must and want.
The should aspect identifies what
ought to be done if there are no obstacles to the action. A should is the
expected standard performance if organizational objectives are to be obtained.
The should is compared with the actual, the performance that is occurring at
the present point in time. The must action draws the line between the
acceptable and the unacceptable action. A must is a requirement that cannot be
compromised. A want action is not firm requirement but is subject to bargaining
and negotiation. Want actions are usually ranked and weighted to give an order
of priority. They do not set absolute limits but instead express relative
desirability.
To summarize this discussion of the
behavioral aspects of decision making, we list the sequence of steps that are
taken in making a good decision.
1. The objectives of a decision must be established
first.2. The objectives are classified as to importance. (Sort out musts and the wants)
3. Alternatives actions are developed.
4. The alternatives are evaluated against the objectives.
5. The choice of the alternatives that holds the best promises of achieving all of the objectives represent the tentative decision.
6. The tentative decision is explored for future possible adverse consequences.
7. The effects of the final decision are controlled by taking other actions to prevent possible adverse consequences from becoming problems and by making sure that the actions decided on are carried out.
DECISION THEORY
Decision making models usually are
classified into four groups with respect to the state of knowledge.
Decision under certainty: Each action results in a
known outcome that will occur with a probability of 1.
Decision under uncertainty: Each state of nature has
an assigned probability of occurrence.
Decision under risk: Each action can result in two or
more outcomes, but the probabilities for the states of nature are unknown.
Decision under conflict: The state of nature are
replaced by course of action determined
by an opponent who is trying to maximize his or her objectives function. This
type of decision theory usually is called game theory.
UTILITY THEORY
Maximax and
maximin are strategies that incorporate attitude toward risk in decision
problems. The examples presented in the previous section presuppose the ability
to determine the utility of each outcomes. A more direct method is to use
Utility Theory in establishing the problem.
In Utility
Theory, everyday words take on precise meanings that are not the same as in
common usage. Definitions are required
Value is an
attribute of an alternative that is implied by choice (e.g., if A is chosen
over B, it is assumed that A has more value than B). Nowadays, money is the
medium of exchange that is used to express value. A buyer will exchange an
amount of money B for a material good only if the buyer perceives A to be worth
more than B at the time exchange.
Preferences is
statement of relative value in the eyes of decision maker. Preference is a
subjective quality that depends totally on the decision maker.
Utility is a
measure of preference order for particular user. Utility is not necessarily
equal to the value of exchange in the market place.
Marginal utility
is a key concept of utility theory is the understanding of the nature of what
is gained by adding one more unit to amount already possessed. Most decision
makers have utility functions that are consistent with the Law of Diminishing
Marginal Utility.
Pugh concept
selection method
1.choose the
criteria by which the concept will be evaluate2.formulate the decision matrix
3.clarify the design concept
4.choose the datum concept
5.run the matrix
6.evaluate the ratings
7.establish a new datum and rerun the matrix
8.examine the selected concept for improvement opportunities
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