2016

PERANCANGAN PRODUK Chapter 5 Gasal 2015/2016

Debrina Puspita Andriani

Teknik Industri Universitas Brawijaya e-Mail : [email protected] Blog : http://debrina.lecture.ub.ac.id/

13/10/2014

Perancangan Produk - Gasal 2014

PRODUCT SPECIFICATIONS

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Needs and Specifications •  Customer Needs describe What the end product or service

does for the user. •  They are expressed in the “language of the customer”. •  The “product__________”

•  Product Specifications allow quantification of the customer

needs. •  A spec consists of a metric, a unit, and a value •  Specs has a set of specs.

•  The Product Metrics describe the measures used to determine

IF the product meets the customer requirements. •  The Value is the actual numeric specification that the designers use to determine when the product meets the customer requirements.

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Needs and Specifications

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Tools for transforming Needs into Specifications

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A Product Spec for each Need Prioritize the Needs. •  It is important to identify the critical factors for success and make sure you have a way of quantifying these factors. Develop a measure and value for each need. Some needs may have more than one specification.

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Product Design Specifications (PDS) •  Basic control and reference document for the design and manufacture •  Specific, measurable, testable criteria •  “Unambiguous, Understandable, Correct, Concise, Traceable, Traced, Design Independent, Verifiable, Unique, Complete, Consistent, Comparable, Modifiable, Attainable” •  Functional decomposition •  Performance targets •  Constraints (Demands, Musts) •  Goals (Wishes, Wants) •  Features

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Our Approach to PDS •  Process recommended for high-risk new product design. •  PDS development will be modified based on your product

or process.

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Importance of Clear Specifications •  Product Specifications are the “blue prints” of a project. •  They will guide the project throughout the development.

•  Developing product specifications is a two step process. •  Step 1 establish target specs to help channel the thinking during the

product concept generation process. •  Target specs: the hope and aspiration of the design (ideal and marginal (Usually

requires making assumptions as to what the final product configuration will be.) •  Step 2 is the refinement of the specifications once the team has picked a

product concept and is ready to go into system level design. Refined specs: trade-offs among different desired characteristics. •  Completed after concept selection.

•  Step 3 is determine Final Specs. It is in the project’s contract book.

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The Product Specs Process

•  Based on customer needs and benchmarks •  Develop metrics for each need •  Set ideal and acceptable values

Set Target Specifications

Refine Specifications •  Based on selected concept and feasibility testing •  Technical and economic modeling •  Trade-offs are critical

•  Critical for ongoing improvement

Reflect on the Results and the Process

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What department in most companies is most concerned with Product Specifications? •  The QA department. •  What does a QA department do? •  Works with design engineers to develop comprehensive specifications for all critical customer requirements. •  Develops test procedures to allow designers to test their designs against the specifications. •  Test products and processes to ensure the end product complies with those design specifications.

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Example: Specialized mountain bike design •  Customer need: The Customer expresses the need in

terms of What the product must do. •  The Suspension enables high-speed descents on bumpy roads.

•  The Product Specification sets metrics and values that

allow quantification of the user need. •  Attenuation from dropout to handlebar at 10 Hz. •  Maximum value from the Monster (suspension test by Mountain Bike

Magazine.) •  Minimum descent time on test track. •  Note: the metric does not yet have an actual value assigned at this point. •  Why not? Product Specifications usually require a preliminary product definition.

Product Specifications Example:

Mountain Bike Suspension Fork

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Start with the Customer Needs: Kebutuhan pelanggan untuk tiang suspensi dan derajat kepentingan The process of developing product specifications begins with your completed matrix of interpreted customer needs. *Again note that there are no values.


# 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

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Interpretaion N E E of D Needs The suspension The suspension The suspension The suspension The suspension The suspension The suspension The suspension The suspension The suspension The suspension The suspension The suspension The suspension The suspension The suspension The suspension The suspension The suspension The suspension

Imp reduces vibration to the hands. 3 allows easy traversal of slow, difficult terrain. 2 enables high speed descents on bumpy trails. 5 allows sensitivity adjustment. 3 preserves the steering characteristics of the bike. 4 remains rigid during hard cornering. 4 is lightweight. 4 provides stiff mounting points for the brakes. 2 fits a wide variety of bikes, wheels, and tires. 5 is easy to install. 1 works with fenders. 1 instills pride. 5 is affordable for an amateur enthusiast. 5 is not contaminated by water. 5 is not contaminated by grunge. 5 can be easily accessed for maintenance. 3 allows easy replacement of worn parts. 1 can be maintained with readily available tools. 3 lasts a long time. 5 is safe in a crash. 5

• •• • • ••• • • • ••• ••• ••• • •••• • • ••• ••• •••• •••• ••••

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Concept Development Process Mission Statement

Identify Customer Needs

Establish Target Specifications

Generate Product Concepts

Select Product Concept(s)

Test Product Concept(s)

Set Final Specifications

Plan Downstream Development

Perform Economic Analysis Benchmark Competitive Products Build and Test Models and Prototypes

Target Specs

Final Specs

Based on customer needs and benchmarking

Based on selected concept, feasibility, models, testing, and trade-offs

Development Plan

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TARGET SPECIFICATIONS

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Process for Establishing Target Specifications

1 2 3 4

Prepare the list of Metrics and measurement units based on your customer needs. Collect the competitive benchmarking information. Establish what “best in class” products would require. Set ideal and marginally acceptable target values for each metric (using at least, at most, between, exactly, etc.) Reflect on the results.

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Membuat Daftar Metrik ! Perhatikan: Metrik harus komplit

Beberapa metrik merupakan variabel dependen, beberapa variabel independen

Beberapa kebutuhan tidak dapat dengan mudah diterjemahkan menjadi metrik yang terukur

Metrik harus praktis

Metrik harus merupakan kriteria yang populer untuk perbandingan di pasar

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Metrik harus komplit •  Setiap kebutuhan harus berhubungan dengan sebuah/

beberapa metrik yang merefleksikan secara lengkap 1 kebutuhan pelanggan •  Nilai dari metrik harus dapat memuaskan kebutuhan terkait

Metrik harus praktis •  Metrik dapat langsung diteliti dan dianalisis dengan

mudah oleh tim.

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Beberapa metrik merupakan variabel dependen, beberapa variabel independen •  Metrik independen dapat di-set oleh desainer. •  misal “panjang pipa kemudi”, “ukuran roda” •  Metrik dependen adalah hasil dari keputusan desain. •  misal “massa total sepeda” •  Sangat penting untuk mengidentifikasi variabel dependen

untuk memastikan bahwa desain yang dipilih tidak mengecewakan pelanggan.

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Beberapa kebutuhan tidak dengan mudah diterjemahkan menjadi metrik yang terukur •  Misal Kebutuhan “menanamkan kebanggaan” •  à hal yang penting dalam menentukan keberhasilan segmen pasar akan pentingnya gaya dan penampilan. •  Bagaimana kebanggaan diukur? •  à Pada kolom unit ditulis “subyektif” dan metrik ini akan dievaluasi oleh sekumpulan pelanggan.

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Metrik harus merupakan kriteria yang populer untuk perbandingan di pasar •  Kebanyakan pelanggan di pasar membeli produk

berdasarkan evaluasi publikasi yang diterbitkan secara bebas. •  Kinerja tinggi yang diinginkan (yang tercantum dalam media) à cerminan keinginan pelanggan à tim pengembang menggunakan metrik yang digunakan media.

STEP 1 ESTABLISHING TARGET SPECIFICATION

Need #s

Metric #

Establish Metrics and Units

1 1,3 2 2,6 3 1,3 4 1,3 5 4 6 5 7 5 8 6 9 7 10 8 11 9 12 9 13 9 14 9 15 10 16 11 17 12 18 13 19 14 20 15 21 16,17 22 17,18 23 19 24 19 25 20 26 20

Metric Attenuation from dropout to handlebar at 10hz Spring pre-load Maximum value from the Monster Minimum descent time on test track Damping coefficient adjustment range Maximum travel (26in wheel) Rake offset Lateral stiffness at the tip Total mass Lateral stiffness at brake pivots Headset sizes Steertube length Wheel sizes Maximum tire width Time to assemble to frame Fender compatibility Instills pride Unit manufacturing cost Time in spray chamber w/o water entry Cycles in mud chamber w/o contamination Time to disassemble/assemble for maintenance Special tools required for maintenance UV test duration to degrade rubber parts Monster cycles to failure Japan Industrial Standards test Bending strength (frontal loading)

Imp Units 3 dB 3 N 5 g 5 s 3 N-s/m 3 mm 3 mm 3 kN/m 4 kg 2 kN/m 5 in 5 mm 5 list 5 in 1 s 1 list 5 subj 5 US$ 5 s 5 k-cycles 3 s 3 list 5 hours 5 cycles 5 binary 5 MN

Link Metrics to Needs:

•

Bending strength (frontal loading)

Monster cycles to failure

•

Japan Industrial Standards test

UV test duration to degrade rubber parts

Special tools required for maintenance

Time to disassemble/assemble for maintenance

Cycles in mud chamber w/o contamination

Time in spray chamber w/o water entry

•

Unit manufacturing cost

•

Instills pride

•

Fender compatibility

Maximum tire width

•

Time to assemble to frame

Wheel sizes

•

Steertube length

•

Headset sizes

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

Lateral stiffness at brake pivots

•

8

Total mass

•

7

Lateral stiffness at the tip

•

6

Rake offset

•

5

Maximum travel (26in wheel)

Spring pre-load

Need 1 reduces vibration to the hands. • 2 allows easy traversal of slow, difficult terrain. 3 enables high speed descents on bumpy trails. • 4 allows sensitivity adjustment. 5 preserves the steering characteristics of the bike. 6 remains rigid during hard cornering. 7 is lightweight. 8 provides stiff mounting points for the brakes. 9 fits a wide variety of bikes, wheels, and tires. 10 is easy to install. 11 works with fenders. 12 instills pride. 13 is affordable for an amateur enthusiast. 14 is not contaminated by water. 15 is not contaminated by grunge. 16 can be easily accessed for maintenance. 17 allows easy replacement of worn parts. 18 can be maintained with readily available tools. 19 lasts a long time. 20 is safe in a crash.

4

Damping coefficient adjustment range

3

Minimum descent time on test track

2

Maximum value from the Monster

1

Attenuation from dropout to handlebar at 10hz

Metric

Quality Function Deployment, or a Needs-Metrics Matrix

•

•

• • •

• • • • • • • • • • •

• •

NEED Imp reduces vibration to the hands. 3 allows easy traversal of slow, difficult terrain. 2 enables high speed descents on bumpy trails. 5 allows sensitivity adjustment. 3 preserves the steering characteristics of the bike. 4 remains rigid during hard cornering. 4 is lightweight. 4 provides stiff mounting points for the brakes. 2 fits a wide variety of bikes, wheels, and tires. 5 is easy to install. 1 works with fenders. 1 instills pride. 5 is affordable for an amateur enthusiast. 5 is not contaminated by water. 5 is not contaminated by grunge. 5 can be easily accessed for maintenance. 3 allows easy replacement of worn parts. 1 can be maintained with readily available tools. 3 lasts a long time. 5 is safe in a crash. 5

Gunhill Head Shox

suspension suspension suspension suspension suspension suspension suspension suspension suspension suspension suspension suspension suspension suspension suspension suspension suspension suspension suspension suspension

Tonka Pro

The The The The The The The The The The The The The The The The The The The The

Rox Tahx Ti 21

# 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Rox Tahx Quadra

ESTABLISHING TARGET SPECIFICATION

Maniray 2

STEP 2

ST Tritrack

Benchmark on Customer Needs

• •• • • •••• • • • •••• •••• ••• • ••••• • • •••• •••• ••••• ••••• •••••

•••• •••• ••••• •••• •• ••• ••• •••• ••••• ••••• • •••• • ••• ••• ••••• ••••• ••••• ••••• •••••

•• ••• •• •• • • • ••• ••• •••• • ••• ••• •••• • •••• •••• ••••• ••••• •••••

••••• ••••• ••••• ••••• •• ••••• ••• ••• ••••• •••• • ••••• • •••• •••• •••• •••• ••••• ••• •••••

•• ••• •• •• ••• • •••• •• ••• ••••• • ••• ••• •• •• ••••• ••••• •• ••••• •••••

••• ••••• ••• ••• ••••• ••••• ••••• ••••• • • ••••• ••••• •• ••••• ••••• • • • • •••••

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12

9 Headset sizes

9 Steertube length

5

in

5

mm list in s list subj US$ s k-cycles s

13 9 14 9 15 10 16 11 17 12 18 13 19 14 20 15 21 16,17

Wheel sizes Maximum tire width Time to assemble to frame Fender compatibility Instills pride Unit manufacturing cost Time in spray chamber w/o water entry Cycles in mud chamber w/o contamination Time to disassemble/assemble for maintenance

5 5 1 1 5 5 5 5 3

22 17,18 23 19 24 19 25 20 26 20

Special tools required for maintenance UV test duration to degrade rubber parts Monster cycles to failure Japan Industrial Standards test Bending strength (frontal loading)

3 5 5 5 5

8 15 10 15 9 550 760 500 710 480 3.6 3.2 3.7 3.3 3.7 13 11.3 12.6 11.2 13.2 0 0 0 200 0 28 48 43 46 33 41.5 39 38 38 43.2 59 110 85 85 65 1.409 1.385 1.409 1.364 1.222 295 550 425 425 325 1.000 1.000 1.000 1.125 1.000 1.125 1.000 1.125 1.250 1.125 1.250 1.125 150 180 210 230 255

140 165 190 215

150 170 190 210

26in 26in 26in 1.5 1.75 1.5 35 35 45 Zefal none none 1 4 3 65 105 85 1300 2900 >3600 15 19 15 160 245 215

list hex hex hex hours 400+ 250 400+ cycles 500k+ 500k+ 500k+ binary pass pass pass MN 55 89 75

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Gunhill Head Shox

Units dB N g s N-s/m mm mm kN/m kg kN/m

Tonka Pro

Imp 3 3 5 5 3 3 3 3 4 2

Rox Tahx Ti 21

Metric Attenuation from dropout to handlebar at 10hz Spring pre-load Maximum value from the Monster Minimum descent time on test track Damping coefficient adjustment range Maximum travel (26in wheel) Rake offset Lateral stiffness at the tip Total mass Lateral stiffness at brake pivots

Rox Tahx Quadra

1,3 2,6 1,3 1,3 4 5 5 6 7 8

Maniray 2

Need #s

1 2 3 4 5 6 7 8 9 10


ST Tritrack

Metric #

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13 680 3.4 11 0 38 39 130 1.1 650

NA

150 170 150 190 190 210 210 230 220 NA 26in 700C 26in 26in 1.75 1.5 1.5 45 35 85 none none all 5 3 5 115 80 100 >3600 2300 >3600 25 18 35 245 200 425 hex, long pin hex hex wrnch 400+ 400+ 250 480k 500k+ 330k pass pass pass 75 62 102

Benchmarking on Metrics

STEP 3 ESTABLISHING TARGET SPECIFICATION

1 2 3 4 5 6 7 8 9 10

Metric Attenuation from dropout to handlebar at 10hz Spring pre-load Maximum value from the Monster Minimum descent time on test track Damping coefficient adjustment range Maximum travel (26in wheel) Rake offset Lateral stiffness at the tip Total mass Lateral stiffness at brake pivots

11 Headset sizes

12 Steertube length 13 14 15 16 17 18 19 20 21 22 23 24 25 26

Wheel sizes Maximum tire width Time to assemble to frame Fender compatibility Instills pride Unit manufacturing cost Time in spray chamber w/o water entry Cycles in mud chamber w/o contamination Time to disassemble/assemble for maintenance Special tools required for maintenance UV test duration to degrade rubber parts Monster cycles to failure Japan Industrial Standards test Bending strength (frontal loading)

Units dB N g s N-s/m mm mm kN/m kg kN/m in

mm list in s list subj US$ s k-cycles s list hours cycles binary MN

Ideal Value

Assign Marginal and Ideal Values

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Marginal Value

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>10 >15 480 - 800 650 - 700 <3.5 <3.2 <13.0 <11.0 0 >200 33 - 50 45 37 - 45 38 >65 >130 <1.4 <1.1 >325 >650 1.000 1.000 1.125 1.125 1.250 150 170 190 210 26in >1.5 <60 none >3 <85 >2300 >15 <300 hex >250 >300k pass >70

150 170 190 210 230 26in 700c >1.75 <35 all >5 <65 >3600 >35 <160 hex >450 >500k pass >100

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Values of Metrics

At least X – set a minimum amount

At most X – set a maximum

Exactly X – set a fixed value

Between X and Y – set a range

Discrete values – beberapa metrik mempunyai nilai beberapa pilihan diskret.

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Reflect on the results. STEP 4 - ESTABLISHING TARGET SPECIFICATION •  Tim memerlukan beberapa

kali pengulangan sampai target disetujui. •  Melakukan pertimbangan

(refleksi) di tiap kali pengulangan à meyakinkan bahwa hasil yang diperoleh sudah konsisten dengan tujuan proyek.

Beberapa Apa anggota tim “bertaruh”? – apa pertimbangan:

wakil bagian pemasaran menyatakan bahwa nilai yang agresif diperlukan untuk metrik tertentu? Jika ditetapkan target tinggi, apa anggota tim mampu?

Haruskah tim mempertimbangkan untuk menawarkan berbagai produk/ pilihan produk agar memenuhi lebih dari satu segmen pasar atau cukup satu produk saja? Apakah ada spesifikasi yang hilang? Apakah spesifikasi merefleksikan karakteristik dalam kesuksesan komersial?

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FINAL SPECIFICATIONS

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Process for setting the final specifications Develop technical models to assess technical feasibility. The input is design variable and the output is a measurement using a metric.

Develop a cost model of the product.

Refine the specifications, making tradeoffs, where necessary to form a competitive map.

“Flow down” the final overall specs to specs for each subsystem (component and part).

Reflect on the results to see

•  Whether the product is a winner, and/or •  How much uncertainty there is in the technical and cost model, or •  Whether there is a need to develop a better technical model.

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Develop technical models to assess technical feasibility STEP 1 – PROCESS FOR SETTING THE FINAL SPECIFICATIONS

Misal Konsep terpilih: kumparan pegas yang dilumuri minyak untuk produk tiang suspensi

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Develop a cost model of the product


•  Produk yang dihasilkan sesuai dengan “target biaya/

target cost” yang ditetapkan. •  Biaya à biaya manufaktur dimana perusahaan

memperoleh cukup keuntungan dan mampu menawarkan produk ke pelanggan dengan harga yang bersaing.

STEP 2 – PROCESS FOR SETTING THE FINAL SPECIFICATIONS

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•  Perkiraan biaya berdasarkan daftar bahan &

komponen sesuai BOM Tree.

N o

Bahan/Komponen

Jumlah

1 2 : n Total

Harga Tertinggi

Harga Terendah

Total Tinggi

Total Rendah

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Profit Margin & Target Cost Where: M: profit margin P: price C: cost

Dengan à Markup = P/C - 1

Where: C = target cost P = price to the end user Mi = the margin at the ith stage.

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Gross Margin Industry


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Contoh Diketahui P=$250. Jika produk langsung dijual ke pelanggan oleh pabrik dan keuntungan kotor yang ingin diperoleh pabrik, MM, adalah sebesar 40%, maka harga produk tersebut adalah: C = P (1 – MM) = $250 (1 – 0,40) = $150 Jika produk dijual ke pengecer dan keuntungan pengecer, MR, adalah sebesar 45%, maka: C = P (1 – MM) (1 – MR) = $82.50 Jika produk dijual ke distributor dan pengecer, kemudian keuntungan kotor yang ingin diperoleh distributor, MD, sekitar 20%, maka?

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Refine the specifications, making tradeoffs, where necessary STEP 3 – PROCESS FOR SETTING THE FINAL SPECIFICATIONS

Peta Persaingan Dibuat berdasarkan bagan analisis pesaing (competitive benchmarking chart)

07/10/15

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Estimated Manufacturing Cost ($)

Specification Trade-offs Trade-off Curves  for Three Concepts

Score on Monster (Gs)

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1 2 3 4 5 6 7 8 9 10


METRIC Attenuation from dropout to handlebar at 10hz Spring pre-load Maximum value from the Monster Minimum descent time on test track Damping coefficient adjustment range Maximum travel (26in wheel) Rake offset Lateral stiffness at the tip Total mass Lateral stiffness at brake pivots

11 Headset sizes

12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

Steertube length Wheel sizes Maximum tire width Time to assemble to frame Fender compatibility Instills pride Unit manufacturing cost Time in spray chamber w/o water entry Cycles in mud chamber w/o contamination Time to disassemble/assemble for maintenance Special tools required for maintenance UV test duration to degrade rubber parts Monster cycles to failure Japan Industrial Standards test Bending strength (frontal loading)

Units

Value

dB N g s N-s/m mm mm kN/m kg kN/m

>12 650 <3.4 <11.5 >100 43 38 >75 <1.4 >425 1.000 1.125 150 170 190 210 230 26in >1.75 <45 Zefal >4 <80 >3600 >25 <200 hex >450 >500k pass >100

in

mm list in s list subj US$ s k-cycles s list hours cycles binary MN

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Set Final Specifications

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•  Masalah yang dihadapi:

Flow down” the final overall specs to specs for each subsystem STEP 4 – PROCESS FOR SETTING THE FINAL SPECIFICATIONS

•  Memastikan spesifikasi subsistem

dapat mencerminkan spesifikasi produk secara keseluruhan.

•  Meyakini bahwa spesifikasi tertentu

untuk subsistem yang berbeda mempunyai tingkat kesulitan yang sama untuk dipenuhi.

•  Contoh: •  Fungsi efisiensi bahan bakar mesin

tersusun dari bahan bakar mesin, daya tahan putaran mesin, koefisien putaran mesin,koefisien tarikan, aero dinamis, dll.

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Reflect on the results to see STEP 5 – PROCESS FOR SETTING THE FINAL SPECIFICATIONS


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Quality Function Deployment (House of Quality)

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BACA: CONTOH 2 Soccer Robot

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Interpreted Customer Needs The process of developing product specifications begins with your completed matrix of interpreted customer needs. Again note that there are no values.


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Example of a customer needs table From 2nd & 3rd of needs

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Needs-Metrics Tables

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Quality Function Deployment, or a Needs-Metrics Matrix

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Competitive Benchmarking – Evaluate the competition

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Example of a Product Specification table

2016

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