Description
ANNA C. THORNTON, PhD, started her career in academia as a faculty member at MIT and then transitioned to industry for 17 years. She works with large and small companies in a wide variety of industries to transform their ideas into reality. She is now a Professor of the Practice in the Mechanical Engineering Department at Boston University where she teaches undergraduate and graduate courses in manufacturing and product realization. Acknowledgements xiii 1 Introduction 1 1.1 Examples 2 1.2 Building Ten Thousand is Very Different from Building One 6 1.3 Product Realization is a Marathon 8 1.4 The Factory is Not a Giant 3D Printer 9 1.5 Three Rules 9 1.6 Why Learn about Product Realization? 10 1.7 Book Structure 12 Summary and Key Takeaways 15 2 Are You Ready to Start? 16 2.1 Is Your Concept Ready? 17 2.2 Is the Technology Mature Enough? 20 2.3 Is the Prototype Mature Enough? 21 2.4 Is the Product Definition Mature Enough? 22 2.5 Is Manufacturing Mature Enough? 24 2.6 Is there Enough Cash and Is there Enough Time? 25 2.7 How Ready is Ready? 27 Summary and Key Takeaways 28 3 Product Realization Process 29 3.1 Product Development Processes 30 3.2 Industry Standards 33 3.3 The Pilot Process 36 Summary and Key Takeaways 52 4 Project Management 53 4.1 Roles and Responsibilities 56 4.2 Critical Path 63 4.3 Risk Management 69 4.4 Managing Your Enterprise Data 74 Summary and Key Takeaways 79 5 Specifications 80 5.1 Integrating with the Product Development Process 83 5.2 Parts of the Specification Document 84 5.3 Gathering Information 89 5.4 Managing a Specifications Document 98 Summary and Key Takeaways 101 6 Product Definition 102 6.1 Types of Parts 105 6.2 Bill of Materials 114 6.3 Color, Material, and Finish (CMF) 123 6.4 Mechanical Drawing Package 126 6.5 Electronics Design Package 130 6.6 Packaging 131 Summary and Key Takeaways 137 7 Pilot-phase Quality Testing 138 7.1 Definition of Quality 140 7.2 Quality Testing 145 7.3 Pilot Quality Test Plan 149 Summary and Key Takeaways 176 8 Costs and Cash Flow 177 8.1 Terminology 179 8.2 Non-recurring Engineering Costs 183 8.3 Recurring Costs 188 8.4 Revenue and Order Fulfillment 203 8.5 Cash Flow 205 Summary and Key Takeaways 210 9 Manufacturing Systems 211 9.1 Production System Types 214 9.2 Dedicated Manufacturing Facilities 215 9.3 Areas in a Manufacturing Facility 220 9.4 Lean Principles 223 Summary and Key Takeaways 227 10 Design for Manufacturability and Design for X 228 10.1 Selecting Manufacturing Processes 230 10.2 Design for Manufacture 234 10.3 Design for Assembly 238 10.4 Design for Sustainability 240 10.5 Design for Maintenance 242 10.6 Design for Testing 244 10.7 Design for SKU Complexity 244 10.8 Eleven Basic Rules of DFX 245 Summary and Key Takeaways 251 11 Process Design 252 11.1 Process Flow 255 11.2 Manual vs. Automation 257 11.3 Work Allocation to Stations 258 11.4 Process Plans 259 11.5 Standard Operating Procedures 262 11.6 Material Handling 266 Summary and Key Takeaways 267 12 Tooling 268 12.1 Types and Their Uses 270 12.2 Tooling Strategy 277 12.3 Tooling Life-cycle 282 12.4 Tooling Plan 284 Summary and Key Takeaways 286 13 Production Quality 287 13.1 Measuring Quality 289 13.2 Tracking Quality 292 13.3 Production Quality Test Plan 296 13.4 Control Plans 303 Summary and Key Takeaways 306 14 Supply Chain 307 14.1 Make vs. Buy 309 14.2 Types of Supplier Relationships 310 14.3 Owning Manufacturing or Using a CM 314 14.4 Supplier Selection 319 14.5 Documents 322 14.6 Managing Your Supply Base 329 14.7 Single vs. Dual Sourcing 330 14.8 Touring a Factory 331 Summary and Key Takeaways 334 15 Production Planning 335 15.1 Production Planning Concepts 336 15.2 Forecast to Order Timeline 343 15.3 Complicating Factors 344 15.4 Shorter Lead Times are Better 349 Summary and Key Takeaways 350 16 Distribution 351 16.1 Distribution Process 353 16.2 Outsourcing Distribution 358 16.3 Distribution System Design 359 Summary and Key Takeaways 362 17 Certification and Labeling 363 17.1 Certifications 364 17.2 Labeling and Documentation 371 Summary and Key Takeaways 377 18 Customer Support 378 18.1 Warranty 381 18.2 Recall 383 18.3 Customer Support 385 18.4 Customer Support Data 393 Summary and Key Takeaways 399 19 Mass Production 400 19.1 Manufacturing Scalability 401 19.2 Continual Improvement 403 19.3 Cost Down 405 19.4 Auditing 408 19.5 Equipment Maintenance 409 19.6 Launching the Next Product 410 19.7 Conclusions 410 Summary and Key Takeaways 411 Glossary 412 Acronyms 428 References 431 Index 438
