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Integrated Product and Process Design and Development: The Product Realization Process, Second Edition 2nd edition [Kietas viršelis]

(University of Maryland, College Park, USA), (University of Maryland, College Park, Maryland, USA), (University of Maryland, College Park, USA), (University of Maryland, College Park, USA)
  • Formatas: Hardback, 352 pages, aukštis x plotis: 254x178 mm, weight: 800 g, 70 Tables, black and white; 104 Illustrations, black and white
  • Išleidimo metai: 28-Jul-2009
  • Leidėjas: CRC Press Inc
  • ISBN-10: 1420070606
  • ISBN-13: 9781420070606
Kitos knygos pagal šią temą:
  • Formatas: Hardback, 352 pages, aukštis x plotis: 254x178 mm, weight: 800 g, 70 Tables, black and white; 104 Illustrations, black and white
  • Išleidimo metai: 28-Jul-2009
  • Leidėjas: CRC Press Inc
  • ISBN-10: 1420070606
  • ISBN-13: 9781420070606
Kitos knygos pagal šią temą:
Since the publication of the first edition of Integrated Product and Process Design and Development: The Product Realization Process more than a decade ago, the product realization process has undergone a number of significant changes. Reflecting these advances, this second edition presents a thorough treatment of the modern tools used in the integrated product realization process and places the product realization process in its new context.





See whats new in the Second Edition:



















Bio-inspired concept generation and TRIZ





Computing manufacturing cost, costs of ownership, and life-cycle costs of products





Engineered plastics, ceramics, composites, and smart materials





Role of innovation





New manufacturing methods: in-mold assembly and layered manufacturing











This book discusses how to translate customer needs into product requirements and specifications. It then provides methods to determine a products total costs, including cost of ownership, and covers how to generate and evaluate product concepts. The authors examine methods for turning product concepts into actual products by considering development steps such as materials and manufacturing processes selection, assembly methods, environmental aspects, reliability, and aesthetics, to name a few. They also introduce the design of experiments and the six sigma philosophy as means of attaining quality.





To be globally viable, corporations need to produce innovative, visually appealing, quality products within shorter development times. Filled with checklists, guidelines, strategies, and examples, this book provides proven methods for creating competitively priced quality products.
Preface---Second Edition xiii
Preface---First Edition xv
Authors xvii
Product Development at the Beginning of the Twenty-First Century
1(18)
Introduction
1(2)
Ideas and Methods Currently Used in the Product Realization Process
3(4)
Introduction
3(1)
Engineering Design
3(1)
Manufacturing
4(1)
Logistics
4(1)
Producibility
4(1)
The Japanese Contribution to the Product Development Process
5(1)
Just-In-Time (JIT) Manufacturing
5(1)
Continuous Improvement
6(1)
Lean Manufacturing
6(1)
Innovation
7(2)
Quality
9(5)
A Brief History of the Quest for Quality Products and Services
9(1)
Quality Quantified
10(3)
Six Sigma
13(1)
ISO 9000
14(1)
Benchmarking
14(1)
Partnering with Suppliers---Outsourcing
15(2)
Mass Customization
17(2)
The Integrated Product and Process Design and Development Team Method
19(16)
Introduction
19(1)
The IP2D2 Team and Its Agenda
20(7)
Stage 1: Product Identification
22(4)
Stage 2: Concept Development
26(1)
Stage 3: Design and Manufacturing
26(1)
Stage 4: Launch
26(1)
Technology's Role in IP2D2
27(1)
IP2D2 Team Requirements
28(7)
Team Requirements
28(2)
Team Creativity
30(2)
Brainstorming
32(1)
Enlarging the Search Space
32(3)
Product Cost Analysis
35(38)
Introduction
35(2)
Engineering Economics and Cost Analysis
35(1)
Scope of the
Chapter
35(2)
Determining the Cost of Products
37(3)
The Cost of Ownership
37(2)
Overhead or Indirect Costs
39(1)
Hidden Costs
39(1)
Design and Manufacturing Costs
40(8)
Design and Development Costs
40(1)
Manufacturing Costs
40(4)
Cost of Manufacturing Quality
44(1)
Test, Diagnosis, and Rework
45(3)
Sustainment Costs: Life Cycle, Operation, and Support
48(6)
Spare Parts and Availability: Impact of Reliability on Cost
48(3)
Warranty and Repair
51(1)
Qualification and Certification
52(2)
Making a Business Case
54(2)
Return on Investment
54(1)
The Cost of Money
55(1)
Examples
56(16)
Process Flow Model: The Manufacture of a Bicycle
56(2)
Consideration of Manufacturing Yield
58(1)
The Total Cost, Selling Price, and Cost of Ownership of a Bicycle
59(3)
Cost of Ownership
62(1)
Parametric Cost Model: Fabrication of Application-Specific Integrated Circuits
63(3)
The Return on Investment Associated with Web Banner Advertising
66(2)
Comparing the Total Cost of Ownership of Color Printers
68(2)
Reliability, Availability, and Spare Parts of New York City Voting Machines
70(2)
Bibliography
72(1)
Translating Customer Requirements into a Product Design Specification
73(18)
Voice of the Customer
73(5)
Recording the Voice of the Customer
75(2)
Analyzing the Voice of the Customer
77(1)
Quality Function Deployment (QFD)
78(7)
Introduction
78(1)
QFD and the House of Quality
79(6)
Product Design Specification
85(6)
Product Functional Requirements and Functional Decomposition
91(22)
Functional Modeling
91(8)
Introduction
91(1)
Functional Decomposition and the Axiomatic Approach: Introduction
92(3)
Functional Decomposition and the Axiomatic Approach: Two Axioms
95(2)
Functional Decomposition and the Axiomatic Approach: Mathematical Representation
97(2)
Examples of Functional Decomposition
99(14)
Introduction
99(2)
Functional Independence versus Integration versus Modularity
101(1)
Phrasing of the Functional Requirements
101(1)
Physical Coupling
101(1)
Example 1---Carton Taping System
101(3)
Example 2---Intelligent V-Bending Machine
104(2)
Example 3---High-Speed In-Press Transfer Mechanism
106(2)
Example 4---Drywall Taping System
108(2)
Example 5---Steel Frame Joining Tool
110(3)
Product Concepts and Embodiments
113(32)
Introduction
113(4)
Initial Feasibility Analysis
114(2)
Estimation Example 1
116(1)
Estimation Example 2
116(1)
Concept Generation and the Search for Solutions
117(17)
Introduction
117(1)
General Activities That Can Generate Ideas
117(1)
Ideas That Can Come from a Brainstorming Session
117(3)
Ideas That Can Come from Thinking about Simplifying Things
120(1)
Crowdsourcing: Consumers as a Source of Ideas
120(1)
Morphological Method
120(3)
TRIZ
123(8)
Bio-Inspired Concepts
131(3)
Product Modularity and Architecture
134(2)
Concept Evaluation and Selection
136(7)
Product Embodiments
143(1)
Bibliography for Bio-Inspired Concepts
144(1)
Design for Assembly and Disassembly
145(10)
Introduction
145(1)
Design for Assembly
146(7)
Why Assemble?
146(1)
Assembly Principles and Guidelines
147(1)
Summary of Design-for-Assembly Guidelines
148(4)
Manual Assembly versus Automatic Assembly
152(1)
Design for Disassembly (DFD)
153(2)
Introduction
153(1)
DFD Guidelines and the Effects on the Design for Assembly
153(2)
Material Selection
155(50)
Introduction
155(7)
Importance of Materials in Product Development
155(1)
Guidelines for Materials Selection
155(2)
Performance
157(1)
Producibility
157(1)
Reliability and Environmental Resistance
157(1)
Cost
158(4)
Ferrous Alloys
162(7)
Plain Carbon Steels
162(1)
Alloy Steels
163(1)
Low-Alloy Steels
163(3)
Tool Steels
166(1)
Stainless Steels
167(1)
Cast Irons
167(1)
Gray Irons
168(1)
Malleable Irons
168(1)
Ductile (Nodular) Irons
169(1)
Alloy Cast Iron
169(1)
Nonferrous Alloys
169(11)
Light Alloys
169(1)
Zinc Alloys
169(1)
Aluminum Alloys
170(4)
Magnesium Alloys
174(1)
Titanium Alloys
174(1)
Heavy Alloys
175(1)
Copper Alloys
175(3)
Nickel Alloys
178(1)
Tin Alloys
178(1)
Cobalt Alloys
179(1)
Refractory Metals
179(1)
Molybdenum Alloys
179(1)
Tungsten Alloys
179(1)
Special Purpose Alloys
180(3)
Low Expansion Alloys
180(1)
Permanent Magnet Materials
180(1)
Electrical Resistance Alloys
181(1)
Resistance Alloys
181(1)
Thermostat Metals
182(1)
Heating Alloys
182(1)
Polymers
183(6)
Introduction
183(1)
Thermoplastics---Partially Crystalline
184(1)
Polyethylene
184(1)
Polypropylene
184(3)
Acetals
187(1)
Nylons
187(1)
Fluorocarbons
188(1)
Polyimides
188(1)
Cellulosic Materials
188(1)
Thermoplastics---Amorphous
189(1)
Polycarbonates
189(1)
Acrylonitrile Butadiene Styrene (ABS)
189(1)
Polystyrene
189(1)
Polyvinyl Chloride
189(1)
Polyurethane
190(1)
Thermosets---Highly Crosslinked
190(2)
Epoxies
190(1)
Phenolics
191(1)
Polyesters
191(1)
Thermosets---Lightly Crosslinked
192(1)
Silicone Resins
192(1)
Acrylics
192(1)
Rubbers
192(1)
Engineered Plastics
193(2)
Mechanical Property Enhancement
194(1)
Conductivity Enhancement
194(1)
Wear Resistance
194(1)
Color
194(1)
Flame Retardant Increase
194(1)
Plasticizers
195(1)
Ceramics
195(3)
Structural Ceramics
195(1)
Electrically Insulating Ceramics
195(2)
Ferroelectrics
197(1)
Thermally Conductive Ceramics
197(1)
Magnetic Ceramics
197(1)
Soft Ferrites
197(1)
Hard Ferrites
197(1)
Composites
198(2)
Metal Matrix Composites
198(1)
Fiber-Reinforced Composites
198(1)
Carbon/Carbon Composites
199(1)
Cemented Carbides
199(1)
Functionally Graded Materials
199(1)
Smart Materials
200(2)
Piezoelectric Materials
200(1)
Magnetostrictive Materials
201(1)
Shape Memory Materials
201(1)
Nanomaterials
202(1)
Sintered Nanoparticle Solids
202(1)
Nanocrystalline Magnetic Materials
202(1)
Carbon Nanotubes
202(1)
Coatings
202(1)
Wear and Scratch Resistance
203(1)
Electrically Conductive/Insulating
203(1)
Bibliography
203(2)
Manufacturing Processes and Design
205(44)
Introduction
205(6)
Common Design Attributes
205(1)
General Guidelines for Reduced Manufacturing Costs
206(3)
Relationship to Part Shape
209(1)
Example---Steel Frame Joining Tool
210(1)
Tool Shell
210(1)
Impact Piston
210(1)
Compression Piston Chamber
211(1)
Casting---Permanent Mold
211(10)
Pressure Die Casting
211(2)
Centrifugal Casting
213(1)
Compression Molding
214(2)
Plastic Injection Molding
216(2)
Metal Injection Molding
218(1)
In-Mold Assembly
219(2)
Casting---Permanent Pattern
221(3)
Sand Casting
221(1)
Shell Mold Casting
222(2)
Casting---Expendable Pattern
224(1)
Investment Casting
224(1)
Cutting---Mechanical Machining
225(4)
Single Point Cutting: Turning and Facing
225(1)
Milling: Multiple Point Cutting
226(1)
Grinding
227(2)
Cutting---Electromachining
229(1)
Electric Discharge Machining (EDM)
229(1)
Forming---Sheet
230(3)
Blow Molding
230(2)
Sheet Metal Working
232(1)
Forming---Bulk
233(5)
Forging
233(2)
Rolling
235(1)
Extrusion
236(2)
Powder Processing
238(1)
Powder Metallurgy
238(1)
Layered Manufacturing
239(9)
Introduction
239(3)
Stereolithography
242(1)
Fused Deposition Modeling
242(2)
Solid Ground Curing
244(1)
Selective Laser Sintering
244(1)
Laminated Object Manufacturing
245(1)
3D Printing
246(1)
Comparisons of the LM Processes
246(2)
Bibliography
248(1)
Design for ``X''
249(20)
Life-Cycle Engineering
249(6)
Introduction
249(1)
Reliability
250(1)
Failure Identification Techniques
251(3)
Design for Wear
254(1)
Poka-Yoke
255(2)
Introduction
255(1)
The Basic Functions of Poka-Yoke
256(1)
Design for Maintainability (Serviceability)
257(2)
Introduction
257(1)
Standardization
258(1)
Design for Packaging
259(1)
Environmental Impact of Packaging
259(1)
Design for the Environment
260(2)
Ergonomics: Usability, Human Factors, and Safety
262(2)
Material Handling
264(1)
Product Safety, Liability, and Design
265(4)
Product Liability Law
267(2)
Product and Process Improvement
269(30)
Introduction
269(1)
What Is Experimental Design?
270(4)
Guidelines for Designing Experiments
274(1)
Designed Experiments and Statistical Process Control
274(1)
Factorial Analysis
275(14)
Analysis of Variance (ANOVA)
275(1)
Single-Factor Experiment
276(2)
Factorial Experiments
278(2)
Factorial Experiments with One Replicate
280(1)
2k Factorial Analysis
281(3)
2k Factorial Analysis with One Replicate
284(3)
Regression Model of the Output
287(1)
2k Fractional Factorial Analysis
288(1)
Examples of the Use of the Analysis of Variance
289(6)
Example 1---Manufacture of Stiff Composite Beams
289(1)
Example 2---Optimum Performance of an Air-Driven Vacuum Cleaner
289(6)
The Taguchi Method
295(2)
Quality Loss Function
296(1)
Six Sigma
297(1)
Bibliography
298(1)
Appendix A: Material Properties and the Relative Cost of Raw Materials 299(4)
Index 303
Magrab, Edward B.; Gupta, Satyandra K.; McCluskey, F. Patrick; Sandborn, Peter