PRODUCTION AND

OPERATIONS
MANAGEMENT

Chapter 5
DESIGN OF PRODUCTION
SYSTEMS
 Chapter 5
Design of Production Systems

Product Design, Process Design and

Production Design
 Product Design: Concerned with form and function of a
product. It refers to the arrangement of elements or parts
that collectively form a product.
 Process Design: Concerned with the overall sequence of
operations required to achieve the design specification of
the product.
 Production Design: Concept of designing products from
the point of view of producibility.

Production and Operations Management

Himalaya Publishing House By K. Aswathappa & K. Shridhara Bhat
 Chapter 5
Design of Production Systems

Importance of Product Design

 A good product design can improve the
marketability of a product by making it easier to
operate or use, upgrading its quality, improving
its appearance, and/or reducing manufacturing
costs.
 An excellent design provides competitive
advantage to the manufacturer, by ensuring
appropriate quality, reasonable cost and the
expected product features.

Production and Operations Management

Himalaya Publishing House By K. Aswathappa & K. Shridhara Bhat
 Chapter 5
Design of Production Systems

Objectives of Product Design

(i) The overall objective is profit generation in the long run.

(ii) To achieve the desired product quality.

(iii) To reduce the development time and cost to the minimum.
(iv) To reduce the cost of the product.
(v) To ensure producibility or manufacturability (design for
manufacturing and assembly).

Production and Operations Management

Himalaya Publishing House By K. Aswathappa & K. Shridhara Bhat
 Chapter 5
Design of Production Systems

Factors Influencing Product Design

i. Customer requirements
ii. Convenience of the operator or user
iii. Trade off between function and form
iv. Types of materials used
v. Work methods and equipments
vi. Cost/Price ratio
vii. Product quality
viii. Process capability
ix. Effect on existing products
x. Packaging

Production and Operations Management

Himalaya Publishing House By K. Aswathappa & K. Shridhara Bhat
 Chapter 5
Design of Production Systems

Characteristics of Good Product

Design
i. Function or performance
ii. Appearance or aesthetics
iii. Reliability
iv. Maintainability
v. Availability
vi. Producibility
vii. Simplification
viii.Standardisation
ix. Specification
x. Safety
Production and Operations Management
Himalaya Publishing House By K. Aswathappa & K. Shridhara Bhat
 Chapter 5
Design of Production Systems

Approaches to Product Design

i. Designing for the customer
• Industrial design
• Voice of the customer
• Quality function deployment (QFD)
ii. Designing for Manufacture and Assembly (DFMA)
• “Over-the-wall approach”
• Concurrent engineering
• Design for Manufacturing (DFM) Design for
Assembly (DFA)

Production and Operations Management

Himalaya Publishing House By K. Aswathappa & K. Shridhara Bhat
 Chapter 5
Design of Production Systems

iii. Designing for ease of production (or for

producibility or manufacturability)
• Specification
• Standardisation
• Simplification
iv. Designing for Quality
a. Designing for robustness (or robust design)
b. Designing for production
i. Modular design
ii.Designing for automation
c. Designing for reliability

Production and Operations Management

Himalaya Publishing House By K. Aswathappa & K. Shridhara Bhat
 Chapter 5
Design of Production Systems

v. Designing for Ergonomics

vi. Designing for environmental protection
vii. Designing for recycling
viii. Designing of disassembly (DFD)
ix. Designing for mass customisation
Delayed differentiation and modular designs are
two tactics used to make mass customisation
possible.

Production and Operations Management

Himalaya Publishing House By K. Aswathappa & K. Shridhara Bhat
 Chapter 5
Design of Production Systems

x. Other issues in product design are (a) Computer

aided design (CAD), (b) Value engineering or
value analysis which
• Computer aided design: Use of computer
graphics for designing the product helps to
generate a number of alternative designs and
identify the best alternative which meets the
designer’s criteria.
• Value engineering/Value analysis: Concerned
with the improvement of design and
specifications at various stages of product
planning and development.

Production and Operations Management

Himalaya Publishing House By K. Aswathappa & K. Shridhara Bhat
 Chapter 5
Design of Production Systems

Process Planning and Process Design

 After the final design of the product has been

approved and released for production, the
production planning and control department
takes the responsibility of process planning and
process design for converting the product design
into a tangible product.

Production and Operations Management

Himalaya Publishing House By K. Aswathappa & K. Shridhara Bhat
 Chapter 5
Design of Production Systems

What is a Process?

 Process: A process is a sequence of activities that is

intended to achieve some result, for example, to create
added value for the customers

Production and Operations Management

Himalaya Publishing House By K. Aswathappa & K. Shridhara Bhat
 Chapter 5
Design of Production Systems

Process Planning
 Process planning: Concerned with planning the
conversion processes needed to convert the raw
material into finished products.
 Process design: Concerned with the overall
sequences of operations required to achieve the
product specifications
 Operations design: Concerned with the design
of the individual manufacturing operation.

Production and Operations Management

Himalaya Publishing House By K. Aswathappa & K. Shridhara Bhat
 Chapter 5
Design of Production Systems

Process Selection

 Process selection refers to the way production of

goods or services is organised.
 Three primary questions to be addressed before
deciding on process selection are:
(i) How much variety of products or services
will the system need to handle?
(ii) What degree of equipment flexibility will be
needed?
(iii) What is the expected volume of output?

Production and Operations Management

Himalaya Publishing House By K. Aswathappa & K. Shridhara Bhat
 Chapter 5
Design of Production Systems

Process Strategy

 Process strategy: An organisation’s approach to

selection of the process for the conversion of
resource inputs into outputs.
Key aspects in process strategy include:
i. Make or buy decisions
ii. Capital intensity and
iii. Process flexibility

Production and Operations Management

Himalaya Publishing House By K. Aswathappa & K. Shridhara Bhat
 Chapter 5
Design of Production Systems

Process Strategies

• Process Focus
• Repetitive Focus
• Product Focus

Production and Operations Management

Himalaya Publishing House By K. Aswathappa & K. Shridhara Bhat
 Chapter 5
Design of Production Systems

Process Selected Must Fit with Volume and Variety

Production and Operations Management

Himalaya Publishing House By K. Aswathappa & K. Shridhara Bhat