Improved new product development through enhanced design architecture for engineer-to-order companies

There are many challenges that face companies today in the new product introduction process. These can include reduced design times, fast times to market, improved quality and the need for constant price reductions in order to keep up with the competition. Engineer-to-order firms face even more challenges because of the ‘build to order’ way that they must do business. This study presents new ways for these companies to meet the challenges posed by the market using a business case relating to the product introduction process at a mid-size (～$75 million annual sales) engineer-to-order manufacturer of flexible printed circuits. The company has developed a new product introduction process that seeks to improve quality and delivery times as well as process development for the project at hand. These suggested outcomes of the improved process are generic and widely applicable to contract manufacturers involved in the new product introduction process enabling them to work closely with customers thereby effectively addressing their design concerns. The updated procedures are examined in-depth and the associated forms and record-keeping methods are presented and analysed. The new product introduction process utilises Deming's plan, do, check and act process improvement cycle. Finally, various contributions emanating from the study that enhance our understanding of any engineer-to-order new product development environment are presented.     

Enhancing product development through a dynamic information interchange approach

In today's increasingly competitive environment, firms are experiencing growing pressure to reduce the product development lead time to meet market expectations. In this paper, a Responsive Product Development System (RPDS), which is used to model the product development process and the components of the process with object technology, introduces a dynamic product information schema characterized by its ability to provide design practitioners with a product data exchange standard, thus transforming data to information and then knowledge. To validate the feasibility of the proposed schema, a case study has been conducted in a plastic product factory based on the suggested approach. Following feedback from these companies, a further review of the design of the proposed system has been conducted to ensure efficient information flow across the heterogeneous computing environment. A measure of loss to society associated with RPDS in product development time is also included as a system evaluation.     

Strategic capacity management: Meeting technological demands and performance criteria

Although manufacturing contributes a large part to the current performance of companies, few companies deal systematically with issues related to strategic capacity management. As well as decisions on outsourcing and acquisition of resources, this involves triggering process innovation, process development and improving performance by adapting organizational structures. Action Research in companies reveals the importance of capacity management at a strategic level as well as the implementation at tactical and operational levels. The methods of Strategic Capacity Management, as proposed in this paper, provide an industrial company with tools for implementing its manufacturing strategy. Only the design of organizational structures has received attention in the past--little research has been done in the area of manufacturing technology and integral models for sourcing. Through matching product configurations with product-market strategies and product development, the methods point to areas of improvement. The new methods include decision-models for outsourcing and capacity management, product development, and a manufacturing technology scan. All the methods deploy performance evaluations as a base for selecting alternatives to define improvements. These improvements lead to decisions on investments for resources, resource utilization and development of processes, including initiation of manufacturing technologies, as demonstrated by four case studies.     

The use of best design practices: An analysis of US navy contractors

Rapid and successful introduction of new products is a potentially significant source of competitive advantage for manufacturing firms. Organizations need to identify and manage those critical elements of the product development process (PDP) that have a positive influence on new product success. This research identifies the distinctive product development and design practices, policies and tools currently followed by companies (Navy contractors) that participated in an empirical research study known as the Best Manufacturing Practices Program. A summary of practices reported in the case studies is compiled using content analysis techniques, and the most interesting practices by individual companies are highlighted. We find numerous examples of sophisticated CAD techniques being used to enhance the development process, including expert system design advisers, computer simulation, and design databases. Companies are emphasizing the design policies of concurrent engineering and teamwork, and documenting design process knowledge into design manuals. Company effort still appear focused primarily on the phase of detailed design rather than the concept selection phase.     

Jetting into the 21st Century: Water-jet cutting of seals and gaskets

In the January 2001 issue we reported on a novel development in the manufacture of alternatives to asbestos sealing products, namely a ‘Triple Alliance’ which led to an award-winning development in the world of water jet-cutting technology. Three UK-based engineering companies have brought to commercial fruition a new system which has great potential for a wide variety of applications, not the least being the manufacture of seals and gaskets made from robust materials such as graphite. However, that article — Water-jet cutting machine offers accurate ‘green’ gasket cutting — elicited responses from other companies active in the field. This has led us to return to the topic with a more general overview of this advanced manufacturing process. In this article we look at the world's biggest market for sealing product — North America — where a growing number of service companies are augmenting their existing cutting processes with water-jet machines.     

An integrated approach to evaluating conceptual design alternatives in a new product development environment

As many companies have demonstrated over time, a conceptual design for a new product contributes greatly to an improvement in competitiveness, because it permits a reduction of costs, an increase in quality, and, often, a shortening of the time necessary to get the product on the market. That is why the evaluation of conceptual design alternatives created in a new product development (NPD) environment has long been very vital and a critical point for the future success of companies in fast-growing markets. These alternatives can be evaluated using the analytic hierarchy process (AHP), one of the most commonly used multiple criteria decision making (MCDM) techniques. This technique is used to reduce the number of conceptual design alternatives after ranking them using the scores obtained from the process. Furthermore, another technique, simulation analysis integrated with the AHP, is also used to help decision makers (product engineers or managers) perform economic analyses of the AHP's high-score alternatives using data from the generated simulation model of a real-life manufacturing system in which the final alternative is produced. In short, the objectives of this research are: first, to use the AHP technique to evaluate conceptual design alternatives in a NPD environment; second, to use a simulation generator integrated with this technique in order to perform economic analyses for the AHP's high-score alternatives. Finally, the results of both techniques, simulation and AHP, are used in a benefit/cost (B/C) analysis to reach a final decision on the conceptual design alternatives.     

Critical Success Factors for New Product Development in Biotechnology Companies

The development of new products has become increasingly critical for the competitiveness of companies, due to increased diversity and variety of products, the reduction of product life cycles, and, primarily, globalization of markets. Thus, the identification and prioritization of critical success factors for developing new products is important, particularly for the high degree of risk and uncertainty involved. The main objective of this article is the identification and prioritization of critical success factors in new product development projects in biotechnology companies in the state of Minas Gerais, Brazil. The research method used was a survey questionnaire, which was sent to a sample of 31 biotechnology companies in Minas Gerais state. The principal findings of this research are that interpersonal skills/relationships of the project leader and technical skills are the most critical factors for successful new product development in this industry. The implications for the biotechnology industry in general, as well as for those responsible for managing new product development, are discussed.     

Bridging customer knowledge to innovative product development: a data mining approach

In the big data era, firms are inundated with customer data, which are valuable in improving services, developing new products, and identifying new markets. However, it is not clear how companies apply data-driven methods to facilitate customer knowledge management when developing innovative new products. Studies have investigated the specific benefits of applying data-driven methods in customer knowledge management, but failed to systematically investigate the specific mechanics of how firms realised these benefits. Accordingly, this study proposes a systematic approach to link customer knowledge with innovative product development in a data-driven environment. To mine customer needs, this study adopts the Apriori algorithm and C5.0 in addition to the association rule and decision tree methodologies for data mining. It provides a systematic and effective method for managers to extract knowledge ‘from’ and ‘about’ customers to identify their preferences, enabling firms to develop the right products and gain competitive advantages. The findings indicate that the knowledge-based approach is effective, and the knowledge extracted is shown as a set of rules that can be used to identify useful patterns for both innovative product development and marketing strategies.     

A STEP-compliant product data model for injection moulding products

In the current rapidly changing manufacturing environment, most manufacturing companies have realised that the ability to quickly develop a customised product at competitive prices is very crucial for them to survive in the keen competitive global market. Product modelling has been recognised as one of the key factors in determining the success of various product development strategies and for industrial competitiveness now and in the future. Standard for Exchange of Product model data (STEP) is an international standard designed to provide a complete, unambiguous, computer-readable definition of the physical and functional characteristic of a product through its lifecycle. This paper proposes a STEP-compliant product data model to fully support the complete product information representation and management for injection moulding product development. The data model is developed based on the structure of an injection moulding company. The entire data model consists of six data models which are defined to express information from various departments of the company. The data model is described in EXPRESS language, which can be integrated with other STEP-based product data models and databases. Consequently, the proposed system can be further extended for helping other injection moulding manufacturers to improve their product development process. An information sharing prototype system is implemented based on the proposed product data model to demonstrate the feasibility of the approach.     

Process development: a theoretical framework

There have already been a number of review articles that focus on product development, but none on process development. Process development is technically difficult, time-critical and competitively important, thus worth being explored as a distinct unit of analysis. This paper develops a theoretical framework to fill this gap in knowledge based on a comprehensive literature review. Five objectives for process development are summarised to align with the goal of product realisation, and 12 enablers (including intra-functional enablers, inter-functional enablers, and learning enablers) are identified and discussed. The authors first locate process development in the product realisation process (including product design, process design, process execution and process improvement) and draw necessary parallel factors between product design and process design as a foundation. Then the attributes of all relevant literature are organised and general principles for successful performance of development projects are used to infer the enablers. The developed framework offers opportunities to further verify the new enablers and theoretical links in future studies. One implication is that process development should be viewed as a strategic function for competitive edge and as such specific measures should be set to create an environment that is conducive to successful performance.     

Dynamic supply chain design: a Delphi study of drivers and barriers

Supply chain management has both in academia and practice proven its important role to sustain and further develop companies’ competitive advantages. This is with initiatives that focus on cost-efficiencies and turnover improvement. During the last two decades, companies have faced complexity in their supply chains currently with increased global operations. The dynamic business environment forces companies to secure a competitive (re-) design of their supply chains. This paper seeks to advance the understanding on the drivers and barriers for such designs. In total, 39 experts (30 from industrial enterprises, 4 senior supply chain consultants and 5 supply chain management professors) have participated in a four-step Delphi study and have identified main drivers for dynamic supply chain design as being cost reduction, delivery reliability and change in demand for agility. The main barriers are identified as forecasting being too weak, supply chain complexity and product portfolio complexity. In addition, an explorative factor analysis has been carried out to identify how drivers and barriers can be grouped together. Finally, the paper compares the drivers and barriers underlining different competitive strategies.     

基于生态伦理的产品再设计研究

通过阐释生态伦理的概念,从产品再设计的功能、形态、结构、材料等方面出发,以实际产品为例进行全面地分析,并且将研究结论运用到具体的产品设计中进行实证。研究表明:基于生态伦理的产品再设计系统有助于企业未来产品战略的发展,对人类生存环境的改善具有积极意义。并且将生态伦理作为产品再设计的伦理基础和哲学基础,对于规范和约束设计行为具有重要的意义。     

Process Uncertainty: A New Dimension for New Product Development

Abstract

Companies pursuing product leadership continually push products into innovative technology areas and new unknown markets. As companies continue to strive for continuous innovation, often leapfrogging even their own technology, new product development (NPD) processes play an increasingly important role in defining the success or failure of many new innovations. In addition, increased competitive rivalry is driving companies to commercialize their new products much more quickly. To meet these pressures, new strategies are being used to supplement the conventional new product development process that consists of strategy formulation, idea generation, screening and evaluation, development, testing, and launch. The primary objective of each of these innovation strategies is to attain sustainable competitive advantage for the company and achieve higher overall performance.

Our research examined product and service innovation strategies of six projects. Half of which were considered successful and the other half failures. Using several emerging innovation strategies including process-driven, speed-to-market, quantitative, market-driven, technology-driven, and learning-driven to classify these projects, we evaluated the innovation strategies employed in an attempt to determine the overall NPD strategy effectiveness. In addition, we also attempted to identify relevant critical success factors and associated activities to construct an ideal innovation strategy model.

In the projects we studied, we found that no one best strategy leads to successful innovation. While evaluating areas of uncertainty that impact project success, we determined that a new dimension, process uncertainty, plays as important a role as market or technical uncertainty previously examined in the emerging scholarship. Furthermore, the insights that were discovered by comparing the different innovation strategies led us to formulate the technical-market-process (TMP) uncertainty mode. The TMP model serves as a predicator for identifying the appropriate innovation strategies that can be brought together to drive project success. We conclude that the combination of identifying the appropriate innovation strategies and proficiently executing these strategies is the key to successful new product development.     

A cost-based methodology for evaluating product platform commonality sourcing decisions with two examples

As more US companies source tooling development and manufacturing overseas in countries like China and Taiwan, are the need and primary drivers for product platforms diminishing? As tooling cost is reduced to a very small percentage of the total project cost, combined with availability of inexpensive purchased components and low labour rates, the need to develop product platforms can decrease substantially. Low cost outsourcing has given firms the ability to develop and manufacture products cheaply without having to spend the additional time and effort to develop product platforms and families. In this paper, two examples involving two consumer product companies and their product lines are presented. Product family components and estimated tooling costs are analyzed, as well as development timing and profit margins to demonstrate why companies are moving away from product platforms in certain types of consumer products. A novel methodology using component commonality decisions relating to major cost drivers is introduced and applied to both examples. Based on the evidence from the examples presented in this paper, there appears to be little financial or functional benefit to develop product platforms that share common components or subsystems when these products are being manufactured offshore; however, even when considering outsourcing, platform-based product development principles can still yield tangible improvements in production costs over the life of the product.     

Relationships between lean product development enablers and problems

The lean product development (LPD) approach uses lean principles and enablers (tools, techniques and practices) to reduce waste and continuously improve the product development processes (PDP). Other than reducing product development lead time, LPD also aims at improving quality by reducing problems that might occur during the process. Several LPD enablers are proposed in the existing literature; however, there is limited knowledge on how these enablers may effectively counteract the occurrence of problems in the PDP. We empirically tested the association between 4 groups of LPD enablers and 11 groups of LPD problems in a sample of 64 companies that are undergoing lean implementation in the shop floor and administrative areas. There are two major contributions here. First, we propose an empirically validated instrument for assessing the adoption of LPD enablers and the incidence of LPD problems in companies filling an existing gap in the literature. Second, we provide understanding on how LPD enablers can mitigate the incidence of LPD problems, allowing companies undergoing lean implementation to better manage their PDP. Moreover, some results demonstrate that the association between enablers and problems may not be as suggested in the existing literature.     

The transformation of Lebanese firms from ISO 9000 certified to TQM.

Over the past decade, the most effective method of implementing a quality system has been ISO 9000 certification. Lebanese companies have recently followed the same path of adopting and improving their status in quality systems. The overwhelming belief is that ISO 9000 is, by itself, not enough. It is a first stepping-stone in the road to business excellence, but ISO 9000 does not guarantee an improvement in the product or service being offered. All indications are that Total Quality Management (TQM) is the method for improving quality as a whole. This improvement is, of course, entirely reliant on the proper implementation and understanding of the scope and underlying objectives. The relatively new adoption of TQM as an effective tool in the struggle to achieve substantial improvements in quality is made clear in the results of a survey that are presented in this article. Recommendations as how to make the transition between ISO 9000 and TQM are made, and a discussion is provided of the need for organizational change, both internal and external, within companies in the Lebanese market. The aim of this work is to present a clear representation of what is actually occurring within the Lebanese domestic market with regards to the understanding the TQM philosophy.     

The Needs and Benefits of Applying Textual Data Mining within the Product Development Process

As a result of the growing competition in recent years, new trends such as increased product complexity, changing customer requirements and shortening development time have emerged within the product development process (PDP). These trends have added more challenges to the already‐difficult task of quality and reliability prediction and improvement. They have given rise to an increase in the number of unexpected events in the PDP. Traditional tools are only partially adequate to cover these unexpected events. As such, new tools are being sought to complement traditional ones. This paper investigates the use of one such tool, textual data mining for the purpose of quality and reliability improvement. The motivation for this paper stems from the need to handle ‘loosely structured textual data’ within the product development process. Thus far, most of the studies on data mining within the PDP have focused on numerical databases. In this paper, the need for the study of textual databases is established. Possible areas within a generic PDP for consumer and professional products, where textual data mining could be employed are highlighted. In addition, successful implementations of textual data mining within two large multi‐national companies are presented. Copyright © 2003 John Wiley & Sons, Ltd.     

应用于快速响应设计的产品动态模型

通过分析产品模型的研究现状,论述建立适应产品快速响应设计需求的产品模型的必要性,并指出相应的产品模型应具有的特性。在此基础之上,引入产品动态模型定义,分析其子模型、子模型的多视图定义及表示方法。     

Balancing concurrent engineering environmental factors for improved product development performance

Global competitive pressure has motivated many companies to change to a more rapid form of product development such as concurrent engineering (CE). Researchers have shown that without establishing the appropriate environments for CE, companies may fail to achieve all the benefits of using CE as a product development process. The primary purposes of this study were to determine: the relationships between a select group of environmental factors that contribute to a successful CE program, and the effects of a balanced approach among the factors on performance. This research design for this study is based on two case studies and a survey of product development managers. Data and information gathered from the case studies and the survey are used in ANOVA statistical procedures to examine the relationship between CE environmental factors and product development performance. Among other things, the results of this study show that CE factors such as the size of the project are less important than balancing the resources (i.e. technology and human) of the organization.     

Lean Product Development—Faster,Better … Cleaner?

To address this challenge, lean product development has emerged to become the leading improvement methodology for companies toward the creation of a competitive advantage on innovation and technology leadership. While lean product development has its origin in the best practice studies of Japanese car manufacturers such as Toyota, it has been further elaborated in defence and aerospace organizations over the last two decades, and recently empirical evidence has become available for successful introductions in sectors different from the traditionally-studied environments. The primary purpose of this work is to untangle the fuzziness that still surrounds lean product development and to ground the key aspects of lean product development based on insights from six studies published in a special issue of the Engineering Management Journal on this topic. This demonstrates how better and faster product development can be achieved through the integration of lean principles with the best of more traditional new product development (NPD) practices, into a holistic system that can be characterised by value-focused and risk-based decision making, the socio-technical integration of people and process, improved project, pipeline and portfolio management, optimized knowledge management, and the creation of a learning organization. Unfortunately, while the increasing global competition offers the potential to improve the quality of life for many, the spirit of faster, better, and cheaper also threatens to endanger the future of our planet as a whole. As the majority of a product’s social and ecological impacts are committed in the design phase, it, therefore, seems imperative to investigate the integration of lean product development and eco-design principles. As a result, this work also explores the symbiosis of both approaches through the identification of tools and methods that can support the triple bottom-line goals for a sustainable future of life and business.