Designing Products for Life Cycle Profitability (DPLCP) is a comprehensive body of knowledge that goes far beyond just the idea of designing products so that production is more cost-effective. DPLCP is an inclusive framework that describes processes, methodologies and techniques for designing products that are easier, safer, and less expensive to manufacture, distribute, use, and service. Learn how to design for sustainability for a circular economy, including material recycle and reuse.
Designing Products for Life Cycle Profitability (DPLCP) is a comprehensive body of knowledge that goes far beyond just the idea of designing products so that production is more cost-effective. DPLCP is an inclusive framework that describes processes, methodologies and techniques for designing products that are easier, safer, and less expensive to manufacture, distribute, use, and service. Learn how to design for sustainability for a circular economy, including material recycle and reuse.
Program Experience
In this course, your team will learn through brief lectures, case studies, videos, and exercises about numerous DPLCP techniques and methods. They will then explore firsthand how to apply these techniques to real products which teams of participants will disassemble, dissect, and evaluate. In two labs, your team will learn how selected products were engineered in the context of the five views of DPLCP.
The course illustrates how to enhance a product's life cycle costs with DPLCP processes, tools and methodologies. Your team will learn how to implement the DPLCP elements to reduce costs and enhance product effectiveness at your company. They will develop several hands-on presentations during this program using various templates and analytical methodologies.
Benefits
This hands-on interactive lab program teaches you how to use Design-for-X thinking in product development. You will learn to:
Apply a framework to your product development processes that specifically addresses:
Design for fabrication (DFF)
Design for assembly (DFA)
Design for environment and safety (DFE&S)
Design for logistics (DFL)
Design for serviceability (DFS)
Define measurable manufacturing variables that your company will need to properly assess life cycle costs and profitability
Build a relevant product life cycle cost and profitability model that simulates the impact of forward costs, specifically focusing on eight DPLCP economic variables
Drive necessary organizational changes for global DPLCP implementation success
Design and execute "design review workshops," that drive real-time product development transparency across all entities in the organization
Build a compendium of design expectations and rules that encourage a life cycle profitability view of product development
Promote cultural changes that will be necessary for your organization to adopt a "product design for profitability" culture
Topics
How do I create a "framework" for comprehensive life cycle product development that works with my products, technologies and enterprise culture?
What key fabrication considerations should be addressed during the product development process?
What key assembly considerations should be addressed during the product development process?
What key life cycle environmental and safety considerations should be addressed during the product development process?
What key logistics considerations should be addressed during the product development process?
What key life cycle serviceability considerations should be addressed during the product development process?
How do I perform a forward-looking life cycle profitability analysis?
How can we measure life cycle costs and profitability, and how will these values drive product portfolio decisions?
How do I "break" silo-thinking and replace it with a more transparent product development process and culture?
Program Detail
Introduction to DPLCP Framework
DPLCP goals and strategies
How DPLCP contributes to enterprise valuation
Product life cycle cost implications of design
Framework for DPLCP process
Product development process in a DPLCP environment
Importance of designing for manufacturability
Manufacturing system inputs that are "designed in" by engineering
A new definition of product cost
Results of poor product development
Overview and Drill-Down on Five DPLCP Critical Elements
Design for fabrication (DFF)
Design for assembly (DFA)
Design for environment and safety (DFE&S)
Design for logistics (DFL)
Design for serviceability (DFS)
Core Technical Principles of DPLCP
DPLCP product development guidelines
A new product development paradigm is needed
Seven manufacturing variables that must be addressed in the design and engineering phases of product development
Guidelines:
Use off-the-shelf components
Reduce total part-count
Apply modular design
Follow specific engineering guidelines
Avoid right and left parts
Design parts with symmetry
If parts symmetry is not possible, design with substantial asymmetry
Design parts to be multi-functional
Design parts for multiple uses
Avoid separate fasteners
Maximize compliance
Minimize physical assembly directions
Design for fixturing
Minimize tooling complexity by concurrently designing tools
Specify optional tolerances for robust design
Understand tolerance step functions and set tolerances wisely
Apply Suh's Theory of Design
Specify quality components from quality suppliers
Select quality suppliers that are predictable
Minimize setups
Minimize material handling
Minimize cutting tools
DPLCP Exploration Lab #1
Working in teams, participants will disassemble and characterize real products in terms of:
External packaging
Internal packaging
Product and accessories
Level-1 assemblies
Level-2 and below subassemblies
Participants will identify all components (including labeling) and describe considerations that would likely be considered in traditional product design and engineering phases.
Each team will document all findings, including photographs, BoM's and other important product data derived from the detailed tear-down activity.
Each team will make presentations using provided templates.
DPLCP Economic Analysis Methods
Identification of product cost elements
Different ways to view product profitability
What’s happening to direct labor costs?
Direct material costs versus performance tradeoffs
Material acquisition burden costs
The difference between product burden and overhead costs and why this is important to the engineer
Eight key DPLCP implementation and redesign costs
Typical product cost analysis methodology
DPLCP Exploration Lab #2
Participants will continue their physical product tear-down and define new approaches to design that will improve the product through:
Design for fabrication (DFF) principles
Design for assembly (DFA) principles
Design for environment and safety (DFE&S) principles
Design for logistics (DFL) principles
Design for serviceability (DFS) principles
This exploration lab will result in a complete product engineering package that defines all DCLCP issues for the selected products. It will define specific design improvements that support DCLCP principles along with an estimate of value derived from the recommended improvements.
Each team will make presentations using provided templates.
Implementation of DPLCP
How to build a robust DPLCP culture
The new DPLCP product development organization paradigm
Critical DPLCP implementation issues
How customer requirements drive all design issues
Establishing preferred material sets
Establishing preferred parts lists
Integrating product and manufacturing safety requirements into the product design and engineering phases
Building a manufacturing plan during the product engineering phase
Developing a clear view of product reliability requirements
Building a product sustainment plan
Enabling tools for integrated global product development
The design review seminar… a staple in the DPLCP environment
Key cultural requirements defined from the lens of the seven deadly sins of manufacturing
What should you expect from your engineering function in a DPLCP environment
Who Should Attend
This program will provide substantial value to anyone who will benefit from product development that maximizes profitability over a product’s entire life cycle. Specifically, this program will benefit engineers and engineering leaders, supply chain professionals, customer service leaders, industrial engineers and operations leaders.
This program blends theory with hands-on exercises. Participants will execute a design for manufacturability process in reverse—tearing down and reassembling real products in workshop labs.
Instructors
Alan G. Dunn
Next-Generation Supply Chain and Operations, Executive Education
