How do you determine procurement costs for product design, materials, and specifications? A superb way to get valuable insights and pinpoint design improvement and cost reduction opportunities is through a product teardown study. What is a product teardown?
In simple words, the process of disassembling a part to understand how it has been made and its functionalities are known as product teardown.
A product teardown process is an orderly way to know about a particular product and identify its parts, system functionality to recognize modeling improvement and identify cost reduction opportunities. Unlike the traditional costing method, tear down analysis collects information to determine product quality and price desired by the consumers. Companies can understand their competitor’s product, on what ground it differs from their own and manufacturing cost associated.
The three primary reasons for a product teardown study are:
- Breakdown and Analysis:
It involves understanding the current technology, functionalities, and components of a product as well as identifying its strengths, weaknesses, and establishing areas for improvement.
Benchmarking is establishing a baseline in terms of understanding and representation of the product. It provides a comparison of new conceptual designs.
- Knowledge and product improvement:
It involves gaining engineering knowledge to enact new room for concept development.
The entire product teardown process can be summed up in five steps:
- Identifying the purpose of the teardown. This is to determine the models to be enacted as a result of the process
- Creating data sheet where all insights will be listed
- Gathering tools and documentation of the process
- Analyzing the distribution of product
- Disassembling of product, component measurement, and functionality assessment
- Creating a bill of materials (BOM), models, and function flow diagram
The product tear down study technique has proven to be suitable to obtain crucial data about the manufacturing method, components, build-up model, functionality and strategies of competitors to find for improvement and coming up with a more refined version of a product.
Material selection stands out to be one of the most crucial aspects of engineering design as it determines the design reliability in terms of industrial and economic viewpoints. A great design needs appropriate material combinations, or else it will fail to be a profitable product. Engineers need to choose the best materials for the same, and there are several criteria they rely upon, such as property and its reaction to given conditions.
Some important points to be included are:
- Mechanical properties: A design needs to go through various manufacturing practices depending on the material. The primary goal is to prevent the failure of the product from a material viewpoint and ensure service fit. The materials are subject to stress, load, strength, and temperature variations.
- Wear of materials: Most of the time, chances are that materials are contacting each other in a product. It can be seen in the case of gears. The selected materials should be able to withstand wear and tear.
- Corrosion: This is a condition where the importance of material selection can be witnessed the most. It is evident in products open to the environment for an extended period. Materials like iron are highly prone to corrosion. So it is essential to make that the material is corrosion resistant and capable of being used for the product.
- Manufacturing: Although the material is fit to be used for a product, it has to be appropriate for the manufacturing process. Improper machining can lead to a faulty product, and incorrect machining stems from an inability to put manufacturing functions of materials.
- Cost: Cost is a crucial fact to consider while selecting materials. Certain metals are rare to obtain, considering their availability and lengthy refining process. Although the cost factor can be neglected when performance is given priority, overall associated costs should be considered nonetheless. There is a reason why plastics have massively replaced metals in the manufacturing process.