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Company Overview Company Overview

Product Development

Concept Evaluation phase:

In the earliest part of the design phase, feasibility studies and risk analysis can be carried out to evaluate new concepts. The intention is to carry out fast evaluations to identify risks and problem areas early. Different design solutions can be considered, and the effect of design changes can be evaluated.

A product concept evaluation is a type of evaluation in which the product concept developed so far is reviewed by the user group. Generally, product concept evaluations are aimed at selecting or optimizing product concepts based on the preferences of the user group and other stakeholders. The product concepts that are evaluated can have different forms (descriptions, drawings or prototypes). Typically, a product concept evaluation takes place in a controlled environment, where a panel of people judge product concepts based on a list with predetermined issues.

Fast concept evaluation, feasibility studies and risk analysis are carried out in the early design phase. Design improvements can be performed speedily since the designer gets quick feedback on the consequences of design changes.

Understanding the initial phase of the product design, Satven has evolved different service offerings which complement the concept evaluation phase. In order to make fast concept evaluation, feasibility studies & risk analysis, Satven has worked on micro to macro level on the service offerings. With a “motto of constant improvement”, Satven is constantly working on increasing its capabilities & taking up challenges to meet the increasing customer demands. Few of the service offerings include

  • Market Research
  • Benchmarking
  • Competitor Analysis
  • Rendering & Styling
  • Reverse Engineering
  • Surfacing
  • Packaging
  • QFD (Quality Function Deployment)
  • Patent Search
  • System Development Specification

Product Engineering Phase:

An increasing demand for innovative solutions at competitive costs presents tremendous challenges for companies trying to satisfy both of these requirements. For product companies, Product Strategy governs company’s ability to outwit the competition and propel business excellence. Product engineering refers to the process of designing and developing a device, assembly, or system such that it is produced as an item for sale through some production manufacturing process. Product engineering usually entails activity dealing with issues of cost, produce-ability, quality, performance, reliability and user features.

Product engineering is an engineering discipline that deals with both design and manufacturing aspects of a product. At Satven, we not only define the right product to address the unmet needs, which is a key starting point; but also translate those needs into a product that is made on time, within acceptable budget constraints.

In the current global scenario, the product development teams of auto manufacturers are facing increased challenges to reduce development cost, improve margins and reduce time–to-market for new products. The focus is on bottom line margins which includes rising raw materials cost, decreasing product price, reduced engineering budgets and improving overall efficiency. With cost reduction as priority, auto manufacturers are trying to reduce the development cost and time.

Moving forward, OEMs dependence on suppliers will increase, as they will play a major role in developing innovative and technically advanced products. OEMs demand for modular assemblies will increase and this will drive suppliers to take more comprehensive design to manufacture responsibilities and create more value for the OEMs. Satven has broad experience in product engineering phase designed & developed over a decade of existence. Satven has mastered in most of the services that can be offered in this phase. The wider knowledge of the automotive industry requirements blended with domain specific specialists Satven is able to offer high quality solutions. Few of the high quality service baskets include

  • Design Support
  • Application Engineering
  • Dimensional Management
  • Change Management
  • Costing
  • D/PFMEA
  • DVP&R
  • Specification Management
  • Reliability & Warranty Issues

Validation Phase:

Design validation means establishing by objective evidence that product specifications conform to user needs and intended use. Verification and validation is the process of checking that a product meets specifications and that it fulfils its intended purpose. Design validation is one step close to the reality, but if being performed with close integration, the results would throw more light than reality.

The never ending urge of seeing a perfect quality product is always a challenge to the designers. The design intent has to be properly captured & validated before it takes the permanent shape. The challenge of validating the shape, fit, finish, appearance & functional specifications of a particular design always lie with the engineering departments in the automotive industry. A typical product engineering department in auto industry would have immediate customers like tooling, manufacturing, quality & sales who will constantly demand a perfect & flawless design which would fulfil their requirements.

Meshing is the foundation for all FE based CAE activity. A quality mesh is a prerequisite for reliable CFD and FE analyses projects as is a thorough comprehension of the effects of a mesh on a result. FEA and CFD meshes have some similarities in the process in which they are created, but the requirements differ particularly on the types of elements used and the source geometry required. In many cases meshing is the bottle neck for the analysis process often taking up the majority of the time in the project. Geometry quality can be directly related to the speed in which a mesh can be generated.

Manufacturing & Production Phase:

When the design is ready to go out to the world — Design done, Testing complete, Requirements satisfied, Business Plan and Marketing Analysis thumbs up — it is ready for production. For many products — and especially for inventors — this is where the real work begins. The Production phase is usually, by far, the most expensive.

The first step into production is to thoroughly document the design. This means detail drawings for the applicable parts and thorough model construction for others. This means final design optimization with an eye to minimizing costs in manufacturing. This means documentation for assembling the product (where appropriate) including bolt torque specs, adhesives application, painting, labeling, assembly order, etc.. This documentation is usually a combination of:

  • Part detail drawings
  • Component specifications – materials, processing, colors, textures, etc.
  • Assembly drawings
  • Assembly process drawings
  • Assembly instructions
  • Product specifications – Bill of Materials, assembly techniques, purchased parts, packaging, etc.
  • Manufacturing specifications
  • Final CAD models

Much of the documentation process can be done in parallel with the long lead manufacturing items like mold making, dies or pattern making.

Production:

The final production process usually includes the following steps. Detail for these steps will differ with each product and schedule.

  • Final production quotes.
  • Vendor selection and kick-off.
  • Design of special tools and/or fixtures (where needed).
  • Inclusion of final design input from manufacturers.
  • First article component verification and sign-off.
  • First assembly validation and sign-off.
  • Launch of production.
  • Sell, distribution of Products

The production processes and costs will differ widely for each product, for each manufacturing process and for each location. Some items (like plastic injection molds or casting patterns or dies) can take months to make and be very expensive. Some items require special tooling or fixtures that must be designed and validated along the way. In any case, the production process is always involved and is usually time consuming. It can also be quite costly. Choosing the right production process for the specific needs and quantities of each product is key to success.

After start of Production Phase:

A continuous improvement process (CIP) is an ongoing effort to improve products, services, or processes. These efforts can seek “incremental” improvement over time or “breakthrough” improvement all at once. Delivery (customer valued) processes are constantly evaluated and improved in the light of their efficiency, effectiveness and flexibility

Quality is a never ending quest and Continuous Process Improvement (CPI) is a never ending effort to discover and eliminate the main causes of problems. It accomplishes this by using small-steps improvements, rather than implementing one huge improvement. The Japanese have a term for this called kaizen which involves everyone, from the hourly workers to top-management.

CPI means making things better. It is NOT fighting fires. Its goal is NOT to blame people for problems or failures. . . it is simply a way of looking at how we can do our work better. When we take a problem solving approach, we often never get to the root causes because our main goal is to put out the fire. But when we engage in process improvement, we seek to learn what causes things to happen and then use this knowledge to:

  • Reduce variation.
  • Remove activities that have no value to the organization.
  • Improve customer satisfaction

Value Analysis/Engineering is a systematic and organized procedural decision-making process. It has been used in almost any kind of application. It helps people creatively generate alternatives to secure essential functions at the greatest worth as opposed to costs. This is referred to as value. It is also known as Value Analysis, Value Management, Value Planning, and a host of other names.

It answers 3 big questions: What must the item do? What does the item cost? What is the item worth?

VA/VE evaluates your products and supply chain from a unique perspective allowing for cost reduction, improved quality, and meaningful supplier relationships.

The force behind the successful shape to an idea: