From Design To Production

New product design and development is a great challenge. It requires creativity, skills, knowledge and resources—but R&D is only part of the work needed to launch a new product.
Production implementation is the process of translating a product design (in the form of CAD files, 2D drawings, and prototypes) into a ready-for-sale product.

Underestimating the time and cost of the production implementation work is a common grave mistake. The production implementation might seem like a straightforward process, but it can take 3-4 times longer than the R&D stage. The reason for this miscalculation is what I call the “trip planning syndrome.” You cannot plan everything in advance; there are always surprises and unexpected failures. As Pareto claimed, it’s the small (and hard to predict) things that cost the most.

Here is a list of common potential issues and failures to help you prepare your production implementation work and reduce costly breakdowns.

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Design-To-Cost (DTC) is one of the most important aspects of a product design. After all, in an average product, every dollar in cost equals five dollars in sales (see calculation). Most product designers and engineers know how to design cost-effective products in terms of engineering and production but tend to overlook the other aspects of DTC.

In this article, I list the main components of DTC and explain how to deal with them during the product design process.

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