Volvo Cars Corporation (VCC) is devoted to Lean and Six Sigma, and has lately considered an imple-mentation of Design for Manufacturing and Assembly (DFMA) with the purpose of improving their product design process and production. The goal for this project work is therefore to investigate if DFMA is a beneficial method for VCC to use, how DFMA can be used and suggest a DFMA method. A literature study is performed as a starting point to understand DFMA methods and its possibilities. Scientific articles, technical books and online sources is used during the study in order to gather in-formation regarding DFMA implementations, application areas, approaches and potential risks that need to be eliminated for a successful implementation. In order to map the product development and manufacturing processes of VCC interviews are per-formed. The interviews also gathered information regarding what VCC employees thinks of DFMA and how they wish to use it. This information is compiled into a demand specification where the de-mands are weighted after importance by the interviewees. After the pre-study, three idea generation sessions is performed with three different focus groups. The generated ideas are then evaluated and classified. The remaining ideas are classified with the purpose of enabling the possibility to use a morphological chart to build whole concepts from the single ideas. Three concepts are chosen amongst the generated concepts. These concepts are then evaluated against the weighted demand specification. The concept considered most suitable is further devel-oped which resulted in a proposed DFMA method for VCC. A case study on a product is performed in order to communicate, test and evaluate the final DFMA method. The project is rounded off with discussions regarding DFMA and the suggested method from sustain-ability point of view and how to motivate usage. All results and discussions from the project are handed over to the company, enabling further research on a possible implementation of DFMA in the organization. / Volvo Cars Corporation arbetar hängivet efter metoderna Lean och Sex Sigma och har avsikt att im-plementera Design for Manufacturing and Assembly (DFMA) i syfte att förbättra deras produkt- och produktutvecklingsprocess. Målet med detta arbete är att undersöka om DFMA är en värdefull me-tod för VCC att använda och hur metoden kan tänkas användas och implementeras inom organisat-ionen. Som utgångspunkt för att förstå DFMA metoden och dess möjligheter genomförs en litteraturstudie. Under studien granskades aktuella vetenskapliga artiklar, tekniska böcker och webbkällor i syfte att samla information om DFMA-implementeringar, användningsområden, tillvägagångsätt och potenti-ella risker som behövs elimineras för en lyckad implementation av metoden. Vidare utförs intervjuer i syfte att kartlägga produktutvecklings- och tillverkningsprocessen samt samla information om hur anställda ställer sig till, och önskar använda DFMA. Denna information sammanställs sedan till en kravspecifikation där kraven i sin tur viktas av intervjuobjekten efter hur viktiga de anses vara. Tre idégenereringssessioner utförs därefter med tre olika fokusgrupper. Dessa idéer gallras sedan ut och klassificeras för att sedan kombineras med hjälp av en morfologisk tabell i syfte att bygga kon-cept av de enskilda idéerna. Tre koncept väljs ut bland de genererade koncepten. Dessa koncept utvärderas sedan mot varandra med kravspecifikationen som bedömningsskala. Det koncept som bedöms som mest lämpligt vidare-utvecklas och en föreslagen metod för VCC tas fram. För att testa och illustrera den slutgiltiga meto-den genomförs en fallstudie på en produkt. Arbetet rundas av med diskussioner kring DFMA och den föreslagna metoden ur både hållbarhets-synpunkt och motivationssynpunkt. Samtliga resultat och diskussioner överlämnas sedan till företa-get för att möjliggöra vidare undersökningar kring en eventuell implementation av DFMA. / DFMA FMEA DFM DFA Lean Produktdesign Metodutveckling

The notion of sustainability has become an extensive area of research ever since the term emerged in the late 1980s, due to the negative effects of unsustainable production and consumption patterns on environmental stewardship, social equity and economic development. There have been various approaches developed for product design and education within the context sustainability. Biomimicry is one of those approaches, and its implications for product design education have recently started to be explored. In this study, an educational tool - Biomimicry Sketch Analysis (BSA) - was developed and integrated into the idea-generation phase of an educational design project at the undergraduate level in the Department of Industrial Design at the Middle East Technical University (METU). This integration is analyzed throughout the graduate thesis study, to understand and explore the implications of the biomimicry approach for sustainability in product design education. The educational tool within this approach was found as influential among the third year industrial design students for the idea-generation phase, yet the results of this study included both pros and cons for the incorporation of the BSA exercise.

Este trabalho aborda a avaliação do processo de projeto e desenvolvimento do produto do ponto de vista do projetista de nível superior. Ao fazê-lo, o autor espera estar pavimentando um caminho, que eventualmente, conduza a um método mais amigável de avaliar a qualidade do processo de projeto do produto e que possa vir a ser realmente considerado útil por divisões e/ou organizações de projeto. As razões para a seleção desta abordagem são explicadas. Ressalta-se também, que o trabalho envolve duas fases: a pesquisa preliminar e a pesquisa propriamente dita. Apresenta-se em seguida uma discussão que conduz à seleção de uma metodologia que combina a utilização da abordagem SERVQUAL e do método do incidente crítico (CIT) na primeira fase. Introduz-se o conceito central de fator de eficácia, bem como se estabelece suas relações com os itens de satisfação e as dimensões SERVQUAL. Com base nos resultados da fase preliminar, elabora-se um questionário de pesquisa abrangente, que é submetido a um grupo de projetistas de nível superior do setor automotivo, compreendendo as operações brasileiras de duas grandes montadoras internacionais, de dois fornecedores diretos (Tier 1) das montadoras e de uma grande montadora internacional de caminhões e ônibus. Os dados obtidos através das respostas ao questionário são compilados, apresentados e discutidos dentro de cada ambiente organizacional. Faz-se então uma análise conjunta, a fim de identificar aquelas ações gerenciais consideradas pelo setor automotivo como sendo mais importantes, tanto para garantir, quanto para avaliar a eficácia do processo de projeto e desenvolvimento do produto. Classifica-se essas ações em ações gerenciais de garantia e de avaliação de acordo com critérios fornecidos pelas normas ISO da qualidade. Finalmente, com base nas ações gerenciais de avaliação, define-se indicadores e se propõe um índice de eficácia único e flexível, que pode ser calculado utilizando-se, tanto dados organizacionais, quanto setoriais para fins de avaliação e benchmark. / This work approaches the subject of product design process evaluation from the designer?s point of view. In so doing, the author hopes to be paving the way that may eventually lead to a more ?friendly? method of evaluating the quality of the product design process and which may actually be found useful by design divisions and/or organizations. The reasons for selecting such an approach are explained. It is also pointed out that the work involves two phases: Preliminary research and research proper. Then, a discussion is made leading to the selection of a methodology combining SERVQUAL and the critical incident technique (CIT) for the first phase. The central concept of effectiveness factor is introduced and its relationship with satisfaction items and SERVQUAL dimensions is established. Based on the results of the preliminary phase a comprehensive questionnaire is drawn up, and submitted to a selected group of designers in the automotive industry, comprising Brazilian plants of two major car manufacturers, two tier 1 suppliers and one major truck (lorry) and bus manufacturer. Data provided by the answers to said questionnaire are compiled, presented and discussed within each organizational environment. A joint analysis is then carried out in order to identify those management actions that are considered by the automotive industry as being more important for both assuring and evaluating the effectiveness of the product design and development process. Assurance and evaluation management actions are classified according to criteria supplied by the ISO quality management standards. Finally, based on the evaluation management actions indicators are defined and a single and flexible effectiveness index is proposed, which can be calculated using both company and industry data for evaluation and benchmark purposes.

Este trabalho aborda a avaliação do processo de projeto e desenvolvimento do produto do ponto de vista do projetista de nível superior. Ao fazê-lo, o autor espera estar pavimentando um caminho, que eventualmente, conduza a um método mais amigável de avaliar a qualidade do processo de projeto do produto e que possa vir a ser realmente considerado útil por divisões e/ou organizações de projeto. As razões para a seleção desta abordagem são explicadas. Ressalta-se também, que o trabalho envolve duas fases: a pesquisa preliminar e a pesquisa propriamente dita. Apresenta-se em seguida uma discussão que conduz à seleção de uma metodologia que combina a utilização da abordagem SERVQUAL e do método do incidente crítico (CIT) na primeira fase. Introduz-se o conceito central de fator de eficácia, bem como se estabelece suas relações com os itens de satisfação e as dimensões SERVQUAL. Com base nos resultados da fase preliminar, elabora-se um questionário de pesquisa abrangente, que é submetido a um grupo de projetistas de nível superior do setor automotivo, compreendendo as operações brasileiras de duas grandes montadoras internacionais, de dois fornecedores diretos (Tier 1) das montadoras e de uma grande montadora internacional de caminhões e ônibus. Os dados obtidos através das respostas ao questionário são compilados, apresentados e discutidos dentro de cada ambiente organizacional. Faz-se então uma análise conjunta, a fim de identificar aquelas ações gerenciais consideradas pelo setor automotivo como sendo mais importantes, tanto para garantir, quanto para avaliar a eficácia do processo de projeto e desenvolvimento do produto. Classifica-se essas ações em ações gerenciais de garantia e de avaliação de acordo com critérios fornecidos pelas normas ISO da qualidade. Finalmente, com base nas ações gerenciais de avaliação, define-se indicadores e se propõe um índice de eficácia único e flexível, que pode ser calculado utilizando-se, tanto dados organizacionais, quanto setoriais para fins de avaliação e benchmark. / This work approaches the subject of product design process evaluation from the designer?s point of view. In so doing, the author hopes to be paving the way that may eventually lead to a more ?friendly? method of evaluating the quality of the product design process and which may actually be found useful by design divisions and/or organizations. The reasons for selecting such an approach are explained. It is also pointed out that the work involves two phases: Preliminary research and research proper. Then, a discussion is made leading to the selection of a methodology combining SERVQUAL and the critical incident technique (CIT) for the first phase. The central concept of effectiveness factor is introduced and its relationship with satisfaction items and SERVQUAL dimensions is established. Based on the results of the preliminary phase a comprehensive questionnaire is drawn up, and submitted to a selected group of designers in the automotive industry, comprising Brazilian plants of two major car manufacturers, two tier 1 suppliers and one major truck (lorry) and bus manufacturer. Data provided by the answers to said questionnaire are compiled, presented and discussed within each organizational environment. A joint analysis is then carried out in order to identify those management actions that are considered by the automotive industry as being more important for both assuring and evaluating the effectiveness of the product design and development process. Assurance and evaluation management actions are classified according to criteria supplied by the ISO quality management standards. Finally, based on the evaluation management actions indicators are defined and a single and flexible effectiveness index is proposed, which can be calculated using both company and industry data for evaluation and benchmark purposes.

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Product life cycle perspective, a concept emanating from sustainable product development has gradually emerged as one of the key areas in product design and development. Several studies and research have shown the direct co-relationship between product design, development and manufacturing and its impact on our environment and ecosystem. The need to take these environmental factors into consideration is fundamental and highly prioritized in organizations that seeks to minimize the environmental impact of their operations in our ecosystem and if possible redirect these operations to contribute positively to saving the natural ecosystem. In the latest revision of ISO 14001:2015 standard, the term product life cycle perspective (LCP) has now become a fundamental requirement for organizations to fulfill. The requirement specifies the need for life cycle perspectives to be a significant factor during product design and development. However, the practical challenges of continuously integrating life circle analysis in product design is enormous for companies and organizations. This thesis will look at the challenges confronting ISO 14001 certified product manufacturing companies and allied services in implementing product LCP during product development and design and also the interpretations given by auditors from certification companies concerning how companies implement product LCP in relation to the requirements in ISO 14001:2015 at the product design and development stages.