Abstract
Poor product design often be the main reason for low production efficiency, high manufacturing cost and low product reliability. However in the study of the past, people usually don't take the weaknesses of the manufacturing process into the consideration of product design. Besides, the change of the relevant processes caused by the design change of the product also needs further re-design consideration. Therefore, it would be a noteworthy issue for the enterprises about how to eliminate the weaknesses of the manufacturing processes by product re-design, and how to rearrange the corresponding processes and manufacturing system systematically. This research integrates variety of diagnosis and design tools from deferent stage of the industry value chain and the technique of systematic innovation (TRIZ). Furthermore, this study established a systematic product - process - manufacturing system re-design method that could guide enterprises to conduct the following activities systematically: (1) Diagnose Products, processes and manufacturing systems;(2)Identify the key disadvantages in the entire system;(3)Product and process innovation and re-design;(4)Design concepts concretization;(5)Line balancing and Facility planning. A domestic company has been considered as a research object in this study, and a recommended improvement measure for redesigning and improving the existing products, processes and manufacturing system has been proposed. In addition to resolve the disadvantages of the system, according to the results provided by the simulation software, the number of operators needs to add to the firm which we recommended is only 40% of the number that the original system needed under the same target capacity. Besides, the performances of the recommended measure were significantly better than the original system.