Product and Process Design

Making product and process design decisions concurrently instead of sequentially... 

Product and process design (product and process datapack)... 

This element covers the translation of customer specifications for the product into the corresponding specifications for materials, products, and processes. Design reviews, product and process acceptance criteria, design change control, and design requalification are all addressed. 

Industry should also continue to commit resources to academic research, for reasons that go far deeper than the desirability of additional funds. The development of any engineering field, and particularly one as closely linked to manufacturing as chemical engineering, needs the intellectual guidance that can only come from an industry with a stake in research outcomes. Also, industry has to be linked to academia so that new laboratory results can be rapidly transferred to product and process design. An industry committed to financial sponsorship and personnel exchanges with academia will make sure that the crucial industrial intellectual involvement needed for success exists. Thus, the committee mges that ... 

Let us now give a brief synopsis of the themes advanced by each of the ten chapters. The five chapters of Volume 21 (Part 1) advance paradigms which are related to product and process design, while the five chapters of Volume 22 (Part II) focus on aspects of process operations. 

Seider, W. D., Seader, J.D., Lewin, D.R. (2004) Product and Process Design Principles, Synthesis, Analysis, and Evaluation, 2nd edition, Wiley. 

Hill, M. (2004) Product and process design for structured products ... 

Ng, K. M. (2004) MOPSD a framework linking business decision-making to product and process design, Computers and Chemical Engineering, 29, 51. 

Initial work on the design of structured products has been presented by, for example, Meeuse et al. 2000, Wibowo and Ng, 2001, 2002. In this chapter a real life example of a process redesign project where process synthesis techniques were applied to a structured food product, is presented. First, we position this work in the framework of integrated product and process design. Then we describe how we translated existing process synthesis techniques into a useful methodology for structured products. Then the actual case study is presented. Finally some perspectives are given. 

Figure 10.4-1. Steps in industrial product and process design...

Process-product interaction Since a chemical product has to be produced, it is clear that a production process is required. When the product properties depend on the process, we say that the chemical product is dependent on the process. Otherwise, we say that the chemical product is independent on the process. This distinction is important in the design. In the former, the product and process design should be made simultaneously, whereas in the latter, the product and process design can be done independently. We will see how useful these definitions can be in the following sections. 

M. Hill, 2004, Product and Process Design for Structurated Products, AIChE J., 50 (8), 1656-1661... 

Karpins, M. and R. N. Porter. 1970. Atoms and Molecules. Menlo Park, CA W. A. Benjamin. Pauling, L. 1960. The Nature of the Chemical Bond. Ithaca, NY Cornell University Press. Westmoreland, P. R. and A. Z. Panagiotoponlos. 2004. Molecnlar-modeling methods and nse for product and process design. In Sixth International Conference on Foundations of Computer-aided Process Design, Flondas C. A. and R. Agrawal eds pp. 83-95. 

The PAT guidance facilitates introduction of new measurement and control tools in conjunction with well-established statistical methods such as design of experiments and statistical process control. It, therefore, can provide more effective means for product and process design and control, alternate efficient approaches for quality assurance, and a means for moving away from the corrective action to a continuous improvement paradigm. 

The cGMP regulations include specific packaging and labeling controls, so packaging and labeling requirement, processes, and controls should be included in a QS-based approach to product and process design and development. 

Feedback is generated to be used for product and process design. Constant improvement of the product and process is enhanced. 

According to the FDA, assurance of product quality is derived from careful and systemic attention to a number of important factors, including selection of quality components and materials, adequate product and process design, and (statistical) control of the process through in-process and end-product testing. 

Byers, T. E. Role of product and process design in assuring quality, Good Manufacturing Practices Conference, Cherry Hill, NJ, Feb. 1977. 

The standard stresses product safety and effectiveness and therefore contributes to safe, effective, and high quality products when necessary, the standard also covers all factors required to ensure safety and effectiveness, including product and process design, and process performance. 

Multiscale modeling can reduce product costs through innovations in material, product, and process designs. 

K. M. Ng, MOPSD A Framework Linking Business Decision-Making to Product and process Design, in Process Systems Engineering 2003, Ed. B. Chen and A. W. Westerberg, p. 63, Elsevier, 2003. 

The selected case study illustrates a complex product and process design. High productivity and good product quality can be achieved simultaneously only if the reaction conditions are well controlled. However, in a batch process the degrees of freedom for reactor sizing are quite limited. The optimality of the design arises from a better operation procedure, but mainly by changing drastically the chemistry. This characteristic is shared by other batch processes. 

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