Product development cost reduction

The principal thrust ol Japan s joint research programs is the development of process technologies to reduce conversion costs and development of high value-added products. Energy cost reduction is a prime concern. Opportunities exist in low energy consuming polymerization and spinning... 

Abstract Many companies are making significant efforts in the development of prototypes of DAFC (mainly DMFC) for replace batteries (battery charge and auxiliary power units) in portable devices. Some of the most relevant prototypes are summarized however, most of these devices are not ready to be commercialized due to the high cost and low power reached. Furthermore, for the massive application of the DAFC technologies is necessary solve some of the drawbacks (as miniaturization, products balance, cost reduction, etc.). The cost of the prototypes is analyzed as well as the degradation of the components that affects the durability of the devices. 

In this chapter, simple analysis techniques are presented that will assist the designer in developing new products to handle the anticipated loading, while keeping stress and deflection within acceptable limits. These techniques will also be useful in product improvement, cost reduction, and the failure analysis of existing parts. The application of simplified, classic stress and deflection equations to plastic parts are presented here. As the complexity of a part increases or when particularly accurate results are required, more exact traditional methods or computerized finite element analysis (FEA) may be required [1, 2, 7-14, 33, 40-45, 62-76, 93, 270, 278, 390-417]. 

Steady-state simulations of the high-pressure tubular reactor for the production of LD P E with distributed parameters are used for reactor design of a new plant as well as for optimization of the operating parameters in an existing plant - for product development and reduction of production costs. 

Considering that geotextile production is increasingly taking on an international scale beyond national boundaries, one can believe that the quest for performance, cost reduction and increased productivity will drive future developments and investments in this industry in years to come. Continuous improvement processes, value-added products and cost reduction should stimulate the manufacturers of geotextile products and of geotextile equipment. Reduction in down time and maintenance time are also opportunities to reduce the costs identified by manufacturers. Improved quality and process control techniques such as automatic product inspection, use of electronic servo-systems and implementation of statistical process control techniques should also continue to advance in the geotextile industry. 

Globally, iron production is expected to iacrease ia developiag couatries as local steel iadustries grow to supply the increasing demand for steel products. Iron production ia already developed couatries is expected to stabilize or possibly decliae as the opportunities for export diminish. Efforts in the developed countries are expected to be in energy efficiency, productivity, quaUty, and cost reduction. 

Finally, the main benefit as far as competitive business performance is concerned is the potential for reduction in failure costs. Studies using CA very early in the development process of a number of projects have indicated that the potential failure costs were all reduced through an analysis. This is shown in Figure 2.47, where this potential failure cost reduction is shown as the difference between pre-CA and post-CA application by the teams analysing the product designs. 

Before setting about the task of developing such a model, the product development process requires definition along with an indication of its key stages, this is so the appropriate tools and techniques can be applied (Booker et al., 1997). In the approach presented here in Figure 5.11, the product development phases are activities generally defined in the automotive industry (Clark and Fujimoto, 1991). QFD Phase 1 is used to understand and quantify the importance of customer needs and requirements, and to support the definition of product and process requirements. The FMEA process is used to explore any potential failure modes, their likely Occurrence, Severity and Detectability. DFA/DFM techniques are used to minimize part count, facilitate ease of assembly and project component manufacturing and assembly costs, and are primarily aimed at cost reduction. 

In the preceding chapters some of the main chemical developments that can help reduce waste, lower harmful emissions, improve process efficiency and generally aid development of more sustainable products and processes were discussed. In this and the following chapter the focus will be more on those aspects of technology that can lead to improved process and energy efficiency as well as process cost reduction. 

At this moment, the price of the used granular PCM exceeds 10 EURO/kg due to the test production stage. Our calculation showed the cost payback time can be less than 10 years when the PCM cost would be reduced to 4 EURO/kg under the electrical utility rate condition in Japan. Further cost reduction will be needed to promote the actual system. In addition we have to care of flammability of paraffin wax as PCM in use of inside the buildings. Fortunately, PCM is placed under the OA floor board made of fireproof cement-mortal and above the concrete slab in this system. It may not have any problems under the Fire Defense Law in Japan. However, further development of noninflammable PCM granules, for example micro encapsulation of mixture of inorganic and organic PCM, is required. 

Phase 3 Market Expansion (10-20 years)-work will seek cost reductions of fuel cells through the development of large-scale manufacturing (mass production) continue hydrogen supply infrastructure development on a national level refinement of policy measures (fiscal and regulatory) and, continue support of RD D in areas of new advancements in hydrogen and fuel cells. 

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