Å utvikle og kommersialisere fysiske produkter er en utfordrende prosess av flere grunner. Selv om potensielle gevinster kan være enorme for dem som lykkes, er risikoen og kompleksiteten høy på grunn av betydelige utfordringer innen design, produksjon, logistikk og skalering, skriver Aggrator partner Salvador Baille.
1. Design is extremely demanding
To create a successful product, you need to balance three factors: Form, Fit and Function . The visual design is only one part of the equation – even more important is the product’s ability to adapt. andre components of the system they must belong to in order to fulfill their functional purpose. At the same time, the design must take into account the supplier's production capabilities and material selection.
2. Production requires precision
While software can be distributed globally without any quality issues, physical products face significant challenges in this regard. Small differences in material properties or physical dimensions of components can lead to catastrophic failures. In addition, manufacturing tools wear out over time, creating additional challenges in maintaining quality and cost-effectiveness.
3. Logistics can be a nightmare
The world’s global value chains are extremely complex, with components often manufactured in different countries before being assembled. Many parts are produced by only a few suppliers, making supply chains even more vulnerable to disruptions. Failures in logistics or poor compatibility between parts can lead to huge financial losses.
4. Scaling challenges
Production increases can lead to large losses instead of increased revenues. Economies of scale can turn into diseconomies of scale. Car manufacturers often experience this when they have to recall massive numbers of defective cars.
The challenges of design, manufacturing, logistics and scaling therefore require a holistic approach to increase the chances of success. Companies that succeed in this arena must have experienced teams working hands-on with design, manufacturing and logistics simultaneously – having the expertise in a board that meets twice a year is not good enough.
Fortunately, there are methods and tools that can make the outlined challenges easier to handle.
1. Digital prototyping and simulation
To ensure that a product meets the requirements of Form, Fit and Function, digital tools such as computer-aided design (CAD) and finite element analysis (FEA) should be used early in the development process. This makes it possible to simulate the product's properties and identify design errors before prototypes are made. In addition, digital copies of the final product, the so-called Digital Twins, can be used to monitor and simulate the product's performance in real time, providing valuable data for further optimization of the real product.
2. Automated quality control
To handle precision requirements and minimize variations in production, machine learning and sensor technology can be implemented in the production line. Automated measurement systems can detect deviations in components in real time and adjust the process before errors occur. This reduces tool wear, increases production capacity and ensures consistent quality.
3. Quality contracts and back-to-back agreements
In the logistics of long supply chains, traceability, transparency and accountability are critical. Clear contracts with reference to international quality standards and back-to-back agreements are therefore essential. The result is improved predictability, better quality and cost control, and fewer delivery discrepancies.
Smart and optimal inventory management also contributes to less risk in the event of a supply disruption.
4. Standardization and modular product design
By developing standardized components that can be used across multiple products, complexity in production and supply chains is reduced. This allows for faster adaptation to market needs. At the same time, a modular approach, where multiple identical products can be assembled to meet the needs of different customers regardless of size, makes it easier to scale production without major cost increases.
Designing and manufacturing physical products can be profitable but vulnerable to inefficiencies. By implementing these suggestions, physical products can still be made robust, cost-effective, and competitive in the (still) globalized world we live in.
Would you like to learn more and implement best practices in your company? Join the masterclass in design and product development on June 5, led by NxTech.