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Abstract:
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Manufacturing complexity is both created and increased by two interdependent
characteristics: the manufacturing process, and the product itself. Understanding the
impact of a product design on manufacturing is an integral part of assessing and reducing
the cost of complexity. An evaluation of product characteristics on production processes
makes it possible to design for manufacture and control cost at the most economical stage
of the product life cycle.
For this investigation, a methodology combining practical experience and
statistical analysis was used to identify the product characteristics contributing to
complexity in textile manufacturing. Woven product characteristics judged as most
critical to production were tested to determine relationships with manufacturing cost. In
addition, interrelationships between product characteristics were tested. Increased
complexity created by the presence of multiple characteristics was investigated for an
effect on cost.
Several product complexity factors were determined to have a significant
relationship with an increase in manufacturing cost. Overall, product complexity
variables were more useful in estimating labor costs, rather than conversion costs.
Together, five key product characteristics can predict 71 % of the variation in labor cost.
These characteristics are (a) picks per inch, (b) number of harnesses, (c) selvage
construction, (d) fabric width, and (e) novelty yarn.
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