Professional Documents
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Design For Manufacturability
Design For Manufacturability
Scott G. Gatherum.
Marriott School of Management
Brigham Young University
Outline of Presentation
Improving Reliability
Increasing Production Speed
Simplify Design
Reduce Necessary Inventory
Savings in the form of Costs, Time, Labor, and
Materials
DFM Basics
Consider the following when bringing a product
design to manufacturing.
Customer Requirements
Process Reliability
Tolerances and
Repeatability
Cost of Manufacturing,
Materials & their Availability
Technology
Customer Requirements
In order to meet the requirements of your
customers, you must first find out what they
want.
Do they want something that is already on the market?
Do they want more or less features?
Process Reliability
To improve process reliability it is important
to look at the relationship between the new
process and current process.
Can any current process be used, and if not, how different
are they?
Can we buy reliable technology to produce the new
product?
Advancement of Technology
Technology changes constantly. While
designing the process for production
consider the following:
How reliable is the technology?
Can it be bought of the shelf or does it need to be
customized?
Can it be integrated with old or future technology?
Example Cont.
They started from the beginning. They first
considered what was necessary to meet the
customer needs. Second, they considered what
requirements the boiler had to ensure quality and
safety. Then they began to look at their resources.
The boiler manufacture found that their current
process of assembling the fasteners to the boiler
unit required a spring clip, nuts and a screw, which
held the sheet metal to form the outside casing of
of the boiler.
Example Cont.
The manufacturer began looking at the technology
that had been developed since they began
producing the boilers. A new technique had been
introduced that solved their problems. The new
fastener was a combination of a screw and
stamping. The new process involved a screw
punched into the assembly base material. The new
fastener sported a buttress type thread that was
designed to capture the outside edge of the
material.
Example Cont.
The screw is stamped directly into the base during
the fabrication. This new process eliminated the
old screws and clips that use to come loose during
transportation. The manufacturer then redesigned
the product to allow the screw to be stamped
during assembly. In doing so, the company
eliminated nuts, inserts, spring clips, and thread
forming screws. The company replaced all of these
parts for one helix screw.
Example Cont.
The end result reduced assembly time by about 15
seconds per part. At 10 parts per unit, for a total of
about 2.5 minutes per unit. This 2.5 minuets
results in an annual savings of $10,000. In
addition, the reduction of inventory and associated
handling costs were reduced 25-30%
Summary
When developing a DFM tool there are three
components needed to make the DFM productive.
A complete understanding of the process design and the
interactions in the manufacturing process, and how they
both affect your overall output.
A developed model that simplifies information into usable
segments.
An early application of this information into the design
flow to allow these tools to make DFM decisions without
compromising accuracy, timing, or power calculations
Summary
Using the a Design for Manufacturability
program will eliminate parts and process
that simply make the overall process
cumbersome. Today, to keep or gain a
competitive edge, it is essential that
companies develop a DFM program before
the waste time, money and resources
producing inferior products.
Summary
Design for Manufacturability simply put:
Improving Reliability
Increasing Production Speed
Simplify Design
Reduce Necessary Inventory
Savings in the form of Costs, Time, Labor, and
Materials
Reading List
Books
Boothroyd, G., 1988, Dewhurst, P., Product
Design for Manufacture and Assembly
Stoll, H.W., 1986, Design for Manufacture: An
Overview
Reading List
Journals
iiE Solutions
The Journal of Technology Studies
Research in Engineering Design
Proceedings of the Institution for Mechanical
Engineers
Professional Enigneering Publishing
Reading List
Web Sites
www.designnews.com
www.elecdesign.com
www.dfma.com
www.machinedesign.com
http://solutions.iienet.org
www.tm.tue.nl/race/ce/dfma_2.html
Bibliography