University of Colorado

MCEN 4026
Fall 2016

Designing for
Manufacturability
 University of Colorado
MCEN 4026
Administrative Stuff Fall 2016

• Let’s look at some drawings

 University of Colorado
MCEN 4026
Design for Assembly Fall 2016

DFA = method of design of a product for

ease of assembly

Optimization of
part/system
assembly

DFA assists in design of products that will transition to production at

a minimum cost - focusing on number of parts, handling and
ease of assembly.
 University of Colorado
MCEN 4026
Design for Manufacturing Fall 2016

DFM = method of design for ease of

manufacturing of parts that form a product
after assembly

Optimization of
manufacturing
process

DFM is used to select most cost effective material and process to be

used in production in early stages of product design.
 University of Colorado
MCEN 4026
Differences Fall 2016

Design for Assembly (DFA)

• concerned with reducing product assembly cost
– minimizes number of assembly operations
– individual parts tend to be more complex in design

Design for Manufacturing (DFM)

• concerned with reducing overall part production cost
– minimizes complexity of manufacturing operations
– uses common datum features
 University of Colorado
MCEN 4026
Similarities Fall 2016

• Both DFM and DFA seek to reduce

material, overhead, and labor costs
• Both shorten product development cycle
• Both attempt to utilize standards to
reduce cost
 University of Colorado
MCEN 4026
DFMA Benefits Fall 2016

What internal organization has most influence

over price, quality, & cycle time?

Manufacturing
20-30%

Design
70-80%
 University of Colorado
MCEN 4026
Design Influence Fall 2016

• Cost of materials
• Number of parts used to achieve a
particular function
• Types of parts
• Modularity
• Design Complexity
 University of Colorado
MCEN 4026
Knowledge and Learning Fall 2016

Marketing
Knowledge
DFSS Cost of Change

High
100 100
90 90
Knowledge of Design
Percentage

80 Behavior 80
70 70
Knowledge
60 60
of Process
50 50 Capability
Low
40 40
30 30
20 Freedom to Make 20
Changes
10 10

Design Process Time

Production
 University of Colorado
MCEN 4026
Sequence of Analysis Fall 2016

Concept Design
Optimize Design for
Part Count and
Design for Assembly
Assembly

Design for
Manufacturing
Optimize Design for
Production Readiness
Detailed Design
 University of Colorado
MCEN 4026
Design for X Topics Fall 2016

• Design for Assembly

• Design for Manufacturing
• Design for Production
• Design for Recycling/Disposal
• Design for Life Cycle
 University of Colorado
MCEN 4026
Gathering DFM Information Fall 2016

• Sketches, drawings, specifications, and

design alternatives
• Detailed understanding of production and
assembly processes
• Estimates of manufacturing costs,
production volumes, and ramp-up timing
 University of Colorado
MCEN 4026
DFM Method Fall 2016

Proposed Design

Estimate the Manufacutring

Costs

Reduce the Costs of Reduce the Costs of Reduce the Costs of

Components Assembly Supporting Production

Consider the Impact of DFM

Decisions on Other Factors

Recompute the
Manufacturing Costs

Good
N
enough
?
Y

Acceptable Design
 University of Colorado
MCEN 4026
DFM Method Fall 2016

• Estimate manufacturing costs

• Reduce costs of assembly
• Reduce costs of components
• Reduce costs of supporting production
• Consider impact of DFM decisions on
other factors
 University of Colorado
MCEN 4026
Estimate the Manufacturing Costs Fall 2016

Equipment Information Tooling

Raw Materials

Labor
Manufacturing System Finished Goods
Purchased
Components

Energy Supplies Services Waste

 University of Colorado
MCEN 4026
Manufacturing Costs Defined Fall 2016

• Sum of all expenditures for inputs

(purchased components, energy, raw
materials, etc.) and for disposal of wastes
 University of Colorado
MCEN 4026
Elements of Manufacturing Cost of a Product Fall 2016

Manufacturing Cost

Components Assembly Overhead

Equipment Indirect
Standard Custom Labor Support
and Tooling Allocation

Raw
Processing Tooling
Material
 University of Colorado
MCEN 4026
Manufacturing Cost of a Product Fall 2016

• Component Costs (parts of product)

– Parts purchased from or made by supplier
– Custom parts made in manufacturer’s plant
• Assembly Costs (labor, equipment, & tooling)
• Overhead Costs (all other costs)
– Support Costs (material handling, quality assurance,
purchasing, shipping, receiving, facilities, etc.)
– Indirect Allocations (not directly linked to particular product
but must be paid to be in business)
 University of Colorado
MCEN 4026
Fixed Costs vs. Variable Costs Fall 2016

• Fixed Costs – incurred in predetermined

amount, regardless of number of units
produced (setting up factory work area or
cost of mold)
• Variable Costs – incurred in direct
proportion to number of units produced
(cost of raw materials)
 University of Colorado
MCEN 4026
Steps to Reduce Cost of Components Fall 2016

• Understand Process Constraints and Cost

Drivers
• Redesign Components to Eliminate
Processing Steps
• Choose Appropriate Economic Scale for
Part Process
• Standardize Components and Processes
• Adhere to “Black Box” Component Design
– Give supplier freedom
 University of Colorado
MCEN 4026
Understand Process Constraints and Cost Drivers Fall 2016

• Redesign costly parts with same

performance while avoiding high mfg costs
• Work closely with mfg engineers
– Raise awareness of difficult operations and
high costs
 University of Colorado
MCEN 4026
Redesign Components to Eliminate Processing Steps Fall 2016

• Reduce number of steps of production

process
– Eliminate unnecessary steps
• Analysis Tools
– Process Flow Chart
– Value Stream Mapping (Lean Mfg) $$$
 University of Colorado
MCEN 4026
Process Flow Chart Example Fall 2016
 University of Colorado
MCEN 4026
Choose Appropriate Economic Scale for Part Process Fall 2016

• Economies of Scale
– As production volume increases,
manufacturing costs decrease
– Fixed costs divided among more units
– Variable costs are lower due to more efficient
processes and equipment
 University of Colorado
MCEN 4026
Standardize Components and Processes Fall 2016

• Economies of Scale
– Unit cost of component decreases as
production volume increases
• Standard Components
– Common to more than one product
 University of Colorado
MCEN 4026
Adhere to “Black Box” Component Design Fall 2016

• Black box
– Only give description of what component has
to do, not how to achieve it
• Successful black box design requires clear
definitions of functions, interfaces, and
interactions of each component
 University of Colorado
MCEN 4026
Factors for Manufacturing Process Selection Fall 2016

• Quantities of parts required

• Complexity – shape, features
• Size
• Material
• Quality (tolerances, finish)
• Cost
• Availability, lead time, delivery schedule
 University of Colorado
MCEN 4026
Quantity of Parts Required Fall 2016

• Two major factors:

– Total number of parts
– Rate of production
• High or low volume process?
• Batch production or continuous?
 University of Colorado
MCEN 4026
Quantity of Parts Required Fall 2016
 University of Colorado
MCEN 4026
Shape and Feature Complexity Fall 2016
 University of Colorado
MCEN 4026
Shape and Feature Complexity Fall 2016
 University of Colorado
MCEN 4026
Influence of Size on Process Selection Fall 2016
 University of Colorado
MCEN 4026
Influence of Material on Process Selection Fall 2016

• Physical constraints
– Melting point
– Deformation resistance
– Ductility/ malleability
• Design requirements
• Post processing
 University of Colorado
MCEN 4026
Influence of Material on Process Selection Fall 2016
 University of Colorado
MCEN 4026
Required Quality of Part Fall 2016

• Freedom from defects

• Surface finish
• Dimensional accuracy and tolerances
 University of Colorado
MCEN 4026
Required Quality of Part Fall 2016
 University of Colorado
MCEN 4026
Cost to Manufacture Fall 2016

• Unit cost (CU)

• 𝐶𝑈 = 𝐶𝑀 + 𝐶𝐿 + 𝐶𝑇 + 𝐶𝐸 + 𝐶𝑂𝐻
– CM = material cost
– CL = labor cost
– CT = tooling cost
– CE = cost of equipment
– COH = overhead costs
 University of Colorado
MCEN 4026
Availability, Lead Time, and Delivery Fall 2016

• Availability of equipment
• Lead time for tooling
• Reliability of delivery dates

• May force business decisions

• May force process selection
 University of Colorado
MCEN 4026
Designing for Economical Production Fall 2016

1. Simplicity
2. Standard materials and components
3. Standardized design of product
4. Liberal tolerances
5. Use most processible materials
 University of Colorado
MCEN 4026
Designing for Economical Production Fall 2016

6. Team with manufacturing during design

7. Avoid secondary operations
8. Design appropriate for expected level of
production
9. Use special process characteristics
10. Avoid process restrictiveness (do not
over specify manufacturing)
 University of Colorado
MCEN 4026
General DFM Rules Fall 2016

1. Simplify design
2. Design for low-cost labor operations
3. Avoid generalized statements on
drawings (Tool marks not permitted,
Corners must be square)
4. Dimension from inspectable surfaces
 University of Colorado
MCEN 4026
General DFM Rules Fall 2016

5. Minimize inspection datums

6. Minimize part weight
7. Design for general purpose tooling
8. Avoid sharp corners (use generous fillets)
 University of Colorado
MCEN 4026
General DFM Rules Fall 2016

9. Design parts so as many manufacturing

operations as possible can be performed
without repositioning
10.Avoid stepped parting lines in molded
and cast parts
11.Uniform wall thicknesses in molded or
cast parts
 University of Colorado
MCEN 4026
Next Time Fall 2016

• Give me another drawing

• One per person
• .pdf format