DFMA

Design For Manufacturing & Assembly

INTRODUCTION
Prof. B K Mishra
Scope and Objective of the course

To apply the theory learned in the course- Design for

Manufacturing & Assembly – using a statistical
analysis software DFA/DFM

Develop the necessary skill set to analyse the

industrial Product design problems with the aid of
commercial software like DFA/

Learning skills to prioritizing both time and cost with

respect to manufacturing and assembly theories to
establish a profitable and sustainable product
production system.

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Course Outcome
 Understand and apply various Design Methodologies in DFMA

Design For Manufacturing & Assembly(DFMA)

DFA(Product Structure): Time-tested and DFM (Piece Parts): Calculation of

proven pathway to simply reduce the cost of manufacturing costs during the early
the product stages of product development.

 Analysis of labor cost and time management for a selected product by DFA
 Perform Redesign and calculate confidence cost intervals
 Use of different DFM tools to study and analyze various processes and materials.
The Software
What is DFMA?
• A registered trademark of Boothroyd Dewhurst, Inc.
• First Developed in 1983
• DFA software identifies cost reduction opportunities in product structure
• DFM software calculates “should-cost” for new or existing piece/parts designs
• Fort company reported saving $ Billions through DFMA…….
• Global manufacturers such as Kohler, Dell EMC, Medtronic, and Dynisco…
continue to report large savings at the International Forum on DFMA®
• DFMA® software use exploded and become standard in many industries
• Awarded by National Medal of Technology….. By U.S. President Bush
…… for having “ dramatically reduced costs, improved product quality, and
enhanced the competitiveness of major U.S. manufactures….”

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Where?
• DELL Builds a Framework for Success
• Re-Design on Vehicle Front Support Structure Using DFMA
• John Deere Harvests Savings with DFMA
• Endress + Hauser Credits $1MM Savings to Successful
DFMA Implementation
• Motorola Solutions uses DFA software to benchmark designs
and measure improvement in its global product portfolio
• Boothroyd Dewhurst’s DFA Software Drives Cost Savings for
Motorola's DS9208 Scanner
• Simplifying Veterinary Device Relieves Maturing Product
Symptoms
• How To Manufacture Success: Here’s Your Plan…
• Design analysis helps SouthCo reduce overall cost on a
medical hinge by 53 percent
• Embry-Riddle Aeronautical University student uses DFMA to
refine the design of a robotic monocopter.
• Hitting the Jackpot with DFMA
• Redesign of Forklift Hydraulic Cylinders
• Symbol Puts It All Together (Faster) with DFMA
• Good Designs Brewing at Access Business Group
• Design For Opportunity With DFA
• Lean Cuisine Whirlpool Sweden puts DFA to work to cut parts
by 29 %
and assembly time by 26 percent
• Cool, Stylish And Green
• NORTEL ENGINEERS dramatically lower product costs
• Redesign Of Aerospace Project cuts costs up to 74%
• On-going effort in Automotive Sector For Cost Reductions
Aided By DFA
• New Generation Of Medical Test Equipment Benefits From
DFMA Input
• Design Study Of Truck Instrument Panel identifies assembly
and environmental impact savings
And many more…………..
On http://www.dfma.com/resources/studies.asp
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When?
Product Development Process

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Design for Manufacturing & Assembly Guidelines

• Simplify the design & reduce the number of parts

• Standardize & use common parts and material
• Design & ease of fabrication
• Design within process capabilities & avoid unneeded surface finish requirements
• Design for parts orientation & handling
• Minimize flexible parts & interconnections
• Design for ease of assembly
• Design for efficient joining & fastening
• Design modular products
• Design for automated production.
• Design printed circuit boards for assembly
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How?
Only 6 steps to do…!!! Here are they:

• Step 1: Read the tutorial carefully.

• Step 2: Identify the appropriate method (DFA/DFM).

• Step 3 : Decide the Input the data (in columns

(worksheet) if required)

• Step 4: Input all the required values in respective tabs

• Step 5 : Select appropriate

process/criteria/method/material & obtain the results

• Step 6 : Analyse the results & deduce a logical

conclusion or redesign

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Approach….

Design For Manufacturing & Assembly(DFMA)

Part, 1. Definition
Sub-Assembly 2. Input Question
Assembly 3. Relation

1. Stage operation
Operation 2. Addition Worksheet
3. Benchmarking

1. Elimination
Redesign 2. Optimisation Redesign
3. Comparison
DFMA Ana lys is
Process include
• Drawing
• Conceptualization • Updates
• Wrong Production
• Analysis • Storage
• Incorrect Assembly
• Redesign

• Conclusion

1. Conceptualization

User Requirement?

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2. Analysis
• Components
• Processes
• Combined components Suspect Component
• Main Assembly Suspect Process
• Sub-assemblies

3 Elimination Questions
1. Should the component move or be able to move in relation to the preceding component in the
assembly diagram?
2. Are there fundamental reasons for the component being made of a different material that does not
otherwise occur in the product?
3. Should the component be fitted or removed separately because otherwise assembly or disassembly
of another theatrically essential component would be impossible?
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3. Redesign
Suspect Component Another Way ?
Suspect Process
4. Conclusion
Creation of DFMA report
• Details of participant
• Date and location
• Key user requirement
• Analysis with assembly diagram
Description of alternative design & evaluation
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DFMA® Software

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DFMA® Software

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DFMA® Software

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DFMA® Software

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DFMA Ana lys is

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Contents in DFMA software

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 Design Simplification
Part Cost or Total Costs of using the Parts?
• Material Cost
• Process Cost
• Tooling Cost
• Assembly Cost.

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 DFMA Book and references
• https://www.pdfdrive.com/product-design-for-manufactureand-assembly-third-edition-
e175958126.html
• https://www.dfma.com/software/dfma.asp
• https://www.youtube.com/watch?v=_LlRof0K0OQ
Hot Chamber Die Casting & Cold Chamber Die Casting (3D animation)
• https://www.youtube.com/watch?v=D6w6tZXKrls
Metal Mechanics 100 Ton Four Column (Post) Vertical Hydraulic Die Casting Trim
Press
• https://www.youtube.com/watch?v=bH1WlgGvOcE
( Part 1-Die Casting Process: What is the die casting process?)
• https://www.youtube.com/watch?v=BoXD0ojw3UI
(Part 2 - Die Casting Defects: Where do they come from?)
• https://www.youtube.com/watch?v=mMRdEfWoMPY
(Scrap Aluminum to pressure die casting Auto Components)
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Summary
• Design determines more than 70% of the product cost
• DFMA is concurrent engineering (involves cross-functional teams) to simplify Product
structure in the early stages of design
• DFMA approach is to obtain an acceptable level of manufacturability, ease of assembly,
serviceability, product cost, product quality, and time to market
• DFA software helps designers in estimating product assembly times and costs based on
reliable time standards
• DFM software contains the process and material information and calculations for
estimating part manufacturing costs

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 Lab Calendar & Evaluation scheme
1. Lab Schedule
Time /Instruction Delivered by
Date Day
Duration
LS No 1 20th-Mar-23 Monday Prof. B K Mishra
LS No 2 21st-Mar-23 Tuesday 7.30 PM-9.30 PM Prof. B K Mishra
LS No 3 27th-Mar-23 Monday 2 Hours/session Prof. B K Mishra/ Dr. Gauri Mahalle
LS No 4 28th-Mar-23 Tuesday Prof. B K Mishra/ Dr. Gauri Mahalle

2. Evaluation Scheme

Evaluation Component Name Type Marks

Lab Quiz-( 2 nos. 4 marks each) Online 8

EC - I Lab Practice Online 6

Lab Assignment Online 6

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 Lab Calendar
3. Lab Practice
Start date End date Total Days
Lab practice 1st April-23 24th April-23 24
Group practice;
 2 students in each Group
 8 Groups/day
 Total practice days -24 days

Groups will be formed and details will be communicated through mail/elearn portal after 4th lab session
4. Important dates Important dates
Evaluation Component Start Date End Date Days
Quiz-1 1st April 23 10th April 23 10
Quiz-2 11thApril 23 21st April 23 10
Lab Practice 1st April 23 24th April 23 24
Lab Assignment Dates will be announced after lab practice
Lab Practice: Group submission (group of 2 students)- 1 DFA tutorial + 1 DFM Tutorial
Lab Assignment : Individual/group assignment 20
Login Details

URL to login to cloud servers for software acess:

https://bits-ad.wilp.bits-pilani.ac.in/RDWeb/Pages/en-US/login.aspx

Username: Your BITS email address

Password: Bitspilan@123# (Common for all)

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Most Important
Important Contact Information For
• Dr. Gauri Mahalle Email: mahalle.gauri@wilp.bits-pilani.ac.in • DFA/DFM Software related
Contact No: +91 8056130859 /+44 7442005753 • DFMA Concept related
• Prof. B K Mishra Email: bkmishra@wilp.bits-pilani.ac.in • Quarries on Assignment/Quiz
Contact No: +91 9892009755

• Shri Akhilesh Bhatkar; Email: akhilesh.bhatkar@wilp.bits-pilani.ac.in For Technical Issues

Contact No: +91 9420425893 Like………
• Blank screen
• No software response
• Other Network related
• Screen Froze …..
COMMUNICATION AND QUERY ADDRESSAL
STEP-1: FIRST CHECK FAQ , FIND YOUR QUERY, IF DIDN’T FIND WRITE THERE
STEP-2: FIRST PUT MASSAGE IN WHATSAPP GROUP
STEP-3: MASSAGE INDIVIDUALS
STEP-4: CONTACT IF NOT GETTING REPLY REQUEST TO NOT TO CALL IN ODD HRS
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 Thank You!
In our next session: Tutorial DFA