Sharing In Growth Teach Point

Design for Manufacture & Assembly

(DFMA)
(DFx – Design for Excellence)
Objectives & Principles

Copyright © 2013-2020 Sharing in Growth

What is DFMA ? DFx?

Design for Manufacture and Assembly (DFMA / DFx) is a

technique used to minimise product & process costs through design
improvement.

• Activity that minimises product and process costs from design

concept & onwards.

• Activity which aligns design and manufacture.

• Evaluates and evolves the product design for ease of manufacture
and assembly.

• Evaluates & reduces complexity and part count.

• Helps with decision making by ranking & rating design &
manufacturing options.
Why Use DFMA / DFx?

Discuss the SQDCP benefits of using DFMA / DFx

Safety: Exposes risks early that could potentially impact product or person safety

Quality: Aligns Design & Manufacturing processes with Quality expectations

Delivery: Aligns Design & Manufacture to single solution, quicker to market products

Cost: Evaluates Design scenarios to identify most cost effective, value for money solution

People: Utilises team skills and knowledge aligned to product, processes & technologies

Discuss the reasons for applying DFMA / DFx in your own areas
 How?

4. Continual
Evaluation

1. Conception
4.0
Continual
Review
1.0
Lessons Learnt

2. Conceptual Evaluation 3. Final Design

2.2 3. Final
1.1 2.0 2.1
Select optimised Design &
Design Generate Ideas Evaluate each solution Manufacturing
Concepts idea option

1.2 Knowledge Base

Manufacturing
Concepts Cross Technology &
Functional Facilitisation
Knowledge
 How – Step 1 Conception

1. Conception Typical Inputs

• CI PFMEA Studies
1.0 • Process performance data
Lessons Learnt • Quality performance data
• Business drivers
• Operator knowledge 2. Conceptual
Evaluation
• Design Standard (Generic)
• Material characteristics
1.1 2.0
• Standard tolerances
Design Generate Ideas
• Product functionality
Concepts
• Product families
• Critical characteristics

• Process Standard (Generic)

1.2 • Quality Standard (Generic)
Manufacturing • Technologies
Concepts • Joining/Fastening
• Complexity
• Commonality
• Workflow
• Handling
• Demand volumes
• Quality targets
 How – Step 2.0 Generate Ideas

1. Conception

1.0
Lessons Learnt
2. Conceptual Evaluation

2.2 3. Final
1.1 2.0 2.1
Select optimised Design &
Design Generate Ideas Evaluate each solution Manufacturing
Concepts idea option

1.2
Manufacturing
Concepts • Understand the product & functionality
• Understand the product quality & demand
• Establish manufacturing options
• Establish assembly process options
• Recognise available technologies
• Generate multiple design options
 How – Step 2.1 Evaluate Ideas

1. Conception

1.0
Lessons Learnt
2. Conceptual Evaluation

2.2 3. Final
1.1 2.0 2.1
Select optimised Design &
Design Generate Ideas Evaluate each solution Manufacturing
Concepts idea option

1.2
Manufacturing
Concepts • Critique each idea – Score & rank
• Primary Considerations
• Part count (minimal)
• Alignment to standard parts and materials
• Utilisation of modular assemblies
• Efficient joining
• No reorientation of parts
• Simplicity and number of operations
• Functionality to scope
• Quality
• Technology & process capability
• Ongoing production costs
• Health & Safety aspects
 How – Step 2.2 Select Solution

1. Conception

1.0
Lessons Learnt
2. Conceptual Evaluation

2.2 3. Final
1.1 2.0 2.1
Select optimised Design &
Design Generate Ideas Evaluate each solution Manufacturing
Concepts idea option

1.2
Manufacturing
Concepts • Select optimum idea based on rating & ranking
• Deep dive & refinement of option
• Alignment to business strategy & Capability
• Specific business strategy (growth, maintain, survive)
• Modularity & platform commonality (future proofing)
• Capital & revenue costs
• Make v’s buy
• Available technologies
• Current & future demand
• Levels of automation
• Supply base capability
• People skills, salary demands.
 How – Step 3 Final Design Agreed

1. Conception

1.0
Lessons Learnt
2. Conceptual Evaluation

2.2 3. Final
1.1 2.0 2.1
Select optimised Design &
Design Generate Ideas Evaluate each solution Manufacturing
Concepts idea option

1.2
Manufacturing
Concepts • Optimum solution defined
• Business benefits defined
• Stakeholder buy-off
• Implementation project scoped
• Communicate cross functional plan
 How – Step 4 Continual Review

4. Continual
Evaluation

1. Conception
4.0
DFMA / DF x Continual Review Continual
• Throughout the product life-cycle continue to perform DFMA / DFx studies Review
1.0 • New Product introductions will need to employ DFMA / DFx
• Build up lessons learnt over time & use to evaluate through DFMA / DFx
Lessons Learnt

2. Conceptual Evaluation 3. Final Design

2.2 3. Final
1.1 2.0 2.1
Select optimised Design &
Design Generate Ideas Evaluate each solution Manufacturing
Concepts idea option

Knowledge Base
1.2
Manufacturing
Concepts Cross Technology &
Functional Facilitisation
Knowledge
Who?

A core team will maintain consistency along with team members

involved from cross functional departments:
• Cross functional team – that understands each process step,
typically consisting of:
• Design engineers
• Manufacturing Engineers
• Assembly Engineers
• Cost Engineers
• Maintenance Engineers
• Service Engineers
• Quality Engineer
• Purchase / supply Chain
• Team Leaders
• Production operatives
• Logistics
• Facilitator – to manage the activity
Summary

Design For Manufacture & Assembly is a logical stepped

process that:

• Minimises product and process costs from design concept

& onwards.

• Aligns design and manufacture.

• Evaluates and evolves the Product design for ease of
manufacture and assembly.

• Evaluates & reduces complexity and part count.

• Helps with decision making by ranking & rating design &
manufacturing options.