Design for Manufacturing

Teaching materials to accompany:

Product Design and DevelopmentChapter 13

Karl T. Ulrich and Steven D. Eppinger5th Edition, Irwin McGraw-Hill, 2012.

Product Design and DevelopmentKarl T. Ulrich and Steven D. Eppinger5th edition, Irwin McGraw-Hill, 2012.

Chapter Table of Contents:1. Introduction2. Development Processes and Organizations3. Opportunity Identification4. Product Planning5. Identifying Customer Needs6. Product Specifications7. Concept Generation8. Concept Selection9. Concept Testing10. Product Architecture11. Industrial Design12. Design for Environment

13. Design for Manufacturing14. Prototyping15. Robust Design16. Patents and Intellectual Property17. Product Development Economics18. Managing Projects

Planning

Product Development Process

ConceptDevelopment

System-LevelDesign

DetailDesign

Testing andRefinement

ProductionRamp-Up

How can we emphasize manufacturing issues throughout the development process?

04/19/2023 4

Outline

• DFX concept• DFM objectives• DFM method• Mfg. cost estimation• DFM impacts• DFM examples

Design for Manufacturing Example:GM 3.8-liter V6 Engine

Understanding Manufacturing Costs

Definition

• Design for manufacturing (DFM) is a development

practice emphasizing manufacturing issues

throughout the product development process.

• Successful DFM results in lower production cost

without sacrificing product quality.

04/19/2023 8

Introduction• DFM is part of DFX• DFM often requires a cross-function team• DFM is performed through the development

process

04/19/2023 9

Major DFM objectives

• Reduce component costs• Reduce assembly cost• Reduce production support costs

04/19/2023 10

The DFM Process (5 steps)1) Estimate the mfg. costs2) Reduce the costs of components3) Reduce the costs of assembly4) Reduce the costs of supporting

production5) Consider the impact of DFM decisions

on other factors.

04/19/2023 11

Estimate mfg. costs• Cost categories

– Component vs. assembly vs. overhead– Fixed vs. variable– Material vs. labor

• Estimate costs for standard parts– Compare to similar part in use– Get a quote from vendors

• Estimate costs of custom made parts– Consider material costs, labor costs, and tooling costs– Depend on the production volume as well

• Estimate costs of assembly – Summing up all assembly operations (time by rate)

• Estimate the overhead costs– A % of the cost drives

04/19/2023 12

Reduce the costs of components• Identify process constraints and cost drivers• Redesign components to eliminate processing

steps• Choose the appropriate economic scale for

the part process• Standardize components and their processes• Adhere the black-box component

04/19/2023 13

Reduce the costs of assembly• Integrate parts (using the Boothroyd

method)• Maximize ease of assembly• Consider customer assembly (do-it-

yourself) technology driven products

04/19/2023 14

Reduce the costs of supporting production

• Minimize systematic complexity (such as plastic injection modeling for one step of making a complex product)

• Error proofing (anticipate possible failure modes in the production system and take appropriate corrective actions early in the development process)

04/19/2023 15

Considering impacts• Development time• Development cost• Product quality• External factors such as

– component reuse and – life cycle costs

04/19/2023 16

Design for Manufacturing Example:1993 GM 3800cc V6 Engine Design

04/19/2023 17

DFM example• Exhibit 13-15 on Page 274• Unit cost saving of 45%• Mass saving of 66% (33 Kg.)• Simplified assembly and service procedures.• Improved emissions performance• Improved engine performance• Reduce shipping costs (due to lighter components)• Increased standardization across vehicle programs.

04/19/2023 18

Cost Appendices

• Materials costs– Exhibit 13-17 on page 279

• Component mfg. costs– Exhibits 13/18-21 on pages 280-283

• Assembly costs– Page 286 for common products– Page 287 for part handling and insertion times on

Ex. 13-23– Cost structures for firms on Ex 13-24.

04/19/2023 24

Design for X – Design principles

• Part shape strategies:– adhere to specific process design guidelines– if part symmetry is not possible, make parts very

asymmetrical – design "paired" parts instead of right and left hand parts.– design parts with symmetry.– use chamfers and tapers to help parts engage.– provide registration and fixturing locations.– avoid overuse of tolerances.

04/19/2023 25

Design for X – Design principles

• Standardization strategy– use standard parts– standardize design features– minimize the number of part types– minimize number of total parts.– standardize on types and length of linear materials and

code them.– consider pre-finished material (pre-painted, pre-plated,

embossed, anodized).– combine parts and functions into a single part.

04/19/2023 26

Design for X – Design principles

• Assembly strategies 1– design product so that the subsequent parts can be added to

a foundation part.– design foundation part so that it has features that allow it to

be quickly and accurately positioned.– Design product so parts are assembled from above or from

the minimum number of directions.– provide unobstructed access for parts and tools– make parts independently replaceable.– order assembly so the most reliable goes in first; the most

likely to fail last.

04/19/2023 27

Design for X – Design principles

• Assembly strategies 2– make sure options can be added easily– ensure the product's life can be extended with

future upgrades.– use sub-assemblies, especially if processes are

different from the main assembly.– purchase sub-assemblies which are assembled and

tested.

04/19/2023 28

Design for X – Design principles

• Fastening strategies 1– use the minimum number of total fasteners– use fewer large fasteners rather than many small fasteners– use the minimum number of types of fasteners– make sure screws should have the correct geometry so that

auto-feed screwdrivers can be used.– design screw assembly for downward motion– minimize use of separate nuts (use threaded holes).– consider captive fasteners when applicable (including

captive nuts if threaded holes are not available).

04/19/2023 29

Design for X – Design principles

• Fastening strategies 2– avoid separate washers and lockwashers (make it be

captivated on the bolt or nut so it can still spin with respect to the fastener)

– use self-tapping screws when applicable.– eliminate fasteners by combining parts.– minimize use of fasteners with snap-together features.– consider fasteners that push or snap on.– specify proper tolerances for press fits.

04/19/2023 30

Design for X – Design principles

• Assembly motion strategies– fastened parts are located before fastener is applied.– assembly motions are simple.– Assembly motions can be done with one hand or robot.– assembly motions should not require skill or judgment.– products should not need any mechanical or electrical

adjustments unless required for customer use.– minimize electrical cables; plug electrical sub-assemblies

directly together.– minimize the number of types of cable.

04/19/2023 31

Design for X – Design principles

• Automation handling strategies 1– design and select parts that can be oriented by automation– design parts to easily maintain orientation– use parts that will not tangle when handled in bulk.– use parts what will not shingle when fed end to end (avoid

disks).– use parts that not adhere to each other or the track.– specify tolerances tight enough for automatic handling.– avoid flexible parts which are hard for automation to

handle.

04/19/2023 32

Design for X – Design principles

• Automation handling strategies 2– make sure parts can be presented to automation.– make sure parts can be gripped by automation.– parts are within machine gripper span.– parts are within automation load capacity.– parting lines, spruces, gating or any flash do not

interfere with gripping.

04/19/2023 33

Design for X – Design principles

• Quality and test strategies– product can be tested to ensure desired quality– sub-assemblies are structured to allow sub-assembly

testing– testing can be performed by standard test instruments– test instruments have adequate access.– minimize the test effort spent on product testing consistent

with quality goals.– tests should give adequate diagnostics to minimize repair

time.

04/19/2023 34

Design for X – Design principles

• DF Maintenance strategies 1– provide ability for tests to diagnose problems– make sure the most likely repair tasks are easy to perform.– ensure repair tasks use the fewest tools.– use quick disconnect features– ensure that failure or wear prone parts are easy to replace

with disposable replacements– provide inexpensive spare parts in the product.– ensure availability of spare parts.

04/19/2023 35

Design for X – Design principles

• Maintenance strategies 2– use modular design to allow replacement of modules.– ensure modules can be tested, diagnosed, and adjusted

while in the product.– sensitive adjustment should be protested from accidental

change.– the product should be protected from repair damage.– provide part removal aids for speed and damage

prevention.– protect parts with fuses and overloads

04/19/2023 36

Design for X – Design principles

• Maintenance strategies 3– protect parts with fuses and overloads– ensure any sub-assembly can be accessed through one door

or panel.– access over which are not removable should be self-

supporting in the open position.– connections to sub-assemblies should be accessible and

easy to disconnect.– make sure repair, service or maintenance tasks pose no

safety hazards.– make sure sub-assembly orientation is obvious or clearly

marked.

04/19/2023 37

Design for X – Design principles

• Maintenance strategies 4– make sure sub-assembly orientation is obvious or clearly marked.– provide means to locate sub-assembly before fastening.– design products for minimum maintenance.– design self-correction capabilities into products– design products with self-test capability.– design products with test ports– design in counters and timers to aid preventative maintenance.– specify key measurements for preventative maintenance programs– include warning devices to indicate failures.

04/19/2023 38

Design for X – Design principles

• Axomatic Design by Nam Suh– Axiom 1

• In good design, the independence of functional requirements is maintained.

– Axiom 2• Among the designs that satisfy axiom 1, the best

design is the one that has the minimum information content.

04/19/2023 39

Design for X – Design principles

• Axiomatic design- corollaries– Decouple or separate parts of a solution if functional requirements are

coupled or become coupled in the design of products and processes.– Integrate functional requirements into a single physical part or

solution if they can be independently satisfied in the proposed solution.

– Integrate functional requirements and constraints.– Use standardized or interchangeable parts whenever possible.– Make use of symmetry to reduce the information content.– Conserve materials and energy.– A part should be a continuum if energy conduction is important.

04/19/2023 40

Design for X – Design principles

• DFA Method: Boothroyd and Dewhurst – Apply a set of criteria to each part to

determine whether, theoretically, it should be separated from all the other parts in the assembly.

– Estimate the handling and assembly costs for each part using the appropriate assembly process - manual, robotic, or high-speed automatic.

04/19/2023 41

Design for X – Design principles

• Three criteria– Is there a need for relative motion?– Is there a need for different materials– Is there a need for maintenance?

Design for Assembly RulesExample set of DFA guidelines from a computer manufacturer.

1. Minimize parts count.2. Encourage modular assembly.3. Stack assemblies.4. Eliminate adjustments.5. Eliminate cables.6. Use self-fastening parts.7. Use self-locating parts.8. Eliminate reorientation.9. Facilitate parts handling.10. Specify standard parts.

Design for Assembly• Key ideas of DFA:

–Minimize parts count–Maximize the ease of handling parts–Maximize the ease of inserting parts

• Benefits of DFA–Lower labor costs–Other indirect benefits

• Popular software developed by Boothroyd and Dewhurst.–http://www.dfma.com

To Compute Assembly Time

Handling Time

+ Insertion Time

Assembly Time

Method for Part Integration

• Ask of each part in a candidate design:

1.Does the part need to move relative to the rest of the device?

2.Does it need to be of a different material because of fundamental physical properties?

3.Does it need to be separated from the rest of the device to allow for assembly, access, or repair?

• If not, combine the part with another part in the device.

Three Methods to Implement DFM

1. Organization: Cross-Functional Teams

2. Design Rules: Specialized by Firm

3. CAD Tools: Boothroyd-Dewhurst Software

DFM Strategy is Contingent

CorporateStrategy

ProductionStrategy

ProductStrategy

DFMStrategy

Other Images