DesignforManufacture
(DFM)
Introduction GeneralGuidance
DFMIntroduction
Manufacturingsystemstypicallycomprisealargenumberofprocessesor
stages
Eachaffectproductcost,productquality,andproductivityoftheoverall
system,eitherindividuallyorcollectively.
Interactionsbetweenthefacetsofthemanufacturingsystemarecomplexso
decisionsconcerningoneaspectmayhaveramificationsthatextendtothe
others.
2
ManufacturingInteractions
Product
Design
Material
MaterialHandling Selection&
Processing
Purchased
QualityControl Components
Assembly
CostContributors?
Whatfactorscontributetotheoverallcostofa
product?
CostContributors?
Designersneedto:
Designproductformanufacturebythemostappropriate
processesintermsof:
Quality
Cost
Availability.
Considerassemblyrequirements fundamentalto
manufactureofmostcomponents.
DFMGuidlines
1. MinimisePartCount
2. ModularDesign
3. MinimisePartVariations
4. MultifunctionalParts
5. PartsforMultipleUse
DFMGuidelines
[Link]
Eliminatingpartsresultsinsavings,fewerpartsmeanless:
time,
drawings,
partnumbers,
records,
purchaseorders,
vendors.
DFMGuidelines
[Link] (contd)
Apartthatiseliminatedcosts:
nothingtomake,
nothingtoassemble,
nothingtomove,
nothingtostore,
nothingtoclean
nothingtoinspect.
DFMGuidelines
[Link] (contd)
Ausefulwaytominimisepartsistosetaminimum
partcountattheconceptualdesignstageand/or
considercombiningtwoormorepartsintoone.
DFMGuidelines
[Link] (contd)
Partstoconsiderforremovalorforcombiningare
partswhichneed:
norelativemotion
nosubsequentadjustment
noservicingorreparability
nodifferenceinmaterials
DFMGuidelines
[Link] (contd)
However,takecare!Removingtoomanypartsor
inappropriatepartscanaddcostsiftheremainingparts
becometooheavyortheirdesignandshapebecomes
toocomplex.
DFMGuidelines
PartsReductionExample
DFMGuidelines
PartsReductionExample contd
Twodifferenttypesofsprocketandgearwheel:
a)Requiresassembly:ismadeofsteel producedbymachining
[Link],[Link]
duetoproductiontechnique.
b) Requiresnoassembly:producedfromsinteredmetal teeth
sinteredinaccordancewiththerequiredtoleranceandsurface
quality;advantages nowastematerial,shortprocessingtime
andnoassembly.
DFMGuidelines
[Link]
Recognisedmethodforreducingpartscountisthe
ValueEngineeringMethod(VEM)
Aim:Toincreaseormaintainthevalueofaproductto
thepurchaserwhilereducingitscosttothe
manufacturer.
DFMGuidelines
[Link]
ValueEngineeringMethodprocedure:
Listseparatecomponentsoftheproduct,andidentify
thefunctionofeachcomponent
Determinethevaluesoftheidentifiedfunctions
Determinethecostsofthecomponents
Searchforwaysofreducingcostwithoutreducingvalue,
oraddingvaluewithoutaddingcost
Evaluatealternativesandselectimprovements.
DFMGuidelines
[Link]
Module aselfcontainedcomponent standard
interfacewithothercomponentsinthesystem,e.g.
interchangeablecameralenses,pluginmodulesfor
electronicinstruments.
Modulardesign opportunitytostandardise but
productscanbecustomisedbyusingdifferent
combinationsofstandardmodules.
DFMGuidelines
[Link]
Resistanttoobsolescence newproductscanutilise
someoldmodules especiallyimportantinthe
automotiveindustrywherespeedofchangeisever
increasing.
Benefitsservice andrepairneeds andaidsthefinal
assemblytask.
Majordisadvantagecost manymoreextrafittingsand
interconnectionsmayberequired
DFMGuidelines
[Link]
Usestandardcomponents preferredsizes standard
partscostlessthanspecials.
Qualityproblemsreducedwhenpartvariationsare
minimised.([Link])
littlejustificationforseveralscrewsizes/typesofmetalina
singlepart.
Reducedpartvariationalsominimisesinformationrequired
bytheproductionsystem.
DFMGuidelines
[Link]
Minimisepartscountbydesigningpartstofulfilmore
thanonefunction,e.g.:
designaparttoactasanelectricalconductorandasa
structuralmember
F1Car gearbox/transmissionformspartofchassis
Motorcycleengineformsastressedmemberoftheframe
DFMGuidelines
[Link]
Keytothisapproachistoidentifycandidatesformultiple
[Link]
consistingof:
partswhichareuniquetoaparticularproduct,
[Link],bearingsetc.
Partsgenerallyneededinallproductsormodels,
[Link],spacers,shaftsetc.
DFMGuidelines
[Link]
[Link]
approachistosortpartsintotwogroupsconsistingof:
Divideeachgroupintocategoriesofsimilarparts(partfamilies)
Create Multiusepartsbystandardisingsimilarparts.
Thensequentiallyseektominimisethenumberofpartcategories,
thenumberofvariations withineachcategoryandthenumberof
designfeatures withineachvariation
DFMGuidelines
1. MinimisePartCount
2. ModularDesign
3. MinimisePartVariations
4. MultifunctionalParts
5. PartsforMultipleUse
DFMGuidelines
[Link]
Requiresthatpartsneedtobe:
Designedusingthe leastcostlymaterial thatjust
satisfiesfunctionalrequirements (includingstyleand
appearance)andminimisesmaterialwasteandcycle
time.
Madebythemostsuitablefabricationprocessavailable
andbeproperlydesignedforthatprocess
Madeusinganearnetshape processwhenever
possible
DFMGuidelines
[Link] (contd)
Requiresthat:
Secondaryprocesses(machining,painting)areavoided,
byspecifyingtolerances,surfacefinishandmaterial
carefully
Selectingprimaryprocesses(casting,moulding,sintering)
whichmeetcomponentrequirements.
Materials which avoidtheneedforpainting,buffing,
[Link]/or
processcostscanbeacceptediftheyleadtolower
overallproductioncosts.
DFMGuidelines
[Link]
Automatedassembly separatefastenersaredifficulttofeed,tend
tojam,requiremonitoringforpresenceandtorqueandrequire
costlyfixtures,partsfeedersetc.
Manualassembly costofdrivingascrewcanbeuptotentimes
thecostofthescrew.
Eliminatefastenersbyusingsnapfitsortabs.
Sometimes,[Link]
anautomotiveplantwherescrewsareusedforsecuringandjoining
[Link],andeaseof
adjustment/replacementmakesthemamust.
DFMGuidelines
[Link] (contd)
Whereused,costandqualityriskscanbereducedbyminimisingthe
number,sizeandvariationofthefastenersused.
Avoidfastenerswhicharetoolong/shortandwhichneedseparate
washersand/ortappedholes.
Wherefastenersareusedselftappingscrewswithcaptivewashers
arepreferred.
VW coneshapedtippedscrewseventhough18%moreexpensive,because
theygointoholesmoreeasily,especiallyifpartsarenotwellaligned.
Enabledassemblytobesimplifiedsothatthefasteningcouldhedoneby
robots,substantiallyreducingcosts.
Becamesopopularthroughouttheautoindustrythatwithintwoyearsthe
priceofconeshapedscrewshaddroppedtothatofordinaryscrews.
DFMGuidelines
[Link]
Assembleallpartsfromonedirection.
Extradirectionsmeanwastedtimeandmotion,need
moretransferstations extracostsduetoreliabilityand
qualityrisks
Ideallyinanyassemblyallpartsaddedinatopdown
fashiontocreateaZaxisstack withallpartspositively
locatedastheyareadded.
DFMGuidelines
[Link]
Excessiveassemblyforcerequiredifpartsarenot
identical/perfectlymade.
Requiresappropriateproductdesignwithcompliance
featurese.g.
Generoustapers,chamfersandradii.
Makingoneofthecomponentsoftheproductthepartto
whichotherpartsareaddedtoavoidtheneedforanassembly
fixture&providingarigidlocationsurfaceintheproductitself.
Mayrequiredesignfeaturesthatarenotneededforthe
productfunction.
DFMGuidelines
ComplianceinAssembly Example
DFMGuidelines
[Link]
Partsshouldbedesignedtoallowtherequiredpositiontobe
achievedeasily.
Morepositionsrequiredinassemblymeansincreasedequipment
[Link]
symmetricalasfunctionwillallow
CorrectOrientationofpartscanbeassistedbydesignfeaturesto
helpguideandlocatepartsintorequiredposition featuresmay
notbeneededforproductfunction
Palletisedtraysandkitsaremethodsofsupplyingproperly
orientedpartstotheassemblyline
Foreaseofhandlingavoidflexiblecomponents,userigidgaskets,
circuitboardsinplaceofcableetc.
DFMGuidelines
[Link] (contd)
Designrulestogivemorefocus include:
Spacingofholesinmachined,cast,stampedparts,to
allowforoneoperationwithouttoolingweakness
thislimitshowcloseholesmaybespaceddueto
strengthinthethinsectionbetweenholes
Avoidgeneralisedstatementsondrawingse.g.
'polishthissurface'ortoolmarksnotpermitted' difficult
formanufacturingpersonneltointerpret
Notesondrawingsshouldbespecificandnotambiguous.
DFMGuidelines
[Link] (contd)
Designrulestogivemorefocus include:
Dimensions generallyfromspecificpointsor
surfacesonthepart(notfrompointtopoint)aidthe
creationoffixtures,gauges,[Link]
tolerancestacking
Particulardesignrules contd
DFMGuidelines
6. Easeoffabrication
7. Avoidseparatefasteners
8. Minimiseassemblydirections
9. Maximisecomplianceinassembly
10. Minimisehandlinginassembly
DFMGuidelines
Designrulestogivemorefocus include:
Designingforminimumweight,consistentwith
strengthandrigidityrequirementsensuresa
reductioninmaterialcostsandapossiblereduction
inlabour/toolingcharges
Designingpartssothatmanyoperationscanbe
performedwithoutrepositioningpromotes
accuracyandminimisehandling
DFMGuidelines
Designrulestogivemorefocus include:
DesigntopermitgeneralpurposetoolingAvoids
specialdies,[Link]
productionwherespecialtoolingcanbejustified
ToolsandTechniques
ToolsusedbyLucasIndustriesintheProduct
IntroductionManagement(PIM)processinclude:
DesignforAssembly(DFA)
QualityfunctionDeployment(QFD)
FailureModeEffectsAnalysis(FMEA)
DesignofExperiments(DOE)
ToolsandTechniques
[Link](DFA)
FunctionalAnalysis 1
Listallcomponents byname&numberonanalysis
chart
Step1 Functionalrequirementofproduct?
Step2 Considerproductaswholeorfunctionalsub
sections? (wholeisbest avoidanceofduplication)
Step3 Identifycategoryofcomponent
AFunctional [Link],driveshafts,
adjustingscrew,timingbeltetc.
B Nonfunctional notcriticaltoperformance,[Link],
locationfeatures,lockingdevicesetc.
FunctionalAnalysis 2
Startwithmajorfunctionalcomponent consider
matingcomponentsinlogicalprogression
Categorise usingtheFunctionalCriteriaChart
DeterminetheDesignEfficiencyfrom:
Number of A components
E 100%
Total Number of components
NB:Highaspossible minimum60%
BenefitsObtained
Anaveragepartcountreductionof46%and
Anaverageassemblycostreductionof47%.
Implementedunitcostsavingsondirectlabourand
materialcostsonlyarereportedintherange15
35%.
PartsCountReduction(example)
ProcessSelectionDrivers
Productquantity Material/process
compatibility
Equipmentcosts
Toolingcosts Componentformand
dimensions
Processingtimes
Tolerancerequirements
Labourintensityandwork
patterns Surfacefinishneeds
Processsupervision Bulktreatmentandsurface
engineering
Maintenance
Processtocomponent
Energyconsumptionand
variability
otheroverheadcosts
Materialcostsand Processwaste
availability Componentrecycling
CostofDifferentProcess
SimultaneousEngineering
DesignEfficiencyExample
DesignEfficiencyExample
Whatisthefunctionofthe
product?
DesignEfficiencyExample
Partcount?
DesignEfficiencyExample
MakesureyouconsiderALLComponents!
DesignEfficiencyExample
Partcount?
DesignEfficiencyExample
