Concept System-Level Detail Testing and Production
Planning Development Design Design Refinement Ramp-Up
How can we emphasize manufacturing issues
throughout the development process?
General Motors Power train Division
manufactures 3,500 3.8-liter V6
engines every day
Facing high production volumes –
reduce cost while simultaneously
enhancing its quality
Improve one of the most expensive
subassemblies in the engine (air
intake manifold
(The intake manifold's- primary function is to route air from the throttle to the
intake valves at the cylinders.)
- redesigned intake manifold assemblies
GM V6 intake manifold as an example
LEARNING OBJECTIVES
At the end of this chapter, student should be able to:
• Explain the concept of DFM in view of product development
process
• Apply the DFM methodology in the product development
process
Design for manufacturing (DFM)
Emphasizing manufacturing issues throughout product
development process.
Successful DFM results
- lower production cost with same quality of product
Example Terminology used:
VACD – Value analysis cost down
How to implement?
- Simplified the design
- Combination no. of parts
- Used different material
- Change the process
1. Organization: Cross-Functional Teams
-Utilized information - sketches, drawings, prod. spec & dsg. alternatives
- fully understand prod. & assy. processes
- estimates mfg costs, prod. volumes, & ramp-up time
2. Design Rules: Specialized by Firm
-determine product's functions & spec
- product concept
- break up the individual components
3. CAD Tools: Boothroyd-Dewhurst Software
5 Step of DFM Process
[Link] mfg costs.
[Link] component cost
[Link] assy. cost
[Link] supporting prod. cost
[Link] impact of DFM decisions on other factors.
Input
-raw materials, purchased components, employees, energy &
equipment
OUTPUT
- finished goods and waste
Consideration
-boundaries of the manufacturing system
- product development activities
- expensive general-purpose equipment
Manufacturing Cost
Components Assembly Overhead
Equipment Indirect
Standard Custom Labor Support
and Tooling Allocation
Raw
Processing Tooling
Material
1 Fixed Costs vs. Variable Costs
2
The Bill of Materials – product tree
3 Estimating the Costs of Standard Components.
- comparing each part with similar part
- soliciting price quotes from vendors or suppliers
4 Estimating the Costs of Custom Components
- types of production processes
5 Estimating the Cost of Assembly
- assembly volume
6 Estimating the Overhead Costs
Understand the Process Constraints and Cost Drivers
- tooling construction
- tooling modification
- part dimension
Redesign Components to Eliminate Processing Steps
- steps in the part fabrication process
Choose the Appropriate Economic Scale for the Part Process
(1) fixed costs - divided among more units
(2) variable costs - more efficient processes and equipment
Standardize Components and Processes
- selection of components and processes
- production volume increases, cost of component decreases
Adhere to "Black Box" Component Procurement
- description of what component has to do, not how to achieve it (Clark and Fujimoto, 1991)
- Leaves vendor to design or select the component for minimum cost
- emphasis on DFA,
Keeping Score
- Boothroyd and Dewhurst (1989)
DFAindex=
(theoritical minimumnumberof parts)x(3 seconds)
estimatedtotalasembly time
Estimated total assembly time
- Does part need to move?
- Must part made from different material ?
- Does part have to separate for assy. replacement, or repair?
Integrate Parts.
- Insert mold
- Combine part: button
Maximize Ease of Assembly
- How to assemble? - No orientation - No tools required
- Part self aligning - One hand assy. - Secure after insertion
Consider Customer Assembly
- D.I.Y concept
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.
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.
[Link]
Minimize Systemic Complexity
- utilize a single process
Error Proofing
- identify possible failure modes
- select correct parts . E.g. Screw size
Handling Time
+ Insertion Time
Assembly Time
Ask of each part in a candidate design:
1. Does the part need to move relative to the rest of
the device?
[Link] it need to be of a different material because of
fundamental physical properties?
[Link] 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.
-Product economic success also depends on quality of product, time product introduce,
cost of development
Impact of DFM on Development Time
- type of product
- DF A guidelines may result in very complex parts
Impact of DFM on Development Cost
- mirrors of development time
- correlation between good project management
Impact of DFM on Product Quality
- cost reduction, weight reduction improved performance?
- improved serviceability, ease of disassembly, and recycling?
Impact of DFM on External Factors
- Component reuse: - time and money to create a low-cost component
- cost implications for other projects.
- Life cycle costs - service and warranty costs
Results
- DFM is an essential part of almost every product development effort
- Some company have reduced production costs up to 50 percent
Corporate
Strategy
Product
Strategy
Production
Strategy DFM
Strategy
Design for manufacturing (DFM) – aim to reduce manufacturing costs & improve
product quality, development time, and development cost.
DFM begins with concept development phase and system-level design phase
( important decisions & manufacturing cost implications is in mind.)
DFM utilizes estimates of manufacturing cost. Suppliers and manufacturing
experts must involved
DFM involves making informed decisions - accurate cost estimation is difficult.
Component costs reduced by understanding what drives these costs.
Assembly costs can be reduced by following well-established design-for-
assembly (DF A) guidelines.
Reduction of manufacturing support costs begins with an understanding of the
drivers of complexity in the production process.
DFM is an integrative method - require inputs across the development team.
DFM decisions can affect product development lead time, product development
cost, and product quality.
Trade-offs necessary between manufacturing cost and these equally important
as broader issues