Tuesday, July 11, 2017

Design for Manufacturing

Design for Manufacturing

1. Estimate the Manufacturing Costs
2. Reduce the Cost of Components
3. Reduce the Cost of Assembly
4. Reduce the Costs of Supporting Production
5. Consider the Impact of DFM Decisions on other Factors

Designing Products for Manufacture and Assembly (DFMA)

Product design has to ensure that manufacturing and assembly feasibility and cost are appropriately considered in the design process.

Reducing the number of parts is an important concern of DFMA. For this purpose for each separate part, the following questions are to be answered by the designer.

1. Does the part move relative to all other parts?
2. Must the part be made of different material?
3. Must the part be separate from all other parts to allow the disassembly of the product for adjustment or maintenance?

DFM Guideline
A1) Understand manufacturing problems/issues of current/past products
A3) Eliminate overconstraints to minimize tolerance demands.

P1) Adhere to specific process design guidelines.
P2) Avoid right/left hand parts.
P3) Design parts with symmetry.
P4) If part symmetry is not possible, make parts very asymmetrical.
P5) Design for fixturing.
P6) Minimize tooling complexity by concurrently designing tooling.
P8) Specify optimal tolerances for a Robust Design.
P9) Specify quality parts from reliable sources.
P10) Minimize Setups.
P11) Minimize Cutting Tools.
P12) Understand tolerance step functions and specify tolerances wisely.

Technologies to reduce production costs

Sep 11, 2005 Leslie Gordon

Software that optimizes product design

Companies can slash costs by improving the design process at its beginning. Design for manufacturing and assembly (DFMA) software includes a design-for-manufacture module, with which engineers obtain early cost estimates on parts or products, and a design-for-assembly module, which they employ to determine the best methods to manufacture products.

Engineers use the software where a design idea might still be scribbled on a napkin. Or, they use it to re-examine fully finished products to ensure design efficiency. For example, engineers take a part's geometry and determine whether the part should be made from a casting, or be machined, or injection-molded. During this process, the software draws from its large database, containing thousands of manufacturing processes, materials, and machinery, which was developed over many years in conjunction with companies such as GM and Ford.

Engineers also evaluate each assembly's function and the relationship between parts. They simplify and streamline designs repeatedly until achieving a minimum per/piece cost. For example, in one application, engineers slashed labor time by streamlining a product design to eliminate assembly screws.


Design for Manufacturability: How to Use Concurrent Engineering to Rapidly Develop Low-Cost, High-Quality Products for Lean Production - David M. Anderson - Book Information

Recent Linkedin Article
26 July 2016
What is Design for Manufacturing or Design for Assembly

Updated 13 July 2017,  30 July 2016,  27 June 2016

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