Engineering in Industrial Engineering - Machine work study or machine effort improvement, value engineering and design for manufacturing and assembly are major engineering based IE methods. All are available as existing methods.
The One Million Dollar Story - Our way to success with DFMA
Dr. Volker Frey, Endress+Hauser, Maulburg / Germany
Endress+Hauser, the People for Process Automation.
Endress+Hauser is a leading global provider of process and laboratory measurement technology, automation solutions and services.
Level Measurement: offers an extensive selection of measurement principles for the continuous measurement of levels, interfaces and density as well as level limit detection.
Flow Measurement: Flow devices measure liquids, gases and steam in both small and large quantities.
Pressure Measurement: offers high-performance devices for measuring process pressure, differential pressure, fill level and flow.
Liquid Analysis: Endress+Hauser offers a comprehensive portfolio for all parameters in liquid analysis. Advanced optical technologies are used in the gas analyzers as well as the Raman analyzers.
Temperature Measurement: A full-range supplier of temperature measurement technology, including compact and modular thermometers, thermowells, measurement inserts, temperature transmitters and accessories.
System products and data managers from Endress+Hauser supply energy to measurement devices and protect them from power surges.
2. Best Cost Position as a strategic target
In 2016, Endress+Hauser (E&H) released new strategy “2020+” which consists of ten major strategic fields and one of them is to improve product related cost position.
Efforts were put in to develop robust and efficient production processes and to develop cost optimized products. The goal is to develop products which are easy to assemble out of cost optimized and prize optimized parts.
DfMA was selected as the preferred tool to fulfil this target. An initial evaluation of tools, methods and consulting companies identified three possible suppliers. With each of them, they had detailed discussions about their methodologies, software and support and tested their capability in a pilot project.The best supplier turned to be BDI and its European representative amc. The company awarded the contract and together with amc/BDI they started their DFMA activity.
3. The importance of Change Management, organization and communication
Endress+Hauser decided to select one responsible coordinator who stands for the implementation of the DfMA Methodology, drives communication throughout the company about the benefit and who organizes the Workshops as well as the Training and the purchasing of the Software. Four DfMA moderators selected together with eight DfM Specialists. Throughout the year 2017 scheduled training programs for the moderators as well as the DfM Specialists were conducted and performed several DfMA workshops together with amc´s support. Each specialist was involved in the development process of a product. Many were involved in the project to bring the knowledge of the many involved people into a new product.
The design of new products was examined from all disciplines of the value generation process until the first designs were released for purchasing or production.
In a first phase the proposed methodology of BDI for our DfMA workshops was adopted. Starting with a Pick-up Workshop where we generated the cost baseline as well as the product structure during disassembly of the first design, generated new ideas during reassembly and improved the ideas along the minimum parts criteria. To evaluate the benefit of all the many concurrent new ideas which were generated during disassembly and reassembly we decided to go for a methodology developed by amc which is called the delta evaluation.
To evaluate the cost benefit of each new idea created in comparison to the initial basic design approach, an Excel form sheet provided by amc was used. Each new solution to other concurrent ideas and the original design were compared in a transparent and traceable manner. This gives not only to a very conclusive process, it also gives us the option to document and store good ideas for further reuse in future development projects.
4. The early bird catches the biggest worm
In combination with a thoroughly designed implementation plan, a stable organizational set up of key players and a good communication plan were used to get a good success during the first year of implementation of DfMA in the organization.
Four DfMA- workshops were done in the first year where already running projects were studied and participants tried to optimize the design of the product according to the rules of DfMA. There was a decent success. The real breakthrough came, when the DfMA Workshops were done on new products at the very initial phase of a development project.
There was much more freedom of ideas and they could influence the project much more which ended up in a much higher amount of savings.
Based on this experience they decided to make a DfMA workshop mandatory for each project which will be started at a very early phase directly connected to its official project release.
5. Success in facts and figures
During the first two years of DfMA at Endress+Hauser, the following benefits were realized.
- 583 ideas generated
- 1.070.679 US$/per year cost saving potential generated
- 3 DfMA cost evaluations
- 6 DfMA Workshops
- 26 DfM evaluation workshops
- 121 different participants of our company
- the cost transparency of products and awareness of the people
- generate a mutual understanding of development, production, procurement, service, marketing
- and a reduction of development times as well as
- more ergonomic assembly,
- increased quality and process stability in production
Two sister companies started to implement this methodology created and maintained by BDI/amc and had a huge success by this methodology.
Each new DfMA workshop, adds further savings.
This Maulburg DfMA team won the E+H Process Innovation Award 2018 which is a big honor for the team and for BDI and amc as well.
Dr. Volker Frey thanks BDI and amc consultants for the excellent tool training and support.
https://www.dfma.com/resources/endress.asp
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https://www.youtube.com/watch?v=00dEjmZlIDY
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