"To manufacture" refers to the manufacturing of the individual component parts of a product or assembly
"To assemble" refers to the addition or joining of parts to form the completed product.
The term "design for manufacture" (or DFM) means the design for ease of manufacture of the collection of parts that will form the product after assembly.
"Design for assembly" (or DFA) means the design of the product for ease of assembly.
Thus, "design for manufacture and assembly" (DFMA) is a combination of DFA and DFM.
1. As the basis for providing guidance to the design team in simplifying the product structure, to reduce manufacturing and assembly costs.
2. As a tool to study competitors' products and quantify manufacturing and assembly difficulties.
3. To support should-cost models.
In 1988 Ford Motor Company reported that Boothroyd DFA software had helped them save billions of
dollars on their Taurus line of automobiles. Later, General Motors (GM) made comparisons between its assembly plant at Fairfax, Kansas, which made the Pontiac Grand Prix, and Ford's Atlanta assembly plant for its Taurus and Mercury Sable models. GM found a large productivity gap and concluded that 41% of the gap could be traced to the manufacturability of the two designs. For example, the Ford car had fewer parts—10 in its front bumper compared with 100 in the GM Pontiac—and the Ford parts fit together more easily.
Subsequently , GM has become one of the leading users of DFMA. It became a driver of quality and cost improvement through technical improvements to both product and process. It was made an integral part of engineering and manufacturing employee training.
Ingersoll-Rand Company reported that the use of DFMA software from Boothroyd Dewhurst, Inc., slashed product development time from two years to one. Examples of benefits: The number of parts in a portable compressor radiator and oil-cooler assembly from 80 to 29, decreased the number of fasteners from 38 to 20, trimmed the number of assembly operations from 159 to 40 and reduced assembly time from 18.5 to 6.5min. The new design went into full production in February, 1990.
DFMA efforts at Hewlett Packard Loveland started in the mid-1980s with redesign of existing products and continued with application to new product design. During these studies, one to three manufacturing engineers interacted frequently with the R&D team members and gave their suggestions and opinion. The studies proved the benefits of DFMA and eventually, by 1992, HP Loveland had incorporated DFMA into a formal concurrent engineering approach. There was significant improvement in their product manufacturing and assembly costs.
DFMA and Value Analysis
DFMA can be compared with Value Analysis. The objectives of DFMA and value analysis are the same. If some think that value analysis is more comprehensive, they have to realize that
13 value analysis techniques of L.D. Miles does not include the steps advocated in DFMA. DFMA is a more technically intensive method. DFMA is meant to be applied early in the design cycle and value analysis does not have any techniques or tools to give proper attention to the structure of the product and its possible simplification. Hence value engineering has to include DFMA in its techniques appropriately. DFMA is a systematic step-by-step procedure that can be applied at all stages of design and that challenges the designer or design team to justify the existence of all the parts and to consider alternative designs. Experience has shown that DFMA still makes significant improvements of existing products even after value analysis has been carried out.
*Design for Manufacture and Rapid Prototyping Both Seek the Same Size Prize: A Better Product Made Faster.
Mechanical Engineering. Sep 1999, 121(09): 72-74 (3 pages)
DFMA One Among Many Techniques
Since the introduction of DFMA, many more design based techniques have been proposed, for example, design for quality (DFQ), design for competitiveness (DFC), design for reliability, and many more. Design for performance is also specially advocated now whereas Miles argued that in his time design for performance is getting all the attention and design for value is not getting attention. Boothroyd remarks that DFMA is the subject that has been neglected over the years, while adequate consideration has always been given to the design of products for performance, appearance, etc. DFMA tools also encourage dialogue between designers and the manufacturing engineers and any other individuals who play a part in determining final product costs during the early stages of design. This means that teamwork is encouraged and the benefits of simultaneous or concurrent engineering can be achieved.
DFMA is an important technique to be used in product industrial engineering.
Further Articles on DFMA
DFMA - Case Studies
DFMA Software Company
When manufacturers need to reduce costs, they call Boothroyd Dewhurst. The company’s innovative software lets manufacturers estimate the cost of components and recommends efficient designs that save time and money. It was founded by two University of Rhode Island engineering faculty and now in the hands of URI alumni. Launched in 1983 by then URI engineering Professors Geoff Boothroyd and Peter Dewhurst, the company now counts more than 800 clients with names like General Electric, Boeing, Whirlpool, Motorola and John Deere. President H.W. Bush awarded the professors the National Medal of Technology for their work.
Brian Rapoza and Nicholas Dewhurst, URI engineering alumni are research and development manager and vice president, respectively, at Boothroyd Dewhurst in Rhode Island. It’s a place where innovation flourishes and a passion for encouraging U.S. manufacturing runs deep. Peter Dewhurst’s son, mechanical engineering undergraduate alumnus Nicholas Dewhurst (’93), is executive vice president on the frontlines of exchanges between client engineers and his company.
COMBINED APPLICATION OF CAXX AND DFMA TECHNIQUES IN THE DESIGN PROCESS
2012
Tamás KULCSÁR, Imre TIMÁR
APPLYING DFMA TECHNIQUES IN THE DESING IN THE DESIGN AND MANUFACTURE OF WIND TUNNEL MODELS
June 2017International Journal Advanced Quality 45(1):35
DOI:10.25137/IJAQ.n1.v45.y2017. p35-40
Authors: Srdjan Živković, Military Technical Institute, Belgrade, Serbia & Dušan Ćurčić
Metal Air Battery Shell Unit Redesign with DFMA Aspect
Design for Manufacturing Analysis on the front wheel hubs
by AACY Yu · 2008
Integration and Application of TRIZ and DFMA: Two case studies; one a simple
system and the other a more complex aerospace system.
Redesigns get radical improvements using DFMA: Precision engineering slices 500 parts off plasma cutter design
Case Study: DFMA guidelines used to compare the three VR controllers, the PlayStation Move controller to design new simpler controller. - Detailed Report
Design for manufacturing and assembly (DFMA) in ABB
Tomasz Nowak, Marcin Chromniak, Robert Sekula, Lucas-Lu Gao
ABB Review 2006.
Small Satellite - DFMA Case Study - Raytheon - 2007
Redesigning of Shopping Cart for Cost Reduction Using DFMA
C. D. Naiju, Pranav. V. Warrier and V. Jayakrishnan
School of Mechanical Engineering, VIT University, Vellore, India
MATEC Web of Conferences 95 matecconf/201
ICMME 2016
DFMA ASPECTS OF THE SHEET METAL PARTS IN A POWER ELECTRONIC
SYSTEM CABINET
Bachelor’s thesis of Jarkko Matikka
2018
39 pages
Application of Design for Manufacturing and Assembly: Development of a Multifeedstock Biodiesel Processor
By Ilesanmi Afolabi Daniyan and Khumbulani Mpofu
Published: November 5th 2018
DOI: 10.5772/intechopen.80085
DFMA helps medical OEM save plenty.
Don’t just demand lower prices from your suppliers; A mechanical engineer at a veterinary device manufacturer used DFMA software and worked with his injection molding supplier, PTA Corp., to turn 43 parts into a single injection molding, and consolidated 30 other parts into just four plastic ones, all courtesy of a mammoth metal-to-plastic conversion.
Matt Defosse | Jan 13, 2011
DFMA for Early Cost Estimation of Pedestal Fan - A Case Study
C. D. Naiju, V. Jayakrishnan and Pranav. V. Warrier
SMEC, VIT University, Vellore, India
Journal of Industrial and Intelligent Information Vol. 5, No. 1, June 2017
Hinge Assembly DfMA Design and Implementation
January 7, 2020
Akshay Harlalka, C. D. Naiju, Mukund Nilakantan Janardhanan & Izabela
Nielsen (2016) Redesign of an in-market food processor for manufacturing cost reduction
using DFMA methodology, Production & Manufacturing Research, 4:1, 209-227, DOI:
10.1080/21693277.2016.1261052
To link to this article: https://doi.org/
Redesigning of Agarwood Extracting Machine Applying DFMA Principle
M S Salim1, M A Lajis1, Z C Ros2, A Nawawi3, S Shamsudin1 and N K Yusuf1
Published under licence by IOP Publishing Ltd
IOP Conference Series: Materials Science and Engineering, Volume 637, The 3rd International Conference on Robotics and Mechantronics (ICRoM 2019) 9–11 August 2019, Sabah, Malaysia
Citation M S Salim et al 2019 IOP Conf. Ser.: Mater. Sci. Eng. 637 012006
DFMA APPLIED in LONGBOW APACHE HELICOPTER .
Design for Manufacturing and Assembly Application on the design of the AH64D Helicopter.
Consultants - DFMA
https://concept274.com/
What is DFMA®? - Video by Boothroyd Dewhurst, Inc.
Design for Manufacture and Assembly (DFMA®) is a powerful cost reduction strategy employed by hundreds of global manufacturers.
DFMA Research Papers
Redesign methodology for mechanical assembly
AbdulRahman El-Nounu, Atanas Popov, and Svetan Ratchev
Res Eng Des. 2018; 29(1): 107–122.
(Interesting developments in DFMA methods mentioned in the paper.
Book
Product Design for Manufacture and Assembly, Second Edition - Contents
Geoffrey Boothroyd, Peter Dewhurst, Winston A. Knight
1.1 What Is Design for Manufacture and Assembly? 1
1.2 How Does DFMA Work? 8
1.3 Reasons for Not Implementing DFMA 16
1.4 What Are the Advantages of Applying DFMA During
Product Design? 21
1.5 Typical DFMA Case Studies 22
1.6 Overall Impact of DFMA on U.S. Industry 34
1.7 Conclusions 39
References 40
2. Selection of Materials and Processes 43
2.1 Introduction 43
2.2 General Requirements for Early Materials and Process Selection 45
2.3 Selection of Manufacturing Processes 46
2.4 Process Capabilities 48
2.5 Selection of Materials 55
2.6 Primary Process/Material Selection 65
2.7 Systematic Selection of Processes and Materials 71
References 83
3. Product Design for Manual Assembly 85
3.1 Introduction 85
3.2 General Design Guidelines for Manual Assembly 86
3.3 Development of the Systematic DFA Methodology 93
3.4 Assembly Efficiency 93
3.5 Classification Systems 96
3.6 Effect of Part Symmetry on Handling Time 96
3.7 Effect of Part Thickness and Size on Handling Time 101
3.8 Effect of Weight on Handling Time 103
3.9 Parts Requiring Two Hands for Manipulation 104
3.10 Effects of Combinations of Factors 104
3.11 Effect of Symmetry for Parts that Severely Nest or Tangle and May Require Tweezers for Grasping and Manipulation 104
3.12 Effect of Chamfer Design on Insertion Operations 105
3.13 Estimation of Insertion Time 108
3.14 Avoiding Jams During Assembly 109
3.15 Reducing Disc-Assembly Problems 111
3.16 Effects of Obstructed Access and Restricted Vision on
Insertion of Threaded Fasteners of Various Designs 112
3.17 Effects of Obstructed Access and Restricted Vision on Pop-Riveting Operations 115
3.18 Effects of Holding Down 115
3.19 Manual Assembly Database and Design Data Sheets 118
3.20 Application of the DFA Methodology 119
3.21 Further Design Guidelines 125
3.22 Large Assemblies 128
3.23 Types of Manual Assembly Methods 130
3.24 Effect of Assembly Layout on Acquisition Times 133
3.25 Assembly Quality 137
3.26 Applying Learning Curves to the DFA Times 141
References 143
4. Electrical Connections and Wire Harness Assembly 147
4.1 Introduction 147
4.2 Wire or Cable Harness Assembly 149
4.3 Types of Electrical Connections 152
4.4 Types of Wires and Cables 159
4.5 Preparation and Assembly Times 160
4.6 Analysis Method 182
References 190
5. Design for High-Speed Automatic Assembly and Robot Assembly 191
5.1 Introduction 191
5.2 Design of Parts for High-Speed Feeding and Orienting 192
5.3 Example 196
5.4 Additional Feeding Difficulties 199
5.5 High-Speed Automatic Insertion 199
5.6 Example 201
5.7 Analysis of an Assembly 202
5.8 General Rules for Product Design for Automation 203
5.9 Design of Parts for Feeding and Orienting 208
5.10 Summary of Design Rules for High-Speed Automatic Assembly 210
5.11 Product Design for Robot Assembly 211
References 217
6. Printed Circuit Board Design for Manufacture and Assembly 219
6.1 Introduction 219
6.2 Design Sequence for Printed Circuit Boards 220
6.3 Types of Printed Circuit Boards 220
6.4 Terminology 222
6.5 Assembly of Printed Circuit Boards 223
6.6 Estimation of PCB Assembly Costs 238
6.7 Case Studies in PCB Assembly 244
6.8 PCB Manufacturability 249
6.9 Design Considerations 252
6.10 Glossary of Terms 263
References 266
7. Design for Machining 267
7.1 Introduction 267
7.2 Machining Using Single-Point Cutting Tools 267
7.3 Machining Using Multipoint Tools 275
7.4 Machining Using Abrasive Wheels 284
7.5 Standardization 290
7.6 Choice of Work Material 291
7.7 Shape of Work Material 293
7.8 Machining Basic Component Shapes 294
7.9 Assembly of Components 307
7.10 Accuracy and Surface Finish 308
7.11 Summary of Design Guidelines 311
7.12 Cost Estimating for Machined Components 313
References 337
8. Design for Injection Molding 339
8.1 Introduction 339
8.2 Injection Molding Materials 340
8.3 The Molding Cycle 342
8.4 Injection Molding Systems 344
8.5 Injection Molds 346
8.6 Molding Machine Size 351
8.7 Molding Cycle Time 353
8.8 Mold Cost Estimation 359
8.9 Mold Cost Point System 367
8.10 Estimation of the Optimum Number of Cavities 369
8.11 Design Example 372
8.12 Insert Molding 374
8.13 Design Guidelines 375
8.14 Assembly Techniques 376
References 379
9. Design for Sheet Metalworking 381
9.1 Introduction 381
9.2 Dedicated Dies and Press-working 383
9.3 Press Selection 403
9.4 Turret Pressworking 409
9.5 Press Brake Operations 413
9.6 Design Rules 416
References 422
10. Design for Die Casting 423
10.1 Introduction 423
10.2 Die Casting Alloys 423
10.3 The Die Casting Cycle 425
10.4 Die Casting Machines 426
10.5 Die Casting Dies 429
10.6 Finishing 430
10.7 Auxiliary Equipment for Automation 432
10.8 Determination of the Optimum Number of Cavities 433
10.9 Determination of Appropriate Machine Size 439
10.10 Die Casting Cycle Time Estimation 443
10.11 Die Cost Estimation 453
10.12 Assembly Techniques 457
10.13 Design Principles 458
References 459
11. Design for Powder Metal Processing 461
11.1 Introduction 461
11.2 Main Stages in the Powder Metallurgy Process 463
11.3 Secondary Manufacturing Stages 464
11.4 Compaction Characteristics of Powders 468
11.5 Tooling for Powder Compaction 475
11.6 Presses for Powder Compaction 478
11.7 Form of Powder Metal Parts 481
11.8 Sintering Equipment Characteristics 484
11.9 Materials for Powder Metal Processing 489
11.10 Contributions to Basic Powder Metallurgy Manufacturing
Costs 492
11.11 Modifications for Infiltrated Materials 511
11.12 Impregnation, Heat Treatment, Tumbling, Steam Treatment,
and Other Surface Treatments 512
11.13 Some Design Guidelines for Powder Metal Parts 514
References 515
12. Design for Sand Casting 517
12.1 Introduction 517
12.2 Sand Casting Alloys 519
12.3 Basic Characteristics and Mold Preparation 519
12.4 Sand Cores 524
12.5 Melting and Pouring of Metal 525
12.6 Cleaning of Castings 526
12.7 Cost Estimating 527
12.8 Design Rules for Sand Castings 537
12.9 Example Calculations 542
References 546
13. Design for Investment Casting 549
13.1 Introduction 549
13.2 Process Overview 549
13.3 Pattern Materials 552
13.4 Pattern Injection Machines 552
13.5 Pattern Molds 554
13.6 Pattern and Cluster Assembly 554
13.7 The Ceramic Shell-Mold 555
13.8 Ceramic Cores 556
13.9 Pattern Meltout 556
13.10 Pattern Burnout and Mold Firing 557
13.11 Knockout and Cleaning 557
13.12 Cutoff and Finishing 557
13.13 Pattern and Core Material Cost 557
13.14 Wax Pattern Injection Cost 561
13.15 Fill Time 562
13.16 Cooling Time 562
13.17 Ejection and Reset Time 564
13.18 Process Cost per Pattern or Core 566
13.19 Estimating Core Injection Cost 567
13.20 Pattern and Core Mold Cost 567
13.21 Core Mold Cost 572
13.22 Pattern and Cluster Assembly Cost 572
13.23 Number of Parts per Cluster 574
13.24 Pattern Piece Cost 575
13.25 Cleaning and Etching 576
13.26 Shell Mold Material Cost 576
13.27 Investing the Pattern Cluster 577
13.28 Pattern Meltout 578
13.29 Burnout, Sinter, and Preheat 578
13.30 Total Shell Mold Cost 579
13.31 Cost to Melt Metal 579
13.32 Raw Base Metal Cost 583
13.33 Ready-to-Pour Liquid Metal Cost 584
13.34 Pouring Cost 584
13.35 Final Material Cost 584
13.36 Breakout 586
13.37 Cleaning 587
13.38 Cutoff 587
13.39 Design Guidelines 590
References 591
14. Design for Hot Forging 593
14.1 Introduction 593
14.2 Characteristics of the Forging Process 593
14.3 The Role of Flash in Forging 595
14.4 Forging Allowances 600
14.5 Preforming During Forging 603
14.6 Flash Removal 609
14.7 Classification of Forgings 610
14.8 Forging Equipment 613
14.9 Classification of Materials 622
14.10 Forging Costs 622
14.11 Forging Die Costs 631
14.12 Die Life and Tool Replacement Costs 636
14.13 Costs of Flash Removal 637
14.14 Other Forging Costs 640
References 641
15. Design for Manufacture and Computer-Aided Design 643
15.1 Introduction 643
15.2 General Considerations for Linking CAD and DFMA
Analysis 643
15.3 Geometric Representation Schemes in CAD Systems 645
15.4 Design Process in a Linked CAD/DFMA Environment 660
15.5 Extraction of DFMA Data from CAD System Database 663
15.6 Expert Design and Cost Estimating Procedures 665
References 668
Nomenclature 669
Index 683
Product Design for Manufacture and Assembly, 3rd Edition
Geoffrey Boothroyd, Peter Dewhurst, Winston A. Knight
CRC Press, Dec 8, 2010 - Science - 712 pages
DFMA - More Articles, Books and Papers
2018 DFMA Forum
DfAM meets DFMA at upcoming International Forum in Rhode Island
Photo of Victor Anusci Victor AnusciJune 29, 2018
Chinese automotive company BAIC (Beijing Automotive Industry Holding Co., Ltd.) will discuss using DFMA to control whole vehicle costs and Goldense Group will address the maturing face of globalization, as countries and states increasingly focus policies and resources on becoming centers of excellence for selected industries and technologies—specifically those with high DFMA requirements.
A Distinguished DFMA Supporter of the Year winner, Bill Devenish, will deliver four Kohler group papers on subjects ranging from early, data-driven product development to using DFMA very late in “the ship has already sailed” phase of production.
Additional presenters include Nick Dewhurst of Boothroyd Dewhurst, Inc., (Opening Address and DFMA Overview), Swiss-based Endress & Hauser (The Million Dollar Story of DFMA at E&H), Starkey Hearing Technologies (The Positive Impacts of DFMA for Hearing Aid Development), and Dynisco (DFMA and Systems Engineering Approaches), among others.
19.12.2021 - 18 Case Studies included.
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