Better Q.C.D .

through
Ten Commandments of M.F.D.
Er Ramalingam K S
DFM & Innovation Consultant
www.dfmhandbook.com
Tao of DFM
 To move DFM from a mere notion to reality by a
paradigm shift of DFM from a Design Engineering
Function to a Regulatory Management Function
Mission under the Head of QMS as a Group Captain with the
of solid anchoring by the Champions of Design &
Manufacturing with added reinforcement by the
Tao of DFM Process Engineering Team with the Design
Engineering Division.
 And a scientific bifurcation of Design For
Manufacturability into Eight Criteria such as
Design For Best Cost , Design For Best Quality,
Design For Best Reliability, Design For Best
Compliance to Regulations /Sustainability, Design
For Best Safety, Design For Best Time-to-Market
Design For Best Function/Style & Design for Best
Satisfaction to Customer
 Under the basic Eight Systems such as
Procurement, Manufacture ,Assembly, Testing,
Packing/Shipping, Supply /Delivery ,
Service/Maintenance & Repair -all by a redefined
Concurrent Engineering Team with a blend of Yang
( men) with in-born LOGIC and Yin ( women) with
in-born CREATIVITY by applying simple
systematic analysis such as Gap Analysis ,SWOT
Analysis ( Process /Competency ) & FMEA ( Design
/Process )through an integrated QFD named as
MFD Manufacturability Function Deployment, the
new Mantra for DFM .
 TDFM recommends simultaneous establishment of
Operation Process Plan /Quality Plan/Control Plan
& Analysis of all cost centres for proper
compatibility of Tao of DFM as a poka-yoke
against deficiency in reaching the goals of both
DFM & QCD using the Soft M S Excel.
TEN
COMMANDMENTS
 Thou shall get Completed Designs as per
the company's standard
procedures/practice by the existing
Design Team and start a kind of
retro-fitting with Tao of DFM.
The Design Team who designed has to
Commandment-1 provide an abstract of the outcome of the
existing Design Specifications under
Cost.Quality,Reliability,Compliance to
Regulations /Sustainability, Safety, Time-
to-Market ,Function /Style & Customer
Satisfaction for necessary upgradation
through Tao of DFM .
 Thou shall Create a Redefined
Concurrent Engineering Team within
the Organization (you can rope in
external consultants also) and make
your Management Representative -MR
(as per ISO) as the Group Captain for
Tao of DFM with additional Captains -
Commandment-2 one from Design & one from
Manufacturing.Thou shall adopt the
Taoist Directions as advised to have a
balanced team of Yang (men) and Yin
(women) under Domain Experts to
have a natural blend of logic of Yang
and creativity of Yin.
 Thou shall Merge Process Engineering
Division with Design Engineering
Division after knowing the real
benefits of the same through a Pilot
Commandment-3 Project under Tao of DFM by merging
the same. Thou shall prepare
Operation Process Sheets to process
the designed products & assemblies.
 Thou shall adopt the MFD (Manufacturability
Function Deployment) charts in MS Excel
Formats -similar to QFD for all the Eight
Systems and for Eight Criteria by getting
inputs from our e-books the
DFM Handbooks.For easy adoption of Tao
Commandment-4 of DFM, thou shall first adopt 'Ten
Commandments of Tao of DFM 'in a Pilot
Project as Level 1 and then go for Level 2 &
then 3-if needed - as highlighted below after
building the Team Strength.
 Thou shall see that the CET jointly do a
Gap Analysis for every process for
Quality, Cost & Delivery as per
Managements or Clients Targets w.r.t
the required Systems for all the Eight
Criteria under Tao of DFM and
Commandment-5 prepare the final summaries for Gap
Analysis for corrective action by
collective decisions by the CET (under
QFD platform) by following Rules
/Guidelines provided for all 8 x 8 =64
modules.
 Similarly, thou shall take up SWOT
Analysis -for both Process and
Competency -for the listed operations
under each cost centre using MFD and
Commandment-6
prepare summaries for favour of
corrective actions by CET by adopting
the proved QFD Platform.
 Similarly, thou shall do FMEA -for both
Design and Process -for the listed
operations under each cost Centre by
using MFD and prepare summaries for
Commandment-7
favour of corrective actions by CET by
adopting the proved QFD Platform.
 Thou shall post values under each as
per Comprehensive DFM Analysis
Chart in the Second DFM Handbook
on Implementations of Tao of DFM
Commandment-8 and present them to top management
for review/approval and make a
prototype .
 Thou shall post values under each as
per Evaluation of TDFM Framework
provided in the First DFM Handbook
on Tao of DFM and present them to top
Commandment-9 management for review of the
prototype and get their approval and
then implement them for production .
 Thou shall see that the Apex Team of Captains
of the redefined Concurrent Engineering Team
headed by the Head of QMS and rightly
supported by the Heads of Design &
Manufacturing will jointly finalize the design
Commandment10 with compliance to Tao of DFM for pilot lots
and adoption after satisfactory testing of the
sample lots and approval by the top
management or the end-client.
 The following are the basic
Solid Foundations foundations for this out-of-box
for the thinking by this author of Tao of DFM
Soft Editions of who is offering a Synergy of the
DFM Handbooks - Eastern thoughts of TAOISM with the
Theory & Practice Western thoughts of DFM to Energize
Innovations & Product Development .
 *Rule of TEN
It costs 10 times more to find a repair or
defect at the next stage of assembly.
10 times more to find a part defect at a sub-
assembly stage.
10 times more to find a sub-assembly defect at
the final assembly stage.
10 times more in a distribution channel and so
forth.
The primary aim is to introduce necessary
corrections @ Design or Re-design stage itself
proactively.
 *According to our Mentor, Dr David M Anderson of
www.design4manufacturability.com
'Design For Manufacturability' is the process of
proactively designing products to: (1) optimize all
the manufacturing functions: fabrication, assembly,
test, procurement, shipping, delivery, service, and
repair,
(2) assure by design, the best cost, quality, reliability,
regulatory compliance, safety, time-to-market, and
customer satisfaction, &
(3) ensure that lack of manufacturability doesn't
compromise functionality, styling, new product
introductions, product delivery, improvement
programs, strategic initiatives and unexpected surges
in product demand.
 Average Reductions by Adopting Design for
Manufacturability & Assembly
Labor Costs - 42% -Parts Count
54% -Separate Fasteners - 57%
Weight - 22%- Assembly Time
60%- Assembly Cost - 45%
Assembly Tools - 73% -
Assembly Operations - 53%
Product Development Cycle - 45% &
Total Cost - 50%
(Results compiled from over 100 published case
studies by www.dfma.com)
 Dr Sanjay Ramaswamy in his Arizona State
Universitys Report on DFM Methodologies has
expressed
Insufficient Scientific base under the softwares and
enormous data are compiled within the computer or
software. Human intervention and feedback are
rare.
DFMA methods have little efforts at the conceptual
stage where most of the product cost is fixed.
Insufficiency due to the inability to provide RE-
DESIGN suggestions to modify shapes in the case of
unsuitable designs.
The above inputs are the starting points for this
book titled as Taoist Directions for Design &
Development.
 The Gap between Design & Manufacturability is
different from Gaps between the following:
Between Theory & Practice
Between Man & Woman
Between Lord Shiva & Parvathi
Between Yang & Yin
Between Voltage & Current
Between Software &
Hardware
Between the Positive & Negative Polarities in
Electricity
Between North & South Polarities in Magnetism or
Between the Right & Left Halves of human brain.
Between the Conscious Mind & the Sub-Conscious
Mind
You can find in-built attractions between the above
kind of opposing entities due to nature /science.
 * According to Taoism, 'YIN & YANG are two
opposing energies in the world that wax & wane and
they represent the relative nature of all earthy
things'.

'Black' represents the energy of YIN, characterized

by the qualities of 'Dark, female, night, cold, soft,
pull & so on'. White represents the energy of YANG,
characterized by the qualities of 'White, male, day,
hot, hard, push & so on'. Within the YIN lies the seed
of YANG as represented by the white dot. Within the
YANG lies the seed of YIN as represented by the
black dot. At the interface between YIN & YANG lies
the Creative Potential-as per Dr Fritjof Capra
through his The Tao of Physics .
 *According to the great Tao Te Ching of Taoism,
Thirty Spokes join in one hub-In its emptiness,
there is the function of a vehicle
Mix clay to create a container-In its emptiness,
there is the function of a container.

Cut open doors and windows, there is the function of

a room,

Therefore, that which exists is used to create

benefits-That which is empty is used to create
functionality
 As per Tao of DFM of this author,
Sixty-four modules (spokes) join in one Tao of
DFM (hub),In its emptiness is the function of a
Design or Yang,
Cut open the product /equipment, there is the
function of Manufacturabilty or Yin.,
Therefore, Manufacturability exists which is used
to create benefits.
That Design , which is empty is used to create
functionality.
 The author has submitted copies of his
first DFM Handbook to Dr David M
Anderson, the author of Design For
Dr David M Manufacturability & Concurrent
Engineering as well as Dr Fritjof
Anderson
Capra, the author of The Tao of
&
Physics and got their appreciation for
Dr Fritjof Capra the contents of the Tao of DFM.
 Mens Brains Vs Womens Brains as per
a latest research in Pennsylvania
University of USA
https://www.truthinsideofyou.org/why-
men-and-women-think-differently-this-
guy-nails-it/
 *As described by Dr. Yoji Akao, who originally
developed QFD in Japan in 1966, QFD is a
method to transform qualitative user demands
into quantitative parameters, to deploy the
functions forming quality, and to deploy
methods for achieving the design quality into
subsystems and component parts, and
QFD ultimately to specific elements of the
manufacturing process.,
& The author combined his work in quality
MFD assurance and quality control points with
function deployment used in value
engineering.
OUR MFD IS DEDICATED TO DR. YOJI AKAO -
FATHER OF QFD .
 *MFD is a method to transform qualitative demands
as per the demands of the Concurrent Engineering
Team under Tao of DFM into quantitative parameters to
deploy the functions synergizing manufacturability
with design by deploying methods like Gap Analysis,
SWOT Analysis & FMEA for meeting all the
objectives/criteria under Tao of DFM into all systems
and ultimately to all elements of the process of
Manufacturability -the author of Tao of DFM.
*It is the combined works of the author of Tao of DFM
in Design and Manufacture with functional deployment
used in Design For Manufacturability as a QMS entity
to achieve better QCD.
*Manufacturability Function Deployment-MFD will
take you through a simple methodology of QFD to
bring home Reliable Designs through Rapid
Developments & Responsible DFM Services to reach
the destination of better QCD Quality Cost Delivery
 Under Tao of DFM fundamental changes in all
processes of Manufacture only can bring in proper
change in the design. And during these processes
each process has to be analyzed for Quality. Cost &
Delivery so that the whole Design is exposed to
DFM requisites .

All processes have to be analyzed by the Concurrent

Engineering Team to bring in better Quality @
lower Cost in faster Delivery the ultimate of DFM .
It is only fundamentals of Changes in Process
Engineering to be adhered to bring constant
improvements with time and technology .
 There are Three Levels for Implementations of Tao
of DFM given as under:
Level 1- Basic Ten Commandments under Tao of
DFM as detailed in the first DFM Handbook for the
Rules/Regulations common to all Eight Systems.
Level 1 Level 2- All 8x8=64 Modules as detailed in the
Level -2 second book with annexures under MFD (series
Level -3 from 1.0)

& MFD 1.0 is an updated version of our MFD.

Tao of DFM Level 3- For any Special Rules /Guidelines

developed by the redefined Concurrent Engineering
Team depending upon the nature & complexity of a
Specific Product /Project .
 What follows is the review on our
Manufacturability Function
Deployment by a review committee of
a Research Forum under Product
Development & Management
Association-PDMA -USA
www.pdma.org during 2016
 On Wed, Jul 20, 2016 at 9:38
PM, Bharadwaj, Neeraj <nbharadw@utk.edu> wrote:

Bharadwaj, Neeraj (nbharadw@utk.edu)

Dear Ramalingam,
Many thanks for your submission.
The approach to innovation and design that you have sketched
out in the Extended Abstract is interesting and has some
practical implications.
Hope that this feedback is helpful as you further develop your
work. We wish you the very best with this domain.
Neeraj Bharadwaj -Associate Professor
Department of Marketing & Supply Chain Management-
University of Tennessee
323 Stokely Management Center-916 Volunteer Boulevard
Knoxville, TN 37996-0530-USA
phone: 865-974-1610 -email: nbharadw@utk.edu
 *We have developed the Two DFM Handbooks as Self-Learning
type to bring this Interesting Methodology on Innovation &
Design with Practical Implications with its own paradigm shift
of DFM from a Design Domain to one of Regulations under
QMS for Engineering Organizations bringing better QCD. The
author has the copyrights & has a registered Trade Mark for
his logo on TDFM as shown at the beginning of this write up on
his DFM Handbooks.
* The first book on the theory of Tao of DFM , was supported
TWO DFM by NDRF National Research & Development
www.ndrf.res.in and released by Hon.Deve Gowda -the

HANDBOOKS former Prime Minister of India @ Bangalore during the Indian

Technology Congress 2014 on 21st August 2014
*The second book on the practice of Tao of DFM is self-
supported & released in CD Version along with the first book
and supporting Annexures for implementations by Dr B V A
Rao -former HOD of IIT-M & an authority on Bearings,
Vibrations & Acoustics @ Madras Management Association,
Chennai on 24th March 2017.
You can visit
www.dfmhandbook.com
to place your orders for the
Twin DFM Handbooks in
e-version.
 Er Ramalingam K S
DFM & Innovation Consultant
Chennai -90
Emails:
erramalingam.ks@gmail.com
erksr2712@dfmhandbook.com
http://www.dfmsolutionsbyre-design.com

Mobile: + 91 97899 65421