OVERVIEW THE DFM PROCESS

Compiled by:
Gracia Sembiring
Sarah Panjaitan
Maria Sibuea
Daniel Sianturi
Loly Silaban
 CONTENTS

Cover ...................................................................................................................................

Contents ............................................................................................................................ 1

BAB 1 : Estimate the manufacturing costs ....................................................................... 2

BAB 2 : Reduce the costs of components ...................................................................... 3-4

BAB 3 : Reduce the costs of assembly .......................................................................... 5-6

BAB 4 : Reduce the costs of supporting reproduction ..................................................... 7

BAB 5 : Consider the costs of supporting production ...................................................... 8

BAB 6 : The manufacturing costs after all the reduce process…………………………..9

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 BAB I

Manufacturing Cost Estimation

A. Component Cost

This table will show all material for making travel pillow and additional. Price is by wholesaler or if
buy it from factory. So it can be cheaper than in market.

No Material Dimension Price

1 Velvet fabric 1m x 1,2m Rp 45.000,00
2 Thread 1 roll Rp 3.000.00
3 Pin 1 pack Rp 2.000,00
6 Volcro 50 cm Rp 5.000,00
4 Button 3 Rp 2.000,00
5 Memory foam 1 Rp 100.000,00

B. The Bill of Materials

The BOM is a list of each individual component in the product. BOM will show total cost for making
each travel pillow. Based on table, we can see that for making a travel pillow the cost is Rp 227.000
cost is including for material, labor, machine and overhead.

Component Purchased Processing Assem Total Unit Tooling and Tooling Total Total cost
Materials and bly Varible Other NRE Lifetim Unit
Assembly( (Labor Cost e, M Fixed
Machine + ) units Cost
Labor)
Travel pillow
Cover Rp 25.000 Rp 30.000 Rp 55.000 Rp 55.000
Memory Rp 60.000 Rp 60.000 Rp 60.000
foam
Additional Travel Pillow
Cover Rp 15.000 Rp 20.000 Rp 35.000 Rp 35.000
Memory Rp 40.000 Rp 40.000 Rp 40.000
foam
Button Rp 2.000 Rp 2.000 Rp 2.000
Bag
Velvet fabric Rp 10.000 Rp 25.000 Rp 35.000 Rp 35.000
Total direct Rp 152,000 Rp 75.000 Rp227.000 Rp 227.000
cost
Overhead charges
Total cost Rp 227.000

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 C. Cost estimation for making each Travel Pillow

Variable cost
Material Velvet pabric 1,2 at Rp 45.000/1.2m2 Rp 45,000
Memory foam 1 sheet at Rp 100.000/sheet Rp 100,000
Thread 1 roll Rp 3.000
Pin 1 pack Rp 2.000
Volcro 50 cm Rp 5.000
Button 3 Rp 2.000
Processing (Sewing) Rp 75.000
Fixed cost 0
Total Direct Cost Rp 232.000
Overhead charge 0
Total Unit Cost Rp 232.000

For making our working prototype, every cost is for standard components. We don’t have custom
components. All of material is standard and we can find it in market. But we do some improvement
for our material to make best working prototype.

BAB II

Reduce the costs of components

BAB III
Reduce the costs of assembly

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 BAB IV

Reduce the costs of supporting production

4.1 Minimize Systemic Complexity

Score card of manufacturing complexity

Drivers of Complexity

Rev. 1 Rev. 2

Number of new parts introduced to the manufacturing system 1 1

Number of new vendors introduced to the manufacturing system 2 2
Number of custom parts introduced to the manufacturing system 0 1
Number of new “major tools” (e.g., molds and dies) introduced to the manufacturing system 0 0
Number of new production processes introduced to the manufacturing system 2 0

Total 5 4

Note:
There is a difference between rev.1 and rev.2. In Rev.1 we don’t use custom parts so we need
more production processes to make the travel pillow, but in Rev.2 we use custom parts to
reduce production processes in manufacturing system. There is no a difference about new
parts, new vendors, new major tools between both.

4.2 Error Proofing

The left and the right versions of travel pillow, that there is some difference between
both. In the left version is showed that the size of travel pillow is bigger than the right

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version. We have a purpose to make customer more comfortable if they use that travel pillow,
so there is reduced the size of travel pillow. And in the right version there is an additional bag
to make travel pillow more portable.

BAB V

Consider the impact of DFM decisions on other factors

5 Consider the Impact of DFM (Design for Manufacturing) Decisions

on Other Factors
5.1 The Impact of DFM on Development Time

As we make this neck travel pillow estimated no longer time to get finish on this product.
Because of the time development this neck travel pillow only need 3 month start from
november until January.The process of making pillows start from Provide materials and
tools,Print pillow patterns,Start cutting patterns and putting them together,Then sewing
with a needle or sewing machine but the fabric is not fully sutured,Give memory foam as
a stuffing pillow,Then sew back the cushions perfectly. As the materials and tools that
we need is easy to get and to produce and the way to making the neck travel pillow, we
spend 2-3 hours per day to make neck travel pillow.

5.2 the impact of DFM on development cost

On this product development there is two factors that related each other there are time and
cost.the more time we need to make this product the lower cost we spent.as we estimated and
run this product in this three month we make a working team from the tailor whose like to
help us to create the design of our product. For making this project we need Rp 390.000,00.
From making alpha prototype until making working prototype, our cost is Rp 390.000,00.
That cost including for buying material, tailor and transportation. We need buying material
like fabric, cotton, memory foam, etc. We need pay for tailor to sewing our travel pillow. We
use tailor to get a good needlework. Also, we have transportation cost.

5.3 the impact of DFM on product quality

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5.4 the impact of DFM on external factors

Components reuse: as we make this product we can create a low cost components of this part,
by the three additional side of the neck travel pillow its also taking cost to make it more
higher of the cost.by the implementation of the neck travel pillow we can make it into
reusable product.

Life cycle costs :by this product we also create and indicate the product how it should be
opened and make acces points obvious,maintain stability and part of this neck travel
pillow,not only how we can indicate them but this neck travel pillow also like to minimize
the number and variety of joining all of the elements.