Muhammad Ali 13-ME-83

SiffatUllah 13-ME-
84
Design for
Manufacturing
Who Casts the biggest
shadow ?
Summary
What is DFM?
Why DFM?
DFM Approach
Tools and Methods
 What is DFM??
Design for
Manufacturing allows
you to improve
efficiency by minimizing
the number of parts
through part
standardization and or
modular architecture so
that the assembly is
cost effective and
efficient.
Successful DFM
results in lower
production cost
without sacrificing
product quality.
The Design Process
Manufacturing Method
Definition
Computer-aided
manufacturing (CAM) is
an application
technology that uses
computer software and
machinery to facilitate
and automate
manufacturing
processes.
Simulations of
manufacturing
processes using
ABAQUS
DFM Method
Proposed Design

Estimate the Manufacutring

Costs

Reduce the Costs of Reduce the Costs of Reduce the Costs of

Components Assembly Supporting Production

Consider the Impact of DFM

Decisions on Other Factors

Recompute the
Manufacturing Costs

Good
N
enough
?
Y

Acceptable Design
 DFM Typical Approach
Product Development
Process
Conceptual DESIGN and
development
Product optimization, TEST Product Development team making it happen!!
- Product requirements and deliverables
TOOL BUILD (ease of assembly) - DFM tools and methods

LAUNCH, ramp, ship, and deliver

Product Team start
Product requirements and finish

deliverables
Collaborative cross functional team
(ME, EE, MFG, Test, Quality, etc.). Design
Test
Not designed in a vacuum Tool Build
Launch

Product Development Steps

Uses DFM tools and methods
Gathering DFM
Information
Sketches, drawings, product specifications, and
design alternatives.
A detailed understanding of production and
assembly processes
Estimates of manufacturing costs, production
volumes, and ramp-up timing.
Design for Manufacturing (DFM)
Methods
Estimate
manufacturing Costs
of Proposed Design

Reduce costs of Reduce costs of Reduce costs of

components assembly Supporting Production

Consider DFM impact

on other factors

Recompute
Manufacturing Costs

Good Enough? Accepted Design

1-Estimate the
manufacturing cost
Fixed Costs
Fixed costs are
costs that are
independent of output.
e.g rent buildings,
machinery etc.
Variable costs
Variable costs are
costs that vary with
output. e.g raw
material used in
production etc.
Manufacturing Cost of a
Product
Equipment Information Tooling
Component
Costs (parts of
the product) Raw Materials
Assembly Costs
(labor, Labor
Manufacturing System Finished Goods
equipment, &
tooling) Purchased
Components
Overhead Costs
(all other costs)
Energy Supplies Services Waste
Estimate the
Manufacturing Cost
Sum of all the
expenditures for
the inputs of the
system (i.e.
purchased
components,
energy, raw
materials, etc.) and
for disposal of the
wastes produced
by the system
Standardize
Components to reduce
Manufacturing Cost
Custom components
increases cost
Standard Components
common to more
than one product
Black boxonly give a
description of what
the component has to
do, not how to
achieve it
2-Reduce the Cost of
Components

Redesign Components
to Eliminate
Processing
Steps
Eliminate unnecessary

steps
3-Reduce the Costs of
Assembly
The purpose of DFM is to minimize assembly cost by
optimizing the assembly process and reducing the number
of parts

Complicated Design Simpler Design

Reduce the Cost of
Assembly
Ensure Access & Visibility
4-Reduce the Costs of
Supporting Production

Use symmetric parts

Error Proofing (Poka

Yoke)
5-Consider the Impact of DFM
Decisions on Other Factors
Product Quality
External Factors
Component re-use
Product Life cost
A Practical Example of
DFM
A boiler manufacture in the U.K.
had developed a boiler using a
spring mounted fastening system.
During transportation of the
boilers the screws that held the
spring clips would often loosen and
fall out. This forced the boiler
manufacturer to reconsider their
whole product design and
manufacturing process to ensure
the end result was a defect free
product and most importantly that
their customers would be happy.
Example Cont.

They started from the beginning. They

first considered what was necessary to
meet the customer needs. Second, they
considered what requirements the boiler
had to ensure quality and safety. Then
they began to look at their resources. The
boiler manufacture found that their current
process of assembling the fasteners to the
boiler unit required a spring clip, nuts and
a screw, which held the sheet metal to
form the outside casing of of the boiler.
Example Cont.

The manufacturer began looking at the

technology that had been developed
since they began producing the boilers.
A new technique had been introduced
that solved their problems. The new
fastener was a combination of a screw
and stamping. The new process involved
a screw punched into the assembly base
material. The new fastener sported a
buttress type thread that was designed
to capture the outside edge of the
material.
Example Cont.

The screw is stamped directly into the

base during the fabrication. This new
process eliminated the old screws and
clips that use to come loose during
transportation. The manufacturer
then redesigned the product to allow
the screw to be stamped during
assembly. In doing so, the company
eliminated nuts, inserts, spring clips,
and thread forming screws. The
company replaced all of these parts
for one helix screw.
Example Cont.

The end result reduced assembly

time by about 15 seconds per
part. At 10 parts per unit, for a
total of about 2.5 minutes per
unit. This 2.5 minuets results in
an annual savings of $10,000. In
addition, the reduction of
inventory and associated handling
costs were reduced 25-30%
DFM Tools: Comparisons

DFM Tools Comparison Table

THANK YOU