The document discusses design for manufacturability (DFM) and its importance in product design and development. DFM involves considering manufacturing requirements during the design process in order to lower costs, shorten development times, and improve quality. A DFM approach uses cross-functional teams and tools like design for assembly, failure mode and effects analysis, and quality function deployment. Implementing DFM helps address challenges of global competition, reducing costs, and shorter product cycles.
The document discusses design for manufacturability (DFM) and its importance in product design and development. DFM involves considering manufacturing requirements during the design process in order to lower costs, shorten development times, and improve quality. A DFM approach uses cross-functional teams and tools like design for assembly, failure mode and effects analysis, and quality function deployment. Implementing DFM helps address challenges of global competition, reducing costs, and shorter product cycles.
The document discusses design for manufacturability (DFM) and its importance in product design and development. DFM involves considering manufacturing requirements during the design process in order to lower costs, shorten development times, and improve quality. A DFM approach uses cross-functional teams and tools like design for assembly, failure mode and effects analysis, and quality function deployment. Implementing DFM helps address challenges of global competition, reducing costs, and shorter product cycles.
The document discusses design for manufacturability (DFM) and its importance in product design and development. DFM involves considering manufacturing requirements during the design process in order to lower costs, shorten development times, and improve quality. A DFM approach uses cross-functional teams and tools like design for assembly, failure mode and effects analysis, and quality function deployment. Implementing DFM helps address challenges of global competition, reducing costs, and shorter product cycles.
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Design For Manufacturability
(DFM) Steve Hanssen Senior Engineer, Hitachi San Jose State University September 15, 2004 1
Agenda Introduction What is DFM? Why use DFM?
DFM Process DFM Approach, DFM Tools and Methods
Summary Overview and DFM comparison table
Where can I get more information?
Resources, DFM Pros and Cons and Comparisons
Introduction
What is DFM? DFM is product design considering manufacturing requirements DFM is the first step in which a team approach is taken to develop the product DFM is an umbrella which covers a variety of tools and techniques to accomplish a manufacturable product
Why DFM?
Lower development cost
Shorter development time Faster manufacturing start of build Lower assembly and test costs Higher quality
Introduction
How do all the pieces fit together?
The objective of DFM is to identify product concepts that are easy to manufacture Focus on component design for ease of manufacture and assembly Integrate manufacturing to ensure the best match of needs and requirements. DFM in industry is typically divided into 2 main activities: A team which will be responsible for the product development and delivery. (cross functional team: ME, EE, MFG., CE, PE, Quality) The tools and methods to enable DFM that ensure the design meets the objectives.
Introduction How much do engineering changes cost after the design has been launched?
Introduction When has the total cost be committed?
Introduction Which is the better process?
Product Launch
Introduction
Manufacturing Today Global Competition Trade barriers have been removed (NAFTA) Must compete with the best from all over the world Japan, Europe, India, Mexico, etc Infrastructure's forming off shore
Quality Requirements ISO 9000 Six Sigma (Motorola Inc)
Product Cycles Every generation is faster Rate of change is increasing
Cost Costs decrease every year (customers expect costs to go down) Performance increasing every year
Development Cycle Endless engineering changes Non standard parts have long lead times Quality Designed and thrown over the wall Lower due to more parts, manual processes, and untested parts
Customer configuration management
Cost Higher due to unique designs and specialized parts Equipment and Tooling Reliability and quality problems
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DFM Typical Approach
Product Development Process
Conceptual DESIGN and development
Product optimization, TEST TOOL BUILD (ease of assembly) LAUNCH, ramp, ship, and deliver
Product Development team making it happen!!
- Product requirements and deliverables - DFM tools and methods
Product Team Product requirements and deliverables Collaborative cross functional team (ME, EE, MFG, Test, Quality, etc.). Not designed in a vacuum Uses DFM tools and methods
start finish
Design
Test
Tool Build
Launch
Product Development Steps
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DFM Product Considerations
Product Considerations Environmental
Ergonomics Safety Pollution Recycling Shock/vibration Temperature
Customer
Depth of product line
Customization Test requirements
Suppliers
Process and Tooling
Cycle time Quality Ease of Assembly Ease of Testing Rework Shipping and Handling Tooling Costs
Failure Mode and Effect Analysis (FMEA), (Sun example) Taguchi Method, (Hitachi experience) Value Analysis--Value Engineering (HP example) Quality Function Deployment (QFD), Going to the Gemba (Hitachi) Group Technology, (IBM example) Cost management and optimization, SPC, Six-Sigma (Motorola), TQC, etc
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DFM Tools: DFA Guidelines
- One assembly direction tops down -No adjustments required -No hidden features
- Test direction access from top
- Sub-assemblies reduce handling of small hard to grip parts
- Holes large enough
(straightness issues if too deep) - Common datums for all fixtures -One common plane for assembly - Tabs for robotic lift
- Easy to fabricate parts
- Standard parts (one screw type)
- Parts are self-guiding
- Avoid tangle with use of
fixtures - Symmetry in two axis
-Die cast with minimal amount
of holes (debris chip) -Standard cutters -Guide features - bottom rails for conveyor
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DFM Tools: DFA Guidelines
Summary of DFA Guidelines
1. Minimize the number of parts 2. Standardize and use as many common parts as possible 3. Design parts for ease of fabrication (use castings without machining and stampings without bend) 4. Minimize the number of assembly planes (Z-axis) 5. Use standard cutters, drills, tools 6. Avoid small holes (chips, straightness, debris) 7. Use common datums for tooling fixtures 8. Minimize assembly directions 9. Maximize compliance; design for assembly 10. Minimize handling 11. Eliminate adjustments 12. Use repeatable, well understood processes 13. Design parts for efficient testing 14. Avoid hidden features 15. Use Guide features 16. Incorporate symmetry in both axis 17. Avoid designs that will tangle. 18. Design parts that orient themselves
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DFM Tools and Methodology
FMEA (Failure Mode and Effects Analysis)
Method for analyzing the causes and effects of failures.
Highlights designs and assemblies most likely to cause failures. Helps identify and prioritize corrective action Indicates where the most improvement in terms of severity, frequency, and detectability can be made. Widely used manufacturing technique (Mil standards, SAE, ANSI Specs)
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DFM Tools and Methodology
FMEA Method On the next page is a simple example of FMEA for a Disk Drive Actuator assembly Heres the method I used: Adopt a correlation scoring system between parts and failure modes. A system commonly used is:
9 for a A- indicates a strong correlation.
3 for a B- indicates some correlation. 1 for a C- indicates possible correlation
Apply a weighting to the parts. For example, 1, 4, 9, 16, where 16 is
more important than 1. Sum these horizontally to give a gross weight for each part. Calculate the percentages in the right-hand column. The percentages prioritize the areas to which attention should be given.
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DFM Tools and Methodology
FMEA for a Disk Drive Actuator Assembly
Failure modes
Weight according to importance
Assembly components should be given highest priority
Most correlations, but
not the highest priority
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Summary
What is DFM? Design considering manufacturing
Why DFM? Shorter Development Cycle Lower costs and higher quality Fewer Engineering Changes
DFM Approach Integrated in product design process. Not designed in a vacuum
Tools and Methods
Design is the first manufacturing step. The essence is use a combination of tools and methods which are appropriate for your application
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DFM Tools Pros and Cons
DFM Tools Pros and Cons
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DFM Tools: Comparisons
DFM Tools Comparison Table
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References
A Few DFM References
Baer, T., With Group Technology Nobody Reinvents the Wheel. Mechanical Engineering, November 1995. Boothroyd, et al., Computer Aided Design for Assembly. Assembly Engineering, February, 1993. Boothroyd, et al., Design for Assembly: Selecting the Right Method., Machine Design, December, 1983. Boothroyd, G. Make it Simple Design for Assembly. Mechanical Engineering, February 1988. Gage, W.L., Value Analysis, McGraw-Hill, Inc, New York, 1967. Owen,T., Assembly With Robots. Prentice-Hall, Inc., Englewood NJ, 1985 Burgam, P.M.,Design of Experiments-The Taguchi Way. Manufacturing Engineering, May, 1985 Evens, B., Simultaneous Engineering. Mechanical Engineering, February 1985. Stoll, H.W., Design for Manufacture. Manufacturing Engineering, January 1988. Boothroyd, G., Design for Assembly. Mechanical Engineering, February 1988. Barkan, P., The Benefits and Limitations of Structured Design Methodologies. ASME, Manufacturing Review, vol. 6, no. 3, September 1993. Baralla, J.G., Handbook of Product Design for Manufacturing. McGraw-Hill, 1988. Harry, M.J., The Nature of Six Sigma Quality. Motorola, Inc., Government Electronics Group. Donnelly, T.A., Robust Product Design. Machine Design, October 8, 1988. Sadri,H, et al., Design of Experiments: An Invaluable. Production Engineering, February 1994. Box G., et al., Statistical Tools for Improving Designs. Mechanical Engineering, January 1988. Miles, L.D., Techniques of Value Analysis and Engineering, McGraw Hill, NY, 2nd ed., 1972.
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I Want to Learn More!
Where else? SCPD.stanford.edu, ME396 (DFM Forum) CACT Center, De Anza College, DFM Seminar University of Rode Island, DFA
