Design for Manufacturability power point presentation, This PPT improve the study of design for manufacturability. DFM is utilized in many industries ranging from industrial products, microelectronics, scientific instruments, and the aerospace industry To design a product that can be easily, efficiently, and cost effectively be manufactured To reduce overall cost of a product – warranty, engineering changes, factory floor space, unnecessary parts, and service Using modules simplifies the manufacturing process Allows for the use of standard components Allows for tests to be conducted prior to the product being assembled Using parts for the same or different operations multiple times in a product Reduces the number of parts that need to be developed Less machines - Less usage of factory floor space Optimal assembly of a product occurs in one direction Preferred direction is from above using gravity to assist in the manufacturing process Errors in insertion due to positioning and dimensional variability cause damage to parts and to machinery Use tapers, chamfers and moderate radii to ease insertion Example – utilization of a rigid base and tactile and visual sensors in assembly Positioning, orienting, and fixing a part are time consuming and costly Use external guiding features to orient the part Ideally the part should be placed one time The process of designing the product and the manufacturing process simultaneously to increase the efficiency and reduce the time to launch a product

1. Design For Manufacturability

2. What you will learn
• What is the main idea behind Design for
Manufacturability?
• Where is it used?
• Why is it used?
• How can products be designed using this
concept?
• How can a manufacturing process be
planed to use DFM?
• How does DFM save money?

3. Introduction
• What is the main idea behind Design for
Manufacturability?
 The definition of Design for Manufacturability
(DFM) is the general engineering art of
designing products in such a way that they are
easy to manufacture.
• Where is DFM used?
 DFM is utilized in many industries ranging from
industrial products, microelectronics, scientific
instruments, and the aerospace industry

4. DFM with respect to Product Design
Presented by Rick Forney

5. Objective
• To design a product that can be easily,
efficiently, and cost effectively be
manufactured
• To reduce overall cost of a product – warranty,
engineering changes, factory floor space,
unnecessary parts, and service

6. How
• Reduce the total
number of parts
• Modular design
• Standard components
• Multi-functional parts
• Multi use parts
• Ease of Fabrication
• Avoid Separate
Fasteners
• Minimize Assembly
Directions
• Maximize compliance
• Minimize handling

7. Reduce the Total Number of Parts
• Designing a product with less parts means less
- Purchases - Assembly Difficulty
- Inventory - Service
Inspection
- Handling - Testing
- Processing Time
- Development Time
- Equipment LEADS TO A CHEAPER
- Engineering Time PRODUCT

8. Develop a Modular Design
• Using modules simplifies the manufacturing
process
• Allows for the use of standard components
• Allows for tests to be conducted prior to the
product being assembled

9. Use of Standard Components
• Standard components less expensive than
custom-made
• Testing already completed
• No need for development

10. Design Parts to be Multi-Functional
• Reduce the total number of parts required
– Reduce manufacturing time
– Reduce inventory required
• Example – A part that acts as a heat dissipating
element and as a structural support

11. Design Parts for Multi-use
• Using parts for the same or different
operations multiple times in a product
• Reduces the number of parts that need to be
developed
• Less machines - Less usage of factory floor
space

12. Design for Ease of Fabrication
• Material Selection
• Avoid
– Post process operations (painting, polishing)
– Excessive tolerance requirements

13. Avoid Separate Fasteners
• Fasteners reduce manufacturing efficiency
• Expensive due to operations required to
produce fasteners
• Instead use snap fits

14. Minimize Assembly Directions
• Optimal assembly of a product occurs in one
direction
• Preferred direction is from above using gravity
to assist in the manufacturing process

15. Maximize Compliance
• Errors in insertion due to positioning and
dimensional variability cause damage to parts
and to machinery
• Use tapers, chamfers and moderate radii to
ease insertion
• Example – utilization of a rigid base and tactile
and visual sensors in assembly

16. Minimize Handling
• Positioning, orienting, and fixing a part are
time consuming and costly
• Use external guiding features to orient the
part
• Ideally the part should be placed one time

17. Concurrent Engineering
• The process of designing the product and the
manufacturing process simultaneously to
increase the efficiency and reduce the time to
launch a product

18. DFM with respect to Manufacturing
Processes
Presented by Caleb Pan

19. Manufacturing Processes
• Casting, foundry, or molding
• Forming or metalworking
• Machining
• Joining and Assembly
• Surface Treatments
• Rapid Prototyping
• Heat Treating

20. Casting Design & Processes
Design Considerations
• Shrinkage, Parting Line,
Draft
• Section Changes
• Features
– Holes
– Ribs
– Fillets
Processes
• Permanent Metal Mold
• Expendable Sand Mold
• Centrifugal
• Plaster Mold
• Ceramic Mold
• Investment Casting
• Die Casting

21. Forming & Metalworking Processes
• Extrusions
• Powder Metallurgy
• Forging
• Stampings
• Fine-blanked Parts
• Spring & Wire Parts
• Spun Metal
• Upset
• Rotary-Swaged
• Tube & Section Bends
• Electroformed Parts
• Cold Extrusion
• Rolled Form
• Metal Injection Molding (MIM)

22. Extruded Parts
• Eliminate Irregularities
• Use standard cross
sections
• Eliminate secondary
drawing operation;
eliminates additional
tooling, handling, and
cost.

23. Powder Metallurgy
• Undesired Features – Steps, Inserts, Screw Threads, Sharp
Corners, Spherical Surfaces
• Limitations – Holes, Inserts, Knurls, Lettering
• Desired features - Small radii, No draft.

24. Forged Parts
• Features of Reduced
Size
• Radii are necessary
• Draft
• Parting Line
– Perpendicular to the
axis of motion
– If not, no more than
75°

25. Machining Processes
• Milling
• Planing, Shaping, Slotting
• Broaching
• Flame-Cutting
• Electrochemical
• Chemical

26. Machined Parts
General Guidelines
– If possible, avoid machining at all costs; the most
expensive form of manufacturing
– Parts must be easily fixtured and must be rigid
enough to withstand the forces of clamping; thin
walls and deep pockets must be avoided.
– Difficult to machine materials must be avoided.
– Avoid features such as tapers, undercuts,
projections, sharp corners.

27. DFM with respect to Cost Management
Presented by C. Spencer Whittingham

28. Cost Management
(Design)
• The machines + processes used
• The materials used
• The form of the materials
• The quantity being manufactured
• The dimensional tolerances + strength
• The design and shape
• The desired quality of the final product

29. Cost Management
(Manufacturing)
• Number of workers
• Escalation
• Risk
• Contingency or management reserve
• Travel and transfer of materials/products
• Fees + profit

30. Cost Management
(Solutions)
• Substitute for less expensive materials
• Assign a person with greater expertise or
more experience to perform or help with the
project/activity to get it done more efficiently
• Reduce the scope or requirements of the work
package or for specific activities
• Improve methods or technology

31. DFM Case Study: Car Engine
Presented by Ryan Loggins

32. • A car engine is a very complex product
with many parts
• Due to the large magnitude of the
automotive industry, it is very important
that these parts are easy to manufacture
and as least expensive as they can be.
• It is also important that these parts can be
easily and quickly assembled
Overview

33. Engine for a 2010 Corvette ZR1

35. • It normally takes between three and five years to
design a car engine
• The design team consists of several engineers
• These engineers usually stay on the same page in
terms of the overall design of the engine.
– But what about the people who are
responsible for designing the processes to
produce that engine
– Or what about the people who are responsible
for putting that engine together
• It is important to keep in mind the entire
production process when designing a good of this
magnitude
Design

36. • When designing a car engine it is
important to keep in mind how the parts
you are designing are going to be produced
• The manufacturing engineers need to be
able to take your design and design the
processes used to create each and every
part
• This can be done by:
– Creating the most simple parts possible
– Using a material that is easily manufacturable
DFM for Manufacturing Processes

37. • The harder a product is to assemble:
–The longer it takes to produce
–The more likely the chance that
something will go wrong
–In most cases, it costs more to produce
DFM for Assembly

38. • As the design for a part gets more
complicated:
– The harder it is to keep high quality standards
– The more complex the manufacturing process
has to be
– The more critical dimensions the design has,
therefore greater frequency of sampling and
inspections has to occur
DFM for Quality Control

39. Conclusion
• To review:
– Design for Manufacturability is a concept that
is used in many industries
– It’s purpose is to make it easier to
manufacture products on large scales
– By adjusting both the product design and the
production design, the ability to produce parts
can be greatly improved
– This increase in efficiency will also reduce
costs