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Edward C. Lai
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Edward C. Lai
                                            What is DFMA?                                                   ...
Edward C. Lai
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Design Complexity                                                                                   Edward C. Lai
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Edward C. Lai
                              How to Attack Complexity ?                                                    ...
Edward C. Lai
                                           DFMA Methodology                                                 ...
Edward C. Lai
                                   DFMA Basic Principles                                                    ...
Edward C. Lai
                                           Typical Participants                                             ...
Edward C. Lai
                              Typical Workshop Agenda                                                       ...
Edward C. Lai
                                               Decision Criteria                                            ...
Edward C. Lai
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Design for Manufacturing and Assembly

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Design for Manufacturing and Assembly

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Transcript of "Design for Manufacturing and Assembly"

  1. 1. Edward C. Lai & Associates es MA P rincipl f parts DF ber o he num fasteners Introduction to imize t 1. Min ize the use o im 2. Min rdize f s da ponent 3. Stan difficult com mblies id se Design For Manufacturing and 4. Avo odular subas arts m 5. Use ultifunctiona n's m lp tio 6. Use ize reorienta ures Assembly (DFMA) im 7. Min lf-locating fe se 8. Use special tooli id at ng ty ps 9. Avo e accessibili & process ste vid ations 10. Pro ze oper nimi 11. Mi © 2009, Edward C. Lai and Associates. OPTIMAL THINKING® is a registered trademark of The World Academy of Personal Development Inc. All Rights Reserved. Page 1
  2. 2. Edward C. Lai What is DFMA? & Associates A proactive product design process that focuses on meeting customer requirements while balancing among cost, quality and performance. It is a concurrent engineering team approach that involves engineering, manufacturing and suppliers early in the design cycle. The best results occur when DFMA is used in the product conceptual stage. The cross-functional team work towards minimizing the number of components, manufacturing steps and operations while designing to proven manufacturing capabilities. Optimal Thinking® is the core of all activities. © 2009, Edward C. Lai and Associates. OPTIMAL THINKING® is a registered trademark of The World Academy of Personal Development Inc. All Rights Reserved. Page 2
  3. 3. Edward C. Lai & Associates es Design Philosophy DF MA P imize t h rincipl f parts er o e numb asteners ff 1. Min ize the use o im 2. Min rdize s da ponent 3. Stan difficult com mblies “The best design is the simplest id 4. Avo odular subas arts m 5. Use ultifunctiona n's se lp m tio 6. Use ize reorienta ures one that works.” im 7. Min lf-locating fe se 8. Use special tooli at ng id ty ps 9. Avo e accessibili & process ste vid t io n s 10. Pro e opera nimiz 11. Mi Albert Einstein © 2009, Edward C. Lai and Associates. OPTIMAL THINKING® is a registered trademark of The World Academy of Personal Development Inc. All Rights Reserved. Page 3
  4. 4. Design Complexity Edward C. Lai & Associates (Components through Systems) & Bells es Ba Requ tl Ha d irem ents Whis bit s ir ase Repa 100% Test in C res Over 1 0 0% J us t Design eatu ows Sp ed F ed C ec s. Creep Add Sacr © 2009, Edward C. Lai and Associates. OPTIMAL THINKING® is a registered trademark of The World Academy of Personal Development Inc. All Rights Reserved. Page 4
  5. 5. Edward C. Lai How to Attack Complexity ? & Associates One Bite at a Time • Apply Design Simplification Rules • Challenge “Old” Beliefs • Take a “New” look at Current Design • Work as a Team • Use a Facilitated Process © 2009, Edward C. Lai and Associates. OPTIMAL THINKING® is a registered trademark of The World Academy of Personal Development Inc. All Rights Reserved. Page 5
  6. 6. Edward C. Lai DFMA Methodology & Associates SELECTION OF BEST IDEAS / DESIGN OPTIONS IMPLEMENTATION AND CONTINUOUS OPTIMIZATION © 2009, Edward C. Lai and Associates. OPTIMAL THINKING® is a registered trademark of The World Academy of Personal Development Inc. All Rights Reserved. Page 6
  7. 7. Edward C. Lai DFMA Basic Principles & Associates 1. Minimize the number and types of parts used in the assembly 2. Minimize the use of fasteners (number & types) 3. Standardize (e.g. material, finishes, parts, processes, tooling, etc.) 4. Avoid difficult components (e.g. open-ended springs, small/loose HW, etc.) 5. Use modular subassemblies 6. Use multifunctional parts 7. Minimize reorientation & assembler awkward movements (e.g. stooping, bending, reaching, tugging, balancing, etc.) 8. Use self-locating features (e.g. molded shapes, keying, chamfers, dimples) 9. Avoid special tooling/test equipment 10. Provide accessibility for assembly, test/inspection and rework 11. Minimize operations & process steps (including excess handling, etc.) Eliminate...Minimize...Standardize...”Productionize” © 2009, Edward C. Lai and Associates. OPTIMAL THINKING® is a registered trademark of The World Academy of Personal Development Inc. All Rights Reserved. Page 7
  8. 8. Edward C. Lai Typical Participants & Associates Systems Eng Electrical Eng Mechanical Eng Material & Process Eng Manufacturing Manufacturing Eng Supply Chain Management Key Suppliers Program Office Customer Quality Subject Matter Experts (Outside of the design team) © 2009, Edward C. Lai and Associates. OPTIMAL THINKING® is a registered trademark of The World Academy of Personal Development Inc. All Rights Reserved. Page 8
  9. 9. Edward C. Lai Typical Workshop Agenda & Associates • Introduction to DFMA • Objectives, programmatics, commonality • DFMA Overview • Scope, deliverables, decision criteria, rules • Baseline design overview • Design ground rules and requirements • Identify issues on cost, schedule and performance • Brainstorm, evaluate and select best alternatives • Define optimal assembly process • Review assumptions, action items and parking lot • Next steps © 2009, Edward C. Lai and Associates. OPTIMAL THINKING® is a registered trademark of The World Academy of Personal Development Inc. All Rights Reserved. Page 9
  10. 10. Edward C. Lai Decision Criteria & Associates • Cost (Implementation) • Cost (Recurring) • Schedule • Risk (Technical, schedule, cost) • Performance : Better than baseline : Same as baseline : Worse than baseline © 2009, Edward C. Lai and Associates. OPTIMAL THINKING® is a registered trademark of The World Academy of Personal Development Inc. All Rights Reserved. Page 10
  11. 11. Edward C. Lai & Associates For more information on DFMA, please contact : Ed Lai 310-365-0629 elai001@aol.com © 2009, Edward C. Lai and Associates. OPTIMAL THINKING® is a registered trademark of The World Academy of Personal Development Inc. All Rights Reserved. Page 11
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