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Design for Manufacturing and Assembly
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Design for Manufacturing and Assembly

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Design for Manufacturing and Assembly

Design for Manufacturing and Assembly


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  • 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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