1. Design for X (Excellence)
• The Design For X (or “Design for Excellence”)
methodology lays out a number of design guidelines
for reaching the product’s objectives.
• The idea is to review and improve the product &
process design before the new product is
manufactured.
2.
3. Design for Manufacturing (DFM)
• During concept phase, customer need & product specifications are guiding tools.
For later development phase of product, DFX plays critical role. Out of all DFX
tools, DFM is more important which directly addresses manufacturing costs of
product.
• Manufacturing cost is a key determinant of the economic success of a
product. In simple terms, economic success depends on the profit margin earned
on each sale of the product and on how many units of the product the firm can
sell.
• Profit margin is the difference between the manufacturer’s selling price and the
cost of making the product.
4. Overview of DFM process
• DFM process consist of five steps plus iterations.
1. Estimate the manufacturing costs.
2. Reduce the costs of the components.
3. Reduce the cost of the assembly [ Design for Assembly (DFA) ]
4. Reduce the costs of the supporting production.
5. Consider the impact of DFM decisions on other factors.
5.
6. Design for Assembly (DFA)
• Design for assembly (DFA) is a process by which products are designed
with ease of assembly in mind. If a product contains fewer parts it will
take less time to assemble, thereby reducing assembly costs.
• In addition, if the parts are provided with features which make it easier to
grasp, move, orient and insert them, this will also reduce assembly time
and assembly costs.
• The reduction of the number of parts in an assembly has the added
benefit of generally reducing the total cost of parts in the assembly.
7. DFA principles
1. Minimizing part count
2. Modularity
3. Built-in fasteners
4. Part symmetry
5. Mistake proofing (Poka - Yoke technique)
6. Use of commercially available standardised parts
7. Use of reasonable tolerances
