DFM basics AWARENESS.pptx

BASIC AWARENESS ABOUT DFMA
 Let the Journey BEGIN
 Be ready with these 7 Is
 Interactive, Involved, Innovative, Interested
Inspired , Imaginative and Intuitive.
 Presented by : Ramesh D Mane
 Karnataka INDIA 580025
 Duration : 60 Minutes
 Email : rdmane520@gmail.com

REASONS TO ADAPT DFMA
 Everbody Desires to have Products &
services which are
 Cheaper
 Light /Compact/Sleek/Durable
 Better –Aesthetics /Look Feel /Ergonomic
 Faster - with Seamless Performance
 Poly functional

MAJOR INGREDIENTS OF DFMA
DFMA
Product
Design-
Innovative
CAD /Reverse
Engg
Manufacturin
g Process-
CNC etc
Latest trends
& Customer
Everchanging
requirements
CAD CAM CAE
Software
Simplification/C
onsolidation
Automation
Material
selection-
Application
/Service
Conditions /Cost
QA
Standards &
Compliances
IATF
/ISO/CCC/CE

DFM
 DFM stands for design for manufacturing
and is a part of the product development
process initiated when the Design shifts
from prototyping to new product
introduction.
 When done professionally & correctly, it
will lower manufacturing and production
time and costs significantly.

WHAT IS DFM AND WHY IS IT IMPORTANT?
 Design for manufacturing (DFM) is the practice of
designing products with parts and assemblies that
are easy to mass-produce and assemble.
 It is the next level of product design necessary to
make products manufactured economically.
 Most seasoned engineers, based on years of
manufacturing experience, build some design for
manufacturing work into earlier phases however,
 The overall process is so detailed that its effort
requires its own phase. There is a right time to do
DFM, and it can be quite costly when done too late in
the product development process.
 Generally, the right time for manufacturing design is
after concept development is frozen, prototypes built
& Evaluated , and enough testing is completed
where the technical team is confident in the design.

 Five Principles of Design For
Manufacturability
The DFM process incorporates five basic
principles –design, material, process,
environment, and compliance and testing. Each
principle is equally important.
 1. Design
DFM starts with the product design. Make sure
your design conforms to accepted manufacturing
principles for the chosen manufacturing process.
Don’t aim unreasonably high; spec tolerances that
are reasonable but still produce a quality product.
 2. Material
Make sure you choose the right material for your
components and final product. If an alternate but
technically acceptable material is available at a
lower cost, use that instead.

 3. Process
You need to choose the best manufacturing process
for your product. The process must be capable of
handling your projected volumes and the types of
parts specified while meeting your quality
requirements. You also want a process that fits your
needs – don’t choose a process that requires a large
capital investment if you’re only producing small runs
of product.
 4. Environment
Ensure that your component parts and the final
product can endure the environment in which it will be
used – but isn’t over-designed in that regard.
 5. Compliance and Testing
Finally, make sure that your final product complies
with all applicable safety and quality standards

How DFM Shortens Product
Development Cycles
 DFM also leads to operational efficiency and inspires
collaboration amongst across CFD , Suppliers & vendors.
 As industries create more complex designs, DFM can be
used to achieve Business goals with Techno commercial
Benchmarks.
 For this we need methods to simplify processes, reduce
costs, increase quality, and get rid of delays.
 DFM can be used to shorten product development cycles. A
good DFM will help identify and get rid of design flaws. This
avoids issues and costly re-design changes.
 A rough design will often turn out to be more difficult to apply.
This leads to higher costs and slower product development.
Simplifying the processes involved in each of the stages can
shorten product development cycles.

 A good DFM will help calculate costs upfront and
lower the total cost of ownership. Via DFM, expenses
can be managed in the design stage itself.
 With DFM, designs can be discussed, and more cost-
effective solutions can be applied, QA is the most
important aspect of any product. Each part and
process needs to be tested to check that quality
meets industry standards.
 DFM can add value to product designs . Different
designs ( Iterations) options can be explored, and
processes can be optimized to lower costs at higher
quality.

FMCG SALES VOLUME-HIGH ???
 The expected sales volume plays a role in
determining part production. If production volumes
are high enough, it may make sense to
consider molding or casting the part. While both
these processes involve substantial tooling expenses,
you can reduce piece part price by amortizing tooling
costs over the product lifetime.
 In some cases, a high-volume part may be initially
machined, for the first few months, to allow for the
design to stabilize. If there are no part design
changes, the production method may transition to
molding or casting as a cost reduction program.

FINISH REQUIREMENTS
 The finish requirements of a part also affect design
for manufacturing.
 Many finishes are available based on material and
environmental factors. For example, metal parts will
need at least one secondary operation to complete.
 The simplest option is stainless steel which requires
only a cleaning process referred to as passivation.
 While With aluminum parts, the choices are
numerous, with anodizing in several colors, hard
anodizing, nickel plating, painting, and powder
coating etc.

REQUIRED TOLERANCING
 Tolerancing lays out what variations in the product dimensions
are allowed before compromising the function of the product.
Reviewing the tolerancing is a necessary aspect of the
manufacturing design process.
 The tolerancing of a part affects not only the pricing but
product assembly and function.
 Parts should be toleranced to ensure that they fit together and
function within the range provided on the prints.
 An excessive number of dimensions or very tight tolerances
on parts can cause inspections to take longer and cost more.
 Tighter tolerances also cost more to manufacture and lead to
higher part fallout. The parts should be toleranced so they can
be easily verified when inspected.
 There can also be cost issues if the tolerances require
specialized equipment to produce or inspect. The Great News
is with the onset of CNC machining centers tighter tolerancing
is almost Feasible .Typically, +/- .005mm used to be the
standard but now +/- .002 is no more costly due to the
precision of machining centers.

ASSEMBLY PROCESS
 With the Increasing cost of Manpower, you need
to consider the required assembly time.
 If simplifying parts change one part into multiple
parts, requiring assembly, one needs to weigh
the cost savings against the added assembly
time and necessary hardware.
 The simpler a product is to assemble, the more
cost-effective it will be. Additionally, moving to a
single complicated part may save money if it
eliminates the need for alignment fixtures or
jigs. All these factors need evaluation during
DFM.

 Another would be that the process is rigorous
and multistep, requiring careful integrated
design work done by engineers well versed
with the Manufactuuring process.
 When going for design for manufacturing,
there is no substitute for experience. If you
are unsure how to get started or would like
some expert advice discuss with your Peers,

Design for Manufacturing / Assembly (DFM/DFA) -Basics
 DFMA is a combination of two methodologies, Design for
Manufacturing (DFM) and Design for Assembly (DFA).
 This combination enables a product design to be efficiently
manufactured and easily assembled with minimum labor cost.
 Through the use of DFM/A, a company can prevent, detect,
quantify and eliminate waste and manufacturing inefficiency
within a product design.
 DFM/A is a break from tradition. With DFM/A, the Design and
Manufacturing Engineers work together as a team in
developing the product’s manufacturing and assembly
methods simultaneously with the design.
 Conventionally, the design engineer designs the product then
hands the drawings to manufacturing who then determine the
manufacturing and assembly processes. Many engineers
automatically separate the two into DFM and DFA since they
have been defined separately for several years. For effective
application of DFM/A the two activities must work in unison to
gain the greatest benefit.

Mistake Proof Product Design and Assembly (Poka Yoke)
 Designers should look for ways to mistake proof their designs,
making the proper assembly of mating parts instantly
recognizable and impossible to assemble incorrectly.
 By the addition of tabs and slots, asymmetrical holes and
interference features the parts can be made difficult or
impossible to assemble in reverse or oriented improperly. The
designer should also avoid the need for any special
adjustments or alignments in the assembly process. With
enough thought put into the design of an assembly many of
the parts can be made mistake proof.
 The designer should also consider how the part or assembly
could be inspected for quality purposes. For some parts,
conformance to design requirements may be verified with
basic go / no-go tools. In other cases the parts may need to
be measured and the designer should indicate any key or
critical to quality dimensions or features.

 Utilize Common Parts and Materials
 Whenever possible the design should
incorporate common parts and materials,
including parts already in use in other
similar products or assemblies.
 Common parts and materials help
minimize inventory levels and will result in
lower cost and higher quality.
 In order to launch successful new product
check whether we can use parts of
previous products i.e carry over / common
parts from a similar product. The Design
risk can be reduced.

Handling Requirements and Part Orientation
 The design engineer should consider how the parts are
going to be handled and oriented during the
manufacturing and assembly processes. If this is not
done, the impact could range from non-value added
motion and part movement to possible operator safety
issues or requirements for special fixtures or lifting
devices.
 There are several basic principles that can be applied to
improve parts handling and orientation. A few examples
can be found below:
 Drawings should consistently indicate the proper
origination when fed into a process. An example would
be how parts are oriented into a brake press for either
bend up or bend down operations.
 The designer should avoid use of parts that can easily
become tangled in the container or that are difficult to
pick up and handle. This slows production and can
increase waste due to damaged, dropped or lost parts.
 When possible design parts that are symmetrical along
both axis. This allows for ease of fabrication and correct
assembly.

CONTD-
 Parts should be designed so that they may be easily grasped,
oriented and placed in an assembly or weld fixture. Examples
would be parts with flat, parallel surfaces that are easily picked-up
and assembled by the operator. Another instance to think about
could be if the part is picked up by a suction or magnetic gripping
device when used in a “pick and place robot” application.
 Always avoid parts with sharp edges, burrs or points. Use radii
and chamfers when possible to reduce chance of operator injury.
 Avoid heavy or oversized parts that will require lifting devices or
may increase worker fatigue and risk of injury. Always consider
assembler and operator safety in all designs.
 When designing a workstation it is good practice to plan for
minimum worker travel time. Minimize the distance to access and
move a part or assembly. A good rule of thumb is that most
components should be within two steps from the point of
assembly and common hardware and tools within easy reach.

 Avoid multiple set-ups or re-orientation during the
assembly process. This creates wasted movement and
time.
 Parts should incorporate lead-in features and chamfers.
This allows for easier insertion of pins or bolts.
 Design the product so it may be assembled from the
bottom up using gravity to your advantage.
 Always allow for adequate tool clearance and assure the
operator can see what they are assembling, with no
hidden interfaces or attachment points.
 Limit the variety of hardware sizes and configurations in
an assembly. This will help prevent incorrect hardware
being used or used in the wrong location.
 Example: One design recently observed utilized one size and
type of self-tapping screw for every sub-assembly and the
parent assembly. Only one type of hardware was required in
the production cell.

Reduce / Eliminate Flexible Parts and
Interconnections
 The designer must consider the usage and
environment in which the product will operate.
Many product failures are due to the component /
parts not being robust to the application.
 Let’s look at one example. There was a display
system that operated a piece of equipment used
outdoors which has inherent vibration during
operation and experiences heavy usage. The
displays were failing due to a fragile ribbon cable
that became brittle over time and would break. It
was also found that the cable connectors did not
lock into place and would sometimes vibrate out,
breaking the connection. The product was
redesigned to include a locking connector
attached to a temperature resistant cable robust to
the operating environment. Here are a few ideas
to think about:

 Design for use of robust connectors and connection
points
 Avoid flimsy flexible cables, tubing and gaskets when
possible
 Minimize the use of wire harnesses – instead design
boards that stack and /or plug directly to one another
when possible
 Utilize direct drive instead of pulleys and belts
 When harnesses are used, error proof the connectors
by using unique connectors that cannot be attached
in the wrong orientation or to the incorrect mating
connection

 Incorporate Easy and Efficient Fastening Methods
 Threaded bolts, washers and nuts are time consuming to
assemble. If they are required, consider weld nuts or nuts
that are captured in the part. The designer must look at
alternative methods of attachment.
 Minimize the variety of hardware required for assembly
 Consider the use of connections integrated into the parts
such as snap fit or tab and slot
 Evaluate other bonding techniques with adhesives
 Match fastening techniques to materials and product
functional requirements
 Consider ease of disassembly for service and repairs

Modular Product Design
 Modular design is becoming more prevalent in
many industries. It has various advantages for the
manufacturer, the dealer and the customers.
Some of the advantages to modular design are
listed below:
 Modules allow for greater outsourcing of parts and
assembly modules, freeing-up manufacturing
capacity and increasing the number of products
delivered on time
 Modules provide for easy and quick installation of
products at the site saving labour and time
 Modules improve servicing and maintenance of
products as well as reduces the number of service
parts that need to be stocked at the dealer
 Modular assemblies can also be improved with
minimal effect on the rest of the product

Design for Automation
 There are many obvious advantages to designing
products or parts for automation. A few of them are
listed below:
 Increased process throughput or efficiency.
 Improved quality or more predictable process results.
 Consistency in the process output.
 Reduced operator labor costs and indirect labor costs
 Something else to consider is the fact that automated
production can require less flexibility in design than
manual production. The product must be designed so
that it can be handled with automated equipment like
gripping or magnetic lifting and placement equipment.
Avoid any requirements for gripper / tool change. You
must also use self-locating parts, simple parts-
presentation devices and avoid the need for clamping
or securing parts during assembly or processing.

INTEGRATION-DESIGN TO MANUFACTURE
 Design for Manufacturing and Design for Assembly
are both important and often interwoven and referred
to simply as DFM/A. The primary goal is to design a
product and process to be as efficient as possible.
Whether a product is assembled by machines or by
operators, the designer and the mechanical engineer
should work together to ensure that labor cost,
overhead and materials are reduced as much as
possible. We should always strive to produce a
quality product the first time and every time and
Design for Manufacturing and Assembly can help!
When DFM/A is applied,
 Our company will operate at higher profit margins,
with higher quality and at a greater level of efficiency.

 Cost reduction:
 Around 70% of the manufacturing costs of a
product can be derived from design decisions
like Proper selection of materials and
manufacturing method.
 The remaining 30% of the costs make up
production decisions like process planning and
tool selection.
 Focusing on design optimization,Parts
Consolidation ,weight Reduction etc reduces
the cost of manufacturing.

CASE STUDIES
 Glass Bottle with Multiple Reentrant sharp
Corners
 Mfg & Using Square Holes for Assembly
 Sheetmetal Furniture with Sharp Corners
 Manufacturing in House - M16 /M20 Nut &
Bolts
 Assembly –Vehicle Body built on Vehicle
Chasis,
 TV Remote / Guard developed,
 Pagers –Text Messages – Technologies getting
Obsolete at Faster Pace
 Ordinary Filament Bulb/CFL Adapter /LED/Solar

CHECK THE AUDIENCE
 Page Left Blank Intentionally
 To Check the Quality of Audience
Involvement & Participation

Basics of Effective Design for Manufacturing

Standardization: Standardization cuts costs by reducing
inventory and scale-up needs. Here are some ways to think about
part standardization:

Design parts that can be reused within a product or shared
between product lines.
 Standardize your hardware within your products to reduce
inventory needs.
 Make your designs modular to simplify product changes or
redesigns.
 Use standard components instead of custom-made ones where
you can.

 Design Simplicity: Simplifying your design cuts down on
the time and inventory needed to make your product,
which correlates to its cost. To simplify your product, you
can:

Minimize assembly steps and inventory by making multi-
functional parts.
 Use designed-in alignment or quick securing methods like
snap fits. Fastening techniques including bolting or
glueing take longer to secure and require more inventory.
 Test your improved designs quickly with 3D printed
prototypes.

 Alignment and Compliance: Errors in alignment can
damage parts or equipment, reducing yield or even
causing line shutdown. Tweak your designs to
account for slop, misalignment, and tolerance
stackup by doing any of the following:

Resolve assembly issues by analyzing how
tolerances will stack up in your assembly.
 Design integrated part features to help with alignment
during assembly.
 Add tapers or chamfers to guide components during
assembly insertion steps.

 Setup Time Reduction: Reduce setup time by
reducing the number of operations required per part,
or simplifying assembly steps with 3D printed
fixtures and workflow improvements.

Reduce the number of setups or rotations required
per part or assembly.
 3D print custom workholding to drop setup time and
assist workers with alignment, inspection, and
assembly.
 Assess where your line could be upgraded with
improved tools or workstations.

Where to Start With Design for Manufacturing

Communication: Iteration in product design goes both ways. Work
with the people on the shop floor /factory floor to iterate and improve
upon your design, because they’ve often experienced many of the
production problems first-hand!

Process: What manufacturing method would be most cost-effective
for production? Additive, subtractive, or forming? Well-designed
parts should be optimized for their manufacturing process – and can
even take advantage of it to further simplify a design. Analyzing the
process by which each part is made can lead to simpler setups and
operations to reduce part cost.

Materials: Your material choice can impact your cost, part quality,
and manufacturing method. What properties does your part require?
How many cycles should it last? Are there any weight
requirements?

Infrastructure: How is your production line set up and supported?
Just as you would optimize a part design for its manufacturing
process, you can optimize your production workflow for its
manufacturing facility.

 How Does 3D Printing Fit in to Design for
Manufacturing?

The key value of additive manufacturing as used in DFM
lies in rapid iteration and improvement. It increases your
productivity by reducing the time and cost to get a part
made – whether it’s a prototype, a tool, or a final part.

Prototypes: 3D printing allows for rapid iteration so you
can test out many different designs early and often. You
can cycle through designs of both your parts and their
manufacturing and assembly fixtures to refine the process
– make it cheaper, higher yield, and faster.

 Tooling: 3D printing your tooling cuts down
your production ramp-up time by eliminating
lead time constraints for tooling fabrication –
making it simple to produce conformal or
ergonomic tooling that match the contours of
the workpiece.
 Just as with prototyping, you can quickly
iterate through multiple versions of a tool to
refine it before implementation on the line.

 End-Use Parts: 3D printing is a viable option
for some end-use applications, often due to
specific design requirements that render
other manufacturing methods cost-
prohibitive. It comes with its own set of
design guidelines, which can vary depending
upon the type of 3D printer used and
Technology being used.

Lowering Manufacturing Costs with DFM
Over the last decade, supply chains across industries
have grown more complex. There is more pressure to
lower costs while keeping quality. As such, it is a great
time for industries to use DFM.
New technology, smart devices, changing consumer
needs, and shrinking product life cycles have added to
the growing tech world. But these changes come with
many problems. Manufacturing companies are finding
it harder to keep up with the complex supply chain
structure.
Competitive pricing, and the constant pressure to keep
up with industry standards are other problems.
With an inflow of New Hi tech devices, manufacturing
costs and standards are a growing topic of concern,
for example. As the industry grows, Appliances /
devices are growing more complex. DFM allows
manufacturers to design high-quality devices much
faster while sticking to safety standards.

5 Basic Factors in Sheet Metal Design for
Manufacturability
 1. Bend Relief
 Bend relief refers to an indentation that designers should make on sheet metal
designs so that the bending process is simple during manufacturing.
 A flange that does not have a bend relief will have a higher degree of
distortion and may cause tearing of the adjacent material.
 According to a general sheet metal design thumb rule, the bend relief’s depth
should be equal to or greater than the inside radius of the bend. The width, on
the other hand, should be equal to or larger than the sheet metal’s thickness.

2. Hole Sizes
 When a sheet metal design has small holes, it requires smaller
punches during operation. This could result in breakage during
manufacturing.
 An important design tip, in this case, is to plan for holes
whose diameter is equal to or greater than the sheet metal’s
thickness.


 .

3. Distance Between a Hole and a Bend
This is a big one.
Designers should leave adequate clearance between a hole and
bend, or else the hole will get deformed when the sheet metal is bent
during manufacturing. The best practice here is to ensure that
the distance between a bend line and the edge of a hole is 2x or more
the thickness of the sheet metal.
4. Sheet Metal Bending Radius
The minimum sheet metal bend radius depends on the
manufacturing process and tool used. The more flexible the metal,
the easier it is to attain a small inner bend radius.
A great practice here is to ensure that the minimum bend radius
for mild steel sheet metal is equal to its thickness

5. Minimum Flange Width
When designing a sheet metal assembly,
make sure that the width of your flange is
always more than 4x the sheet metal’s
thickness.
Failure to do so will cause the tooling to
leave marks on the sheet’s surface. This is
especially problematic if your project
needs to be aesthetically pleasing.

 Winding Up –Lets Recollect
 Why Perform Design for Manufacturing / Assembly
(DFM/DFA)
 The DFMA methodology allows for new or improved
products to be designed, manufactured and offered to
the consumer in a shorter amount of time.
 DFM/DFA helps eliminate multiple revisions and
design changes that cause program delays and
increased Project cost.
 With DFM/A the design is often more comprehensive,
efficient to produce and meets the customer
requirements the first time. F T R & E T R
 A shorter total time to market frequently results in
lower development costs.
 The application of the DFMA method results in shorter
assembly time, lower assembly cost, elimination of
process waste and increased product reliability.

THANKS FOR INVESTING YOUR TIME
 Questions welcome
 Ready for Objective Test- 5 Minutes
 Next Training Topic : GD & T Duration 30
Minutes
 Basics of Design –Duration 30 Minutes
 Any specific Topic for Interactive Training ?????

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