This document discusses design for manufacturing (DFM) which emphasizes manufacturing considerations throughout the product development process. It aims to lower production costs without compromising quality. The document outlines DFM objectives like reducing component, assembly and support costs. It describes a 5-step DFM process including estimating manufacturing costs, reducing costs at each stage, and considering impacts. An example of a GM engine redesign that achieved major cost savings through DFM is provided. Finally, the document lists numerous design principles for various stages of manufacturing like assembly, fastening, automation, quality testing, and maintenance.

1. Design for Manufacturing
Teaching materials to accompany:
Product Design and Development
Chapter 13
Karl T. Ulrich and Steven D. Eppinger
5th Edition, Irwin McGraw-Hill, 2012.

2. Product Design and Development
Karl T. Ulrich and Steven D. Eppinger
5th edition, Irwin McGraw-Hill, 2012.
Chapter Table of Contents:
1. Introduction
2. Development Processes and Organizations
3. Opportunity Identification
4. Product Planning
5. Identifying Customer Needs
6. Product Specifications
7. Concept Generation
8. Concept Selection
9. Concept Testing
10. Product Architecture
11. Industrial Design
12. Design for Environment
13. Design for Manufacturing
14. Prototyping
15. Robust Design
16. Patents and Intellectual Property
17. Product Development Economics
18. Managing Projects

3. Planning
Product Development Process
Concept
Development
System-Level
Design
Detail
Design
Testing and
Refinement
Production
Ramp-Up
How can we emphasize manufacturing issues
throughout the development process?

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Outline
• DFX concept
• DFM objectives
• DFM method
• Mfg. cost estimation
• DFM impacts
• DFM examples

5. Design for Manufacturing Example:
GM 3.8-liter V6 Engine

6. Understanding Manufacturing Costs

7. Definition
• Design for manufacturing (DFM) is a development
practice emphasizing manufacturing issues
throughout the product development process.
• Successful DFM results in lower production cost
without sacrificing product quality.

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Introduction
• DFM is part of DFX
• DFM often requires a cross-function team
• DFM is performed through the development
process

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Major DFM objectives
• Reduce component costs
• Reduce assembly cost
• Reduce production support costs

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The DFM Process (5 steps)
1) Estimate the mfg. costs
2) Reduce the costs of components
3) Reduce the costs of assembly
4) Reduce the costs of supporting
production
5) Consider the impact of DFM decisions
on other factors.

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Estimate mfg. costs
• Cost categories
– Component vs. assembly vs. overhead
– Fixed vs. variable
– Material vs. labor
• Estimate costs for standard parts
– Compare to similar part in use
– Get a quote from vendors
• Estimate costs of custom made parts
– Consider material costs, labor costs, and tooling costs
– Depend on the production volume as well
• Estimate costs of assembly
– Summing up all assembly operations (time by rate)
• Estimate the overhead costs
– A % of the cost drives

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Reduce the costs of components
• Identify process constraints and cost drivers
• Redesign components to eliminate processing
steps
• Choose the appropriate economic scale for the
part process
• Standardize components and their processes
• Adhere the black-box component

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Reduce the costs of assembly
• Integrate parts (using the Boothroyd
method)
• Maximize ease of assembly
• Consider customer assembly (do-it-
yourself) technology driven products

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Reduce the costs of
supporting production
• Minimize systematic complexity (such as
plastic injection modeling for one step of
making a complex product)
• Error proofing (anticipate possible failure
modes in the production system and take
appropriate corrective actions early in the
development process)

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Considering impacts
• Development time
• Development cost
• Product quality
• External factors such as
– component reuse and
– life cycle costs

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Design for Manufacturing Example:
1993 GM 3800cc V6 Engine Design

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DFM example
• Exhibit 13-15 on Page 274
• Unit cost saving of 45%
• Mass saving of 66% (33 Kg.)
• Simplified assembly and service procedures.
• Improved emissions performance
• Improved engine performance
• Reduce shipping costs (due to lighter components)
• Increased standardization across vehicle programs.

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Cost Appendices
• Materials costs
– Exhibit 13-17 on page 279
• Component mfg. costs
– Exhibits 13/18-21 on pages 280-283
• Assembly costs
– Page 286 for common products
– Page 287 for part handling and insertion times on
Ex. 13-23
– Cost structures for firms on Ex 13-24.

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Design for X
– Design principles
• Part shape strategies:
– adhere to specific process design guidelines
– if part symmetry is not possible, make parts very
asymmetrical
– design "paired" parts instead of right and left hand parts.
– design parts with symmetry.
– use chamfers and tapers to help parts engage.
– provide registration and fixturing locations.
– avoid overuse of tolerances.

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Design for X
– Design principles
• Standardization strategy
– use standard parts
– standardize design features
– minimize the number of part types
– minimize number of total parts.
– standardize on types and length of linear materials and
code them.
– consider pre-finished material (pre-painted, pre-plated,
embossed, anodized).
– combine parts and functions into a single part.

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Design for X
– Design principles
• Assembly strategies 1
– design product so that the subsequent parts can be added to
a foundation part.
– design foundation part so that it has features that allow it to
be quickly and accurately positioned.
– Design product so parts are assembled from above or from
the minimum number of directions.
– provide unobstructed access for parts and tools
– make parts independently replaceable.
– order assembly so the most reliable goes in first; the most
likely to fail last.

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Design for X
– Design principles
• Assembly strategies 2
– make sure options can be added easily
– ensure the product's life can be extended with
future upgrades.
– use sub-assemblies, especially if processes are
different from the main assembly.
– purchase sub-assemblies which are assembled and
tested.

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Design for X
– Design principles
• Fastening strategies 1
– use the minimum number of total fasteners
– use fewer large fasteners rather than many small fasteners
– use the minimum number of types of fasteners
– make sure screws should have the correct geometry so that
auto-feed screwdrivers can be used.
– design screw assembly for downward motion
– minimize use of separate nuts (use threaded holes).
– consider captive fasteners when applicable (including
captive nuts if threaded holes are not available).

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Design for X
– Design principles
• Fastening strategies 2
– avoid separate washers and lockwashers (make it be
captivated on the bolt or nut so it can still spin with respect
to the fastener)
– use self-tapping screws when applicable.
– eliminate fasteners by combining parts.
– minimize use of fasteners with snap-together features.
– consider fasteners that push or snap on.
– specify proper tolerances for press fits.

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Design for X
– Design principles
• Assembly motion strategies
– fastened parts are located before fastener is applied.
– assembly motions are simple.
– Assembly motions can be done with one hand or robot.
– assembly motions should not require skill or judgment.
– products should not need any mechanical or electrical
adjustments unless required for customer use.
– minimize electrical cables; plug electrical sub-assemblies
directly together.
– minimize the number of types of cable.

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Design for X
– Design principles
• Automation handling strategies 1
– design and select parts that can be oriented by automation
– design parts to easily maintain orientation
– use parts that will not tangle when handled in bulk.
– use parts what will not shingle when fed end to end (avoid
disks).
– use parts that not adhere to each other or the track.
– specify tolerances tight enough for automatic handling.
– avoid flexible parts which are hard for automation to
handle.

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Design for X
– Design principles
• Automation handling strategies 2
– make sure parts can be presented to automation.
– make sure parts can be gripped by automation.
– parts are within machine gripper span.
– parts are within automation load capacity.
– parting lines, spruces, gating or any flash do not
interfere with gripping.

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Design for X
– Design principles
• Quality and test strategies
– product can be tested to ensure desired quality
– sub-assemblies are structured to allow sub-assembly
testing
– testing can be performed by standard test instruments
– test instruments have adequate access.
– minimize the test effort spent on product testing consistent
with quality goals.
– tests should give adequate diagnostics to minimize repair
time.

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Design for X
– Design principles
• DF Maintenance strategies 1
– provide ability for tests to diagnose problems
– make sure the most likely repair tasks are easy to perform.
– ensure repair tasks use the fewest tools.
– use quick disconnect features
– ensure that failure or wear prone parts are easy to replace
with disposable replacements
– provide inexpensive spare parts in the product.
– ensure availability of spare parts.

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Design for X
– Design principles
• Maintenance strategies 2
– use modular design to allow replacement of modules.
– ensure modules can be tested, diagnosed, and adjusted
while in the product.
– sensitive adjustment should be protested from accidental
change.
– the product should be protected from repair damage.
– provide part removal aids for speed and damage
prevention.
– protect parts with fuses and overloads

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Design for X
– Design principles
• Maintenance strategies 3
– protect parts with fuses and overloads
– ensure any sub-assembly can be accessed through one door
or panel.
– access over which are not removable should be self-
supporting in the open position.
– connections to sub-assemblies should be accessible and
easy to disconnect.
– make sure repair, service or maintenance tasks pose no
safety hazards.
– make sure sub-assembly orientation is obvious or clearly
marked.

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Design for X
– Design principles
• Maintenance strategies 4
– make sure sub-assembly orientation is obvious or clearly marked.
– provide means to locate sub-assembly before fastening.
– design products for minimum maintenance.
– design self-correction capabilities into products
– design products with self-test capability.
– design products with test ports
– design in counters and timers to aid preventative maintenance.
– specify key measurements for preventative maintenance programs
– include warning devices to indicate failures.

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Design for X
– Design principles
• Axomatic Design by Nam Suh
– Axiom 1
• In good design, the independence of functional
requirements is maintained.
– Axiom 2
• Among the designs that satisfy axiom 1, the best
design is the one that has the minimum
information content.

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Design for X
– Design principles
• Axiomatic design- corollaries
– Decouple or separate parts of a solution if functional requirements are
coupled or become coupled in the design of products and processes.
– Integrate functional requirements into a single physical part or
solution if they can be independently satisfied in the proposed
solution.
– Integrate functional requirements and constraints.
– Use standardized or interchangeable parts whenever possible.
– Make use of symmetry to reduce the information content.
– Conserve materials and energy.
– A part should be a continuum if energy conduction is important.

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Design for X
– Design principles
• DFA Method: Boothroyd and Dewhurst
– Apply a set of criteria to each part to
determine whether, theoretically, it should be
separated from all the other parts in the
assembly.
– Estimate the handling and assembly costs for
each part using the appropriate assembly
process - manual, robotic, or high-speed
automatic.

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Design for X
– Design principles
• Three criteria
– Is there a need for relative motion?
– Is there a need for different materials
– Is there a need for maintenance?

42. Design for Assembly Rules
Example set of DFA guidelines
from a computer manufacturer.
1. Minimize parts count.
2. Encourage modular assembly.
3. Stack assemblies.
4. Eliminate adjustments.
5. Eliminate cables.
6. Use self-fastening parts.
7. Use self-locating parts.
8. Eliminate reorientation.
9. Facilitate parts handling.
10. Specify standard parts.

43. Design for Assembly
• Key ideas of DFA:
–Minimize parts count
–Maximize the ease of handling parts
–Maximize the ease of inserting parts
• Benefits of DFA
–Lower labor costs
–Other indirect benefits
• Popular software developed by
Boothroyd and Dewhurst.
–http://www.dfma.com

44. To Compute Assembly Time
Handling Time
+ Insertion Time
Assembly Time

45. Method for Part Integration
• Ask of each part in a candidate design:
1.Does the part need to move relative to the rest of
the device?
2.Does it need to be of a different material because
of fundamental physical properties?
3.Does it need to be separated from the rest of the
device to allow for assembly, access, or repair?
• If not, combine the part with another part in the
device.

46. Three Methods to Implement DFM
1. Organization: Cross-Functional Teams
2. Design Rules: Specialized by Firm
3. CAD Tools: Boothroyd-Dewhurst Software

47. DFM Strategy is Contingent
Corporate
Strategy
Production
Strategy
Product
Strategy
DFM
Strategy

48. Other Images