Design for Manufacturing and Assembly (DFMA) is a methodology used to minimize product cost through design and process improvements. DFMA integrates product design and process planning to design products that are easily and economically manufactured. The goal of DFMA is to reduce material, overhead, and labor costs, shorten product development times, and utilize standardization to reduce costs. Key principles of DFMA include reducing the total number of parts, developing modular designs, using standard components, designing parts for multi-functionality and multi-use, and minimizing assembly directions.

2. DFMA – Design for manufacturing and
assembly

3. Purpose Statement
To provide an overview of Design for
Manufacturing and Assembly (DFMA)
techniques, which are used to minimize
product cost through design and process
improvements.

4. Design for Manufacturing
Definition: DFM is the method of design for ease of manufacturing of the
collection of parts that will form the product after assembly.
‘Optimization of the
manufacturing
process…’
DFA is a tool used to select the most cost effective material and
process to be used in the production in the early stages of product
design.

5. Major DFM objectives
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.

6. Design for Assembly
Definition: DFA is the method of design of the product for
ease of assembly.
‘…Optimization
of the part/system
assembly’
DFA is a tool used to assist the design teams in the design of
products that will transition to productions at a minimum cost,
focusing on the number of parts, handling and ease of assembly.

7. Differences
Design for Assembly (DFA)
• concerned only with reducing product assembly cost
– minimizes number of assembly operations
– individual parts tend to be more complex in design
Design for Manufacturing (DFM)
• concerned with reducing overall part production cost
– minimizes complexity of manufacturing operations
– uses common datum features and primary axes

8. Similarities
• Both DFM and DFA seek to reduce material, overhead, and
labor cost.
• They both shorten the product development cycle time.
• Both DFM and DFA seek to utilize standards to reduce cost

9. Terminology
Design for Manufacturing (DFM) and Design for Assembly (DFA)
are now commonly referred to as a single methodology,
Design for Manufacturing and Assembly (DFMA) .

10. Sequence of Analysis
Concept Design
Design for
Assembly
Design for
Manufacturing
Detailed Design

11. Estimating Manufacturing Costs
Estimate manufacturing
Costs of Proposed Design
Reduce costs of assembly Reduce costs of
Supporting Production
Reduce costs of
components
Consider DFM impact on
other factors
Recompute
Manufacturing Costs
Good Enough? Accepted Design
N Y

12. DFMA – Design for manufacturing and
assembly
Design for Manufacturing (DFM) and design for
assembly (DFA) are the integration of product
design and process planning into one common
activity.
The goal is to design a product that is easily and
economically manufactured.

13. The heart of any design for manufacturing system is a group of
design principles or guidelines that are structured to help the
designer reduce the cost and difficulty of manufacturing an
item. The following is a listing of these rules

14. Reduce the total number of parts
The reduction of the number of parts in a product is probably the best
opportunity for reducing manufacturing costs. Less parts implies less
purchases, inventory, handling, processing time, development time,
equipment, engineering time, assembly difficulty, service inspection,
testing

15. Develop a modular design
The use of modules in product design simplifies manufacturing
activities such as inspection, testing, assembly, purchasing,
redesign, maintenance, service

16. Use of standard components
Standard components are less expensive than custom-made
items. The high availability of these components reduces
product lead times.

17. Design parts to be multi-functional
Multi-functional parts reduce the total number of parts in a
design, thus, obtaining the benefits given in rule 1. Some
examples are a part to act as both an electric conductor and
as a structural member, or as a heat dissipating element and
as a structural member.

18. Design parts for multi-use
In a manufacturing firm, different products can share parts that
have been designed for multi-use. These parts can have the
same or different functions when used in different products.
In order to do this, it is necessary to identify the parts that are
suitable for multi-use. For example, all the parts used in the
firm (purchased or made) can be sorted into two groups: the
first containing all the parts that are used commonly in all
products.

19. Design for ease of fabrication
Select the optimum combination between the material and
fabrication process to minimize the overall manufacturing
cost. In general, final operations such as painting, polishing,
finish machining, etc. should be avoided. Excessive tolerance,
surface-finish requirement, and so on are commonly found
problems that result in higher than necessary production cost.

20. Avoid separate fasteners
The use of fasteners increases the cost of manufacturing a part
due to the handling and feeding operations that have to be
performed. Besides the high cost of the equipment required
for them, these operations are not 100% successful, so they
contribute to reducing the overall manufacturing efficiency. In
general, fasteners should be avoided and replaced, for
example, by using tabs or snap fits.

21. Fastener Cost
• Select the
most
inexpensiv
e fastening
method
required
plastic bending
riveting
screwing
snap fit

22. Minimize assembly directions
All parts should be assembled from one direction. If possible, the
best way to add parts is from above, in a vertical direction,
parallel to the gravitational direction (downward).
In this way, the effects of gravity help the assembly process,
contrary to having to compensate for its effect when other
directions are chosen.

23. Reference
1. Assembly Automation and Product Design
G. Boothroyd, Marcell Dekker, Inc. 1992
2. Product Design for Manufacture and Assembly
G. Boothroyd and P. Dewhurst, Boothroyd Dewhurst, Inc. 1989
Marcell Dekker, Inc. 1994
3. Design and Analysis of Manufacturing Systems
Prof. Rajan Suri University of Wisconsin 1995
4. Product Design for Assembly: The Methodology Applied
G. Lewis and H. Connelly