Tao of Design For Manufacturability by Er Ramalingam DFM & Innovation Consultant - CHENNAI - INDIA www.dfmhandbook.com

1. SYNERGIZE
DESIGN WITH MANUFACTURABILITY
TO ENERGIZE INNOVATION
Presented by Er Ramalingam

2. BEST DESIGN AND THE BEST
DESIGNER
 The best design on this earth is only the
 Body Machine –Human being .
 Mankind has survived millions of years on this earth .
 Some of the other creations of nature have become extinct .
 We don’t know who is the Designer of these ?
 Human being is the Best Biological Product with Two Genders .
 Is it by natural selection or by fate or survival of the fittest ?
 And the best example for survival of the fittest also .
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3. BEST DESIGN AND THE BEST
DESIGNER
 But these best products are brought to this earth by
procreations by men and women for millions of years.
 By synergizing between the eligible male adult and a
female adult .
 It is for the new born to be nursed by the parents well or
society .
 The Person has to self protect and grow by
 Proper foods . Knowledge additions and Maintenance .
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4. BEST DESIGN AND THE BEST
DESIGNER
.
 In this world of intense competition money has become a
common scale of capability index for the individuals as age
grows and Man has to learn & un-learn.
 The basic secrets are the continuous
 Renewal of the life cells , the mini power plants -
an important point to be noted by
 Design Engineering Professionals while designing
for products of higher life cycles.
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5. ENGINEERING PRODUCTS & BODY MACHINE
 Most of the engineering products right from ordinary levers to
robots are only reflections or reverse engineered products or
systems from the Body Machine
 This design has all examples for :
 Symmetry and Style
 Balancing & Stabilizing ,
 Engineering Machines & Chemical Process Equipments
 Electronics & Computers
 Telecommunications & Media.
 Chemical Plants & Battery Charging
 Energy & Renewable Energy ,
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6. ENGINEERING PRODUCTS & BODY MACHINE
 Ships and Material Handling ..
 Standby Tools like two hands ,two legs two ears, two kidneys ,two
eyes & a virtual eye for blind persons.
 But only one Brain with two functions –Analytical and Creative
 And Single Heart with two functions – Pumping & Suction of
Blood
 In short the Body Machines are having the ‘Yang’ or ‘Yin’.
 1-Human intellects have developed systems like Computers to
multiply the human capacity in knowledge &
 2- ‘Yoga’ to synergize the breathing ( media of life )with the body ..
 Cloning by scientific means have proved man’s ability to research
and innovation in creations – but at huge costs .
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7. ENGINEERING PRODUCTS & BODY MACHINE
 In short ,this Body Machine is the best designed ‘animal
on earth ‘having acquired powers to create and destroy
also .
 It is the best reliable product out of ‘Tao of DFM ‘-
Designed to be a Reliable Product with higher Quality at
lower cost ( if out of normal delivery ) in faster time (about
ten months standard time )
 All born are supposed to be of better quality by birth .
 Due to the DNA factors or Genetic Factors some in-born
features are passed on to generations down the line.
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8. AVERAGE OF REDUCTIONS OBTAINED THROUGH DFMA
 “ Labor Costs - 42% ,
 Parts Count - 54%,
 Separate Fasteners - 57% ,
 Weight - 22% ,
 Assembly Time - 60% ,
 Assembly Cost - 45%,
 Assembly Tools - 73% ,
 Assembly Operations - 53% ,
 Product Development Cycle - 45% &
 Total Cost - 50% “
 By adopting Design for Manufacturability & Assembly –DFMA - the above
reductions were made possible ,as per www.dfma.com , the world’s first
software entity on DFM from USA based on the average of net results produced
for 100 Clients by them.
 Tell me which other methodology is able to deliver this kind of results.?
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9. DEFINITION OF DESIGN FOR MANUFACTURABILITY-DFM
 According to Dr David M Anderson( my mentor for DFM) 'Design
For Manufacturability' is the process of proactively designing
products to:
 (1)optimize all the manufacturing functions: fabrication,
assembly, test, procurement, shipping, delivery, service and
repair,
 (2) assure by design, the best cost, quality, reliability, regulatory
compliance, safety, time-to-market and customer satisfaction &
 (3) ensure that lack of manufacturability doesn't compromise
functionality, styling, new product introductions, product delivery,
improvement programs, strategic initiatives and unexpected
surge in demand. www.design4manufacturability.com
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10. STARTING POINTS FOR THIS ‘TAO OF
DFM’
 Dr Sanjay Ramaswamy in his Arizona State University’s
report on DFM Methodologies has expressed that “Insufficient
Scientific base under the softwares and enormous data are
compiled within the computer or software.
 Human intervention and feedback are rare.,DFMA methods
have little efforts at the conceptual stage where most of the
product cost is fixed .&Insufficiency due to the inability to
provide RE-DESIGN suggestions to modify shapes in the
case of unsuitable designs.”
 The above inputs are the starting points for this ‘Tao of
DFM” .
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11. INSPIRATIONS FOR TAO OF DFM
 Inspirations came from Dr Fritjof Capra (The author of
'The Tao of Physics')
 ‘The Taoist saw all changes in nature as manifestations
of the dynamic interplay between the polar opposites
YIN & YANG, and thus they come to believe that any pair
of opposites constitutes a polar relationship where each
of the two poles is dynamically linked to each other.
 At the balancing point, the two energies are found to be
in harmony and create conditions for new forms to
merge.”
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12. INNOVATION’S DOUBLE HELIX
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13. INNOVATION’S DOUBLE HELIX
 “A Technology without a Market is as valuable
 As a Market without a Technology –
 They are both worthless !
 At one end of the spectrum you have something
interesting running in the lab and at the other end you
have an interesting insight around a new market..
 But one won’t do ,and from the either end of the
rainbow your quest is to find the pot of gold at the
other end “- thanks to Dr Shipulski
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14. INNOVATION’S DOUBLE HELIX
 “ Innovation is always a clustered –jumble of two extremes .
 In fact it’s more like a double helix where the customer strand
winds around the technology and the technology strand winds
around the customer .
 One strand takes the lead and mutates the other ,which in turn
spirals learning in unforeseen directions.”
 There is no getting around it-market & technology co-evolve …
Instead of spending time and money sequencing the innovation
genome ,take your cue from nature- try stuff and do more of
what worked and less of what didn’t ,
 And remember the cardinal rule – the organization with the best
genes wins”- thanks to Dr Shipuski
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15. TAO OF DFM
 Here comes the methodology of ‘Tao of DFM’ which stipulates that the
organization should have the best genes as members of the Concurrent
Engineering Team of cross functional experts with a golden mix of
Holistic Minds & Creative Minds
 “ Thirty spokes join in one hub
 In its emptiness ,there is the function of a vehicle.
 Mix clay to create a container.
 In its emptiness ,there is the function of the container.
 Cut open doors and windows to create a room
 In its emptiness ,there is the function of a room.
 Therefore ,that which exists is used to create benefit
 That which is empty is used to create functionality”- from reflections of
the Tao Te Ching.
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16. TAO OF DFM
 Sixty-four spokes join in one hub -Tao of DFM .
 In its emptiness , the Design or the Yang
 There is the function of
 Manufacturability, the Yin.
 That which exists is the manufactured product
used to create benefits :
 That which is empty, the Design is used to create
Product /functionality – This is Tao of Design For
Manufacturability
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17. TAO OF DFM
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In the well known symbol of the yin and
yang, two fishes encircling one another, is
a picture of the complementary nature of
the sexes,
Their need for one another and their
interdependence.
The two eyes of the fish show that even
within the masculine there is some of the
feminine, and vice versa.

18. TAO OF DFM
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According to Chinese philosophy, harmony
between the sexes is not only a problem for
those who are married:
Half of life is best understood from the feminine
point of view and the other half by the
masculine.
Both poles are needed to get at the whole "great
mystery" of life.
.

19. TAO OF DFM
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Complementary is a better word to use than
opposites in describing the differences between
the sexes remembering also that this
phenomena does teach equality of the sexes.
The generic term men or brothers unless
otherwise stated means men and women
because the two sexes are the same in spirit,
the innermost core of our being.

20. TAO OF DFM
 TDFM provides the Rules & Guidelines of assuring Design For
Manufacturability and TDFM provides basic Rules & Guidelines
..
 Tao of DFM directs to synergize Creative Minds with Holistic
Minds to bring Innovative Products /Processes by a viable Gap
Analysis and by adopting DMAIC type Analysis.
 Mantras of TDFM are to make the holistic minds & creative
minds to think and work together under a common platform of
Concurrent Engineering.
 It has to be a golden blend of the West with the East and vice
versa. This is the essence of TDFM, a dynamic
interplay/synergy between Design & Manufacturability .
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21. TAOISM & ARTHANAREESWARA
 In typical Hindu /Indian words 'Design' is the
function of Shiva and 'Manufacturability' is
the function of Parvathy.’.
 In other words 'Design' is the function of
Shiva (YANG ) and 'Manufacturability' is the
function of Parvathy (YIN) under my 'Tao of
DFM’.
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22. TAOISM & ARTHANAREESWARA
 Some of you might be perplexed to find that a scientific/technical
method of design/development is being interpreted through a
mystical thought of Taoism.
 I expect the Designer’s understanding of TDFM should progress
steadily & simultaneously, re-engineering their thoughts and actions
through understanding the Eastern Schools of Taoism and
Arthanarishvara – which are to be experienced and not merely
learning from books.
 A deeper understanding of TDFM can only be felt when one decides
to become actively involved in TDFM by doing TDFM analysis by
adopting both holistic & creative approaches and then a Gap
Analysis through an integrated Taoist Approach through a CET
comprising of cross-functional experts.
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23. COMPARISON OF GAPS
 The Gaps between Design & Manufacturability are
the reflections of Gaps between the following:
 Between Theory & Practice,
 Between Man & Woman,
 Between Lord Shiva & Parvathy,
 Between Yang & Yin,
 Between Voltage & Current,
 Between Software & Hardware,

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24. COMPARISON OF GAPS
 Between the Positive & Negative Polarities in
Electricity ,
 Between North & South Polarities in Magnetism ,
 Between the Right & Left Halves of human brain,
 Between the Conscious Mind & the Sub-
conscious Mind &
 Between the Body & Mind
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25. ‘BERLIN WALL’ BETWEEN DESIGN &
MANUFACTURABILITY
 You can find in-built attractions between the above
kind of opposing entities due to nature /science.
 Mission of TDFM is to embed similar attractions
between Design & Manufacturability which are
having a ‘Berlin Wall’ in between them .
 In our planet, there are numerous things of dual
forces or entities that are complementary to each
other and are also independent of each other; the
integration of these two opposing forces alone can
create the essentials of life & matter..
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26. BERLIN WALL BETWEEN DESIGN &
MANUFACTURABILITY
 Each has a destined role to play and without
proper integration /synergy between the two
opposing entities, nothing can be created on
earth.
 Design & Manufacturability are equated to
these dual entities under TDFM..
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27. “BERLIN WALL” BETWEEN
DESIGN & MANUFACTURABILITY
 TDFM arrives here to break the ‘Berlin Wall’
between ‘Design’ & 'Manufacturability' by
adopting TDFM.
 'Design' and 'Manufacturability' have to dance
together 'not merely with arms to arms’
 But also with cheek to cheek’ with
‘Music ' from Innovation Engineering &
‘Lyrics ' from 'Concurrent Engineering'.
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28. EIGHT CRITERIA OF TDFM
 Both the holistic & creative minds of the CET
will do a Gap Analysis − Criteria-wise/Pillar-
wise – of the assurances for Design as per
the following Criteria :
 Design for Best Cost (DFBC),
 Design for Best Quality (DFBQ),
 Design for Best Reliability (DFBR),
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29. EIGHT CRITERIA OF TDFM
 Design for Best Compliance to
Regulations/Sustainability (DFBCRS),
 Design for Best Safety (DFBS),
 Design for Best Time-to-Market (DFBTM),
 Design for Best Function/Style (DFBFS) &
 Design for Best Satisfaction to Customer
(DFBSC).
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30. EIGHT SYSTEMS OF
MANUFACTURABILITY
 The above Pillars/Criteria will be synergized
with the following Systems for
Optimization :
 Best System for Procurement (BSP),
 Best System for Manufacturing (BSM) ,
 Best System for Assembly (BSA) ,
 Best System for Testing (BST),
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31. EIGHT SYSTEMS OF
MANUFACTURABILITY
 Best System for Packing/Shipping (BSPS) ,
 Best System for Supply/Delivery (BSSD) ,
 Best System for Service/Maintenance
( BSSM) &
 Best System for Repair (BSR) as per the
Taoist recommendations of the Concurrent
Engineering Team.
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32. T-SHAPED PROFESSIONALS NEEDED
 This is an honest attempt to bring DFM-
knowledge based Rules/Guidelines to Design
Engineers which will require less time to
implement, in the long run.
 It will also help new professionals who would
like to take up DFM as a profession by ,
T-Shaped Professionalism with strengths in
Design & Manufacturing Engineering as well
as QMS & Resources Management.
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33. SIMPLICITY THE MANTRA OF TDFM
 DFM itself is a vast subject. In the true spirit of
Lean, this TDFM calls for tools or practices by
applying Simplicity .
 Simplicity is the main mantra under TDFM .
 The main focus is on the TDFM methodology
by applying Holistic, Creative, Taoist Practices
and the simple Gap Analysis way of TDFM
Analysis for 8 x 8 = 64 Modules ( spokes) −
8 Criteria &. 8 Systems.
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34. TO BRING ALL OUT-OF-BOX INTO-THE-
BOX
 The Goal is to get reliable products of better
quality @ lower costs through rapid
development .
 Innovation is brought out by allowing ‘out-
of-box ‘ ideas/designs/solutions “into-the-
box ‘ by a team of cross functional experts of
the Concurrent Engineering Team.
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35. SUPERMAN
 We need a Superman as the next evolution of Man on earth .
 We have seen Electronics & CNC Occupying Mechanical
Equipments to have flexibility& accuracy & repeatability .
 In a similar manner we need synergizing of Medical Specialties
with Design Engineering and vice versa .
 Let Design Engineering synergize with Medical Sciences to bring
out more out-of-box ideas /solutions designs to launch an
innovation revolution !
 Let Mechanical Engineering gain lot of additional /new energy to
serve the society and Medical Sciences also gain more by
synergizing with engineering to serve the society more efficiently .
 .
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36. SUPERMAN
.
 By proper application of TDFM and with the Collaborative /
Co-creation Efforts we can integrate the best out of the human
systems in engineering systems through a new Design
Thinking in tune with the customers 'needs and aspirations
and by utilizing the best out of technology to overcome the
spiraling effects of the twin helixes .
 Let a superman be evolved with twin brains and twin hearts to
multiply the human potential and proactively rule the present
world by bringing reliable/innovative engineering products
with faster speed and lower costs with higher quality ..
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37. “NIAGEN-GOD VITAMIN “BY DR DAVID SINCLAIR
 We are hearing good news of breakthrough in
cell research which claims that they can can
help individuals to live longer by providing the
proper vitamins directly to the cells by initiating
better communications in between cells .
 http://livecellresearch.com/livelonger-v21.php
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38. PRODUCTS DEVELOPED BEFORE DFM INITIATIONS
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39. PRODUCTS DEVELOPED BEFORE DFM INITIATIONS
 Design for State Govt Approval
 Development & Manufacture of
 Trailers for Tractors /Tillers
 Tipper Bodies for Leyland Chassis
 While @ Arasan & Co/- Tirunelveli
– 1974-76
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40. PRODUCTS DEVELOPED BEFORE DFM INITIATIONS
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41. PRODUCTS DEVELOPED BEFORE DFM INITIATIONS
 Bogie Type Tipping Trailer to OE for
TAFE-Massey Fergusson
 Developed for TAFE while @ Arasan &
Co/- Tirunelveli - 1976
 Done Innovations in Tow-bar Design to
suit easy manufacturability at the vendor
end which even the OE accepted for the
sake of improved strength
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42. PRODUCTS DEVELOPED BEFORE DFM INITIATIONS
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43. PRODUCTS DEVELOPED BEFORE DFM INITIATIONS
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44. PRODUCTS DEVELOPED BEFORE DFM INITIATIONS
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45. PRODUCTS DEVELOPED BEFORE DFM INITIATIONS
 Design & Development of
 Smart Rotary Tablet Press for
 Pacific Tools Pvt Ltd – Chennai- 2005
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47. PRODUCTS DEVELOPED BEFORE DFM INITIATIONS
 The objectives of DFM were reached with
minimum variety of materials, tooling, taps &
drills and spanners for assemblies.
 Maximum test runs were done using a
variety of input chemistry of tablet powders
and a low cost automation for the feeding of
powders into cavities/dies.
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48. PRODUCTS DEVELOPED BEFORE DFM INITIATIONS
 Other Engineering Products for OE
-Developed :
 Rocker Levers /Rocker Shafts / Rocker
Brackets / Shifter Shafts / Lub Oil Pumps/
 Replacement Parts for Textile Machineries
through Reverse Engineering/ Replacement
Parts for Chemical Engineering through
Reverse Engineering .
 1977 to 1995
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49. MENTORED FOR DESIGN & DEVELOPMENT FOR AN
UNIVERSITY PROJECT @ ANNA UNIVERSITY
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50. MENTORED FOR DESIGN & DEVELOPMENT FOR AN
UNIVERSITY PROJECT @ ANNA UNIVERSITY
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51. MENTORED FOR DESIGN & DEVELOPMENT FOR AN
UNIVERSITY PROJECT @ ANNA UNIVERSITY
 Basics of DFM applied while mentoring
 The PG Student in Product Design @ AU.
 Because of the novelty in Design &
Execution
 National Institute of Design- had sanctioned
Rs 1.20 Lakhs for the Project -2013
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52. PRODUCTS UNDER DESIGN AFTER DFM INITIATIONS
 Developing an eco- friendly
 Energy Independent Vehicle –EIV
 Objective :
 Eco-friendliness -
 Zero Effects as per ‘Make-in-India ‘&
 Almost -Nil Operating Cost
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53. SOLICITS ENQUIRIES FOR CO-
CREATIONS
 Engineers InnoVentures
 Solicits enquiries
 To Innovate –by-co creations
 EIV is a registered Design Firm under
 Design Clinic Scheme –DCS -of
 National Institute of Design – NID .
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54. TDFM TRAINING AND
IMPLEMENTATIONS
 Engineers InnoVentures
 Offers to bring home a
 Viable Tao of DFM
 To your Organization.
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55. REDESIGN THROUGH TDFM
 EIV is open to
 Redesign
 Through Co-creations through
 Faster Time with better Quality @ Lower
Cost
 And by signing Confidentiality MOU with
Clients
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56. DFM HANDBOOK FOR DESIGN ENGINEERING
PROFESSIONALS
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57. DFM HANDBOOK FOR DESIGN ENGINEERING
PROFESSIONALS
 My book titled as
 “ Taoist Directions for
 Design & Development”
 Sponsored by NDRF – www.ndrf.res.in
 Released during Indian Technology
 Congress 2014 @ Bangalore on 21st
August
2014 by former PM of India Hon. Deva
Gowda .
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58. DFM HANDBOOK FOR DESIGN ENGINEERING
PROFESSIONALS
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59. THANK YOU
 Welcome to a Dance where
 Design & Manufacturability will Dance together
 Not merely with Arms to Arms - but
 Also with Cheek to Cheek.
 Music by Innovation Engineering .
 Lyrics by Concurrent Engineering .
 Please call 97899 65421
 Email: erramalingam.ks@gmail.com
 Web: http://dfmsolutionsbyredesign.blogspot.in/
 www.dfmhandbook.com
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