final dfma

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Design For Manufacturing and Assembly

DFMA is a proactive and concurrent design

process that allows for early consideration of

manufacturing aspects

The purpose is to generate an environment

where a cross-functional team works together

to optimize the design for cost effectivemanufacturing

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benefits

Tangible

Shortened Development Time

Reduced Development Costs

Enhances a smooth transition to production

Reduced parts count

Simplified assembly processes

Improved Quality

Reduced manufacturing costs

Intangible

Improved communication within entire designteam

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DFMA Principles

Minimize the number of parts

Standardize

Avoid difficult components

Use modular subassemblies

Use multifunctional parts

Minimize reorientation

Use self-locating features

Avoid special tooling/test equipment

Provide accessibility

Minimize operations & process steps

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Introduction

What is DFM?

DFM is product design considering manufacturingrequirements

DFM is the first step in which a team approach istaken to develop the product

DFM is an umbrella which covers a variety of toolsand techniques to accomplish a manufacturableproduct

Why DFM? Lower development cost

Shorter development time

Faster manufacturing start of build

Lower assembly and test costs

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Introduction

How do all the pieces fit together?

The objective of DFM is to identify product concepts

that are easy to manufacture

Focus on component design for ease of manufactureand assembly

Integrate manufacturing to ensure the best match of

needs and requirements.

DFM in industry is typically divided into 2 main

activities:

vA team which will be responsible for the product

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Introduction

(DFM) is the general engineering art of

designing products in such a way that they are

easy to manufacture. The basic idea exists in

almost all engineering disciplines, but of course

the details differ widely depending on the

manufacturing technology. This design practice

not only focuses on the design aspect of a part

but also on the producibility. In simple language it

means relative ease to manufacture a product,

part or assembly.

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DESIGN for manufacturability (DFM) is the process

of proactively designing products to:

a) optimize all the manufacturing functions:

fabrication, assembly test, procurement, shipping, service,

and repair;

b) assure the best cost, quality, reliability, regulatory

compliance, safety, time to market, and customer

satisfaction; and

c) ensure that lack of manufacturability doesnt

compromise functionality, styling, new product

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DFM Method

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DFM Method

Estimate the manufacturing costs.

Reduce the costs of components.

Reduce the costs of assembly.

Reduce the costs of supporting production.

Consider the impact of DFM decisions on otherfactors.

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Estimate the ManufacturingCosts

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Manufacturing Costs Defined

Sum of all the expenditures for the inputs of the

system (i.e. purchased components, energy, raw

materials, etc.) and for disposal of the wastes

produced by the system

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Elements of the Manufacturing Cost of a Product

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DFA Systems

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

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Introduction

The aim ofdesign for assembly(DFA) is to simplify the

product so that the cost of assembly is reduced.

DFA recognizes the need to analyze both the part design and

the whole product for any assembly problems early in the

design process. We may define DFA as "a process for

improving product design for easy and low-cost assembly,

focusing on functionality and on assimilability concurrently."

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TYPES AND CHARACTERISTICS OF ASSEMBLYMETHODS

Manual Assembly

In manual assembly, the operations are carried out

manually with or without the aid of simple, general

purpose tools like screwdrivers and pliers.

Individual components are transferred to the

workbench either manually or by employing

mechanical equipment such as parts feeds or transfer

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Automatic Assembly Using Robots / Robotic

Assembly:

Production volume is higher than that of a manual

assembly system but lower than that of an automatic

assembly system (Fixed automation). Common forms

of Robotic Assembly:

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Comparison of Assembly Methods Manual assemblyrequires the least capital investment followed by thetwo simplest forms of robotic assembly.

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Automatic Assembly Using Robots / Robotic

Assembly:

Production volume is higher than that of a manual

assembly system but lower than that of an automatic

assembly system (Fixed automation). Common forms

of Robotic Assembly:

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Design Guidelines for Manual Assembly

the following guidelines depend on the skill of the

worker:

eliminate the need for workers to make decisions or

adjustments.

ensure accessibility and visibility.

eliminate the need for assembly tools and gauges (i.e. prefer

self-locating parts).

minimise the number of different parts - use "standard" parts.

avoid or minimise part orientation during assembly (i.e. prefer

symmetrical parts).

prefer easily handled parts that do not confuse within one

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Design Guidelines for Automation

The main different here is that assembly is performed by machinesinstead of by humans.

reduce the number of different components by considering

does the part move relative to other parts?

must the part be isolated from other parts (electrical, vibration,etc.)?

must the part be separate to allow assembly (cover plates,etc.)?

use self-aligning and self-locating features

avoid screws/bolts

use standard components and materials.

avoid tangling or nesting parts.

avoid flexible and fragile parts.

avoid parts that require orientation.

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Design Guidelines for Robotic Assembly

design the part so that it is compatible with

the robot's end effector.

design the part so that it can be fed in theproper orientation.

Basic DFA Guidelines

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Minimise part count by incorporating multiple functions into

single parts

Modularize multiple parts into single subassemblies

Assemble in open space, not in confined spaces; never bury

important components

Make parts such that it is easy to identify how they should be

oriented for insertion

Prefer self-locating parts

Standardise to reduce part variety

Maximise part symmetry

Design in geometric or weight polar properties if

nonsymmetric


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Prevent nesting of parts; prefer stacked assemblies

Provide orienting features on nonsymmetries

Design the mating features for easy insertion

Provide alignment features

Insert new parts into an assembly from above

Eliminate re-orientation of both parts and assemblies

Eliminate fasteners

Place fasteners away from obstructions; design in fastener access

Deep channels should be sufficiently wide to provide access to

fastening tools; eliminate channels if possible

Provide flats for uniform fastening and fastening ease

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Click to edit Master subtitle style

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Mass Customization

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Introduction

Mass production ofgoods with differing

individual specifications through the use of

components that may be assembled in a

number of different configurations. Mass

customization is a cost-efficient way ofoffering

some of the benefits of customization.
http://www.investorwords.com/3003/mass_production.htmlhttp://www.investorwords.com/2209/goods.htmlhttp://www.investorwords.com/11153/specification.htmlhttp://www.investorwords.com/10438/number.htmlhttp://www.investorwords.com/3390/offering.htmlhttp://www.investorwords.com/461/benefit.htmlhttp://www.investorwords.com/461/benefit.htmlhttp://www.investorwords.com/3390/offering.htmlhttp://www.investorwords.com/10438/number.htmlhttp://www.investorwords.com/11153/specification.htmlhttp://www.investorwords.com/2209/goods.htmlhttp://www.investorwords.com/3003/mass_production.html

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Mass Customization

We define mass customization as providing

products and services which meet the needs

of each individual customer with regard to

certain product features with near mass

production efficiency.
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Mass Customization is an academic term,

attributed to Stan Davis in his book

Future Perfect

where he writes about mass customization,

the production and distribution of

customized goods and services on a mass

basis.

Mass Customization
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Types of Mass Customization (1)

The Four Faces of Mass Customization

1. Collaborative Customization:

Consumer and producer engage in a conversation

to determine customer requirements

Computers, clothing and footwear, furniture, some

services

2. Adaptive Customization:

Product is designed so that users can alter it

themselves to fit unique requirements on different

occasions
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Types of Mass Customization (2)

3. Cosmetic Customization:

Product is unique in appearance only

Customers chosen text or image on T-shirts,

mouse mats, baseball caps, mugs etc.

Also called Personalization

4. Transparent Customization:

Producer provides customized product without

consumer being necessarily being aware that it has

been customized

Can be used when consumers needs are
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31 October2005

CopyrightMadeForOne.com 2005

True Mass Customization

True Mass Customization requires:

System for customer to specifyrequirements easily e.g. online ordering,

call centerAdvanced manufacturing systems

Enable economies of scope (keep cost and pricelow)

Build-to-order approach

product is not made until order is received

Minimum order quantity of one
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Advantages of MC

Customer has control over product

Does not have to pay for features he/shedoes not want (computers etc.)

Company does not have finished productinventory better use of working capital

Easier for company to differentiate product

Levels out economic fluctuations

When slowdown occurs, less backlog of inventory

Prices do not have to be cut as much

Therefore, less likelihood of recession
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What Mass Customization Isnt

Massive Product Variety Customer has Choicebut not Control;

E.g. Personalize your cellphone with any of our 2000skins

Advanced ordering system linked to craftproduction;

Example: Well known snowboard maker customercan specify exact requirements online but boards arehand-made

Personalization or mass customization ofMarketing:

Use of knowledge about customer to personalizemarketing of standard products.

Data gathered from loyalty schemes, etc.

Customized products with minimum quantities
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Examples of Mass Customization

Dell

Build to order computers

Assembly, not manufacture (modular

components)

MC sometimes associated with higherprices but Dell cheaper than most

Why? Massive efficiency of supply chainmanagement

Living in Dell Time - Fast Company, Nov.2004

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Examples of Mass Customization

Clothing and Footwear

NikeID, MiAdidas, Otabo Shoes, Vans

Bivolino (shirts), U-Jeans, Lands End,

Target, Tommy HilfigerClothing and footwear very suited to MC

due to each person being unique in size andshape

Sports EquipmentNautilus (treadmills)

Industrial equipment, construction

Kingspan insulated roof and wall panels,
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Product-Process Matrix

VERY LOW VOLUMES VERY HIGH VOLUMES

LOW STANDARDIZATION LOW VOLUMES HIGH VOLUMES HIGH STANDARDIZATION

One-of-a-kind Products Many Products Few Products Commodity Products

JUMBLED FLOW

(Job Shop)

DISCONNECTED LINE FLOW

(Batch Flow)

CONNECTED LINE FLOW

(Machine or Worker paced)

CONTINUOUS FLOW

STRUCTURE

PROCESS

PRODUCT STRUCTURE
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3737


Movement along the Diagonal

VERY LOWVOLUMES VERY HIGHVOLUMES

LOWSTANDARDIZATION LOWVOLUMES HIGHVOLUMES HIGHSTANDARDIZATION

One-of-a-kind Products Many Products FewProducts Commodity Products

JUMBLED FLOW

(Job Shop)

DISCONNECTEDLINE FLOW

(Batch Flow)

CONNECTEDLINE FLOW


CONTINUOUS FLOW

PRODUCT STRUCTURE

STRUCTURE

PROCESS

Rarely does a company move directly from one cell on thediagonal to another. Usually, due to a internal decision or aexternal factor, a company follows one of two paths:

the red path (over & down) ORthe green path below (down & over).
http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953

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Movement along the Diagonal (continued)

VERY LOWVOLUMES VERY HIGHVOLUMES

LOWSTANDARDIZATION LOWVOLUMES HIGHVOLUMES HIGHSTANDARDIZATION

One-of-a-kind Products Many Products FewProducts Commodity Products

JUMBLED FLOW

(Job Shop)

DISCONNECTEDLINE FLOW

(Batch Flow)

CONNECTEDLINE FLOW


CONTINUOUS FLOW

PRODUCT STRUCTURE

STRUCTURE

PROCESS

Which path red or green can be described as Conservative, putspressure on Manufacturing, and results in Opportunity Costs?

Which path red or green can be described as risky, puts pressureon Marketing/Sales, and results in out-of-pocket costs?
http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953http://www.amazon.com/Future-Perfect-Anniversary-Stan-Davis/dp/0201327953

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Service Process Matrix

Low

DEGREE

OF

LABOR

INTENSITY

High

The Service Factory

Mass Service

The Service Shop

Professional Service

Low High

DEGREE OF CONTACT WITH, AND CUSTOMIZATION FOR, THE CONSUMER

final dfma

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