make informed design decisions avoid costly … informed design decisions avoid costly design...
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Make Informed Design Decisions
Avoid Costly Design Mistakes
Joe Barkai July 24, 2014
Waste in Design, Fabrication and Assembly
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0%
20%
40%
60%
80%
Preventable Other Issues
Assembly Issues
Costing Issue
Error Discovered During Simulation / PrototypingError: Geometry, Drawing, BOMManufacturability
Mistake Proofing
Production Line Problems
Supplier Capabilities
Source: Geometric Global
Too many product variants
New technologies, materials and
processes
Multiple domains / multidisciplinary
constraints
Too many disconnected design tools
Inability to capture and implement best practices
Aging workforce – the big brain drain
Manufacturing topics come little too late in the design
process, other considerations even later
Never enough time (or budget…)
It Isn't That Easy
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Direct costs
Design iterations
Manufacturing and assembly ramp up
Tooling and tool breakage
Scrap, energy and other waste
Poor quality!
Cost of poor quality
Service & warranty
Brand image
Money Down The Drain
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Why Is It So Difficult To Make Better Decisions?
5
Your processes are ad-hoc
Your systems are fragmented
Your data is messy
Your expertise networks are disconnected
You make critical decisions too late in the process
Joe Barkai
Formalize and apply design and manufacturing
process knowledge uniformly and consistently
Drive up reuse
Frontload decisions
Automate decisions
Leading Manufacturing Companies Get It
6
Source: Joe Barkai, 2013
6%
16%
19%
19%
39%
0% 5% 10% 15% 20% 25% 30% 35% 40%
Maximize Design Reuse
Use Knowledge Based Design Rules
Maximize Communication and Collaboration
Implement Best Practices
Frontload Decisions
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Design for Manufacturing In Practice
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3D Model
Manufacturability report
Geometric’s DFX solution
Manufacturability and Cost drivers
Optimized
design
Ready
For Manufacturing
Design
Sourcing
Supplier Capability
Global Best practices
Input Output Create
Modify
Competency
Knowledge Capture
Elements of cost
Manufacturing Service
Knowledge database
Design for Manufacturing Excellence
Capture and share knowledge throughout
the organization
Encapsulate best practices as design, process
and business rules
Validate downstream requirements early in the
design phase
Eliminate unnecessary features in designs
Drive design and process standardization
Early and systematically
Design for Manufacturing Excellence
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Accelerating Design Time
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We have integrated GeomCaliper into our design process and it has resulted in a
75% reduction in the time taken to check wall thickness of complex models.
Scott Lanski
Design Manager
Chrysler
As a result, we successfully reduced 75% of the checking time of the wall
thickness to enhance the efficiency and effectiveness of our design improvement
before the release of drawings.
Kaoru Mizoroki
Group Manager Design & Development Center
Toshiba
The net reduction in total time for checking of product design by using DFMPro
software is approximately 15%.
Amol Mane
Manager, Engineering Department
Sulzer India
Improving Manufacturability and Quality
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Our designers are able to detect & correct 80-85% of the issues that they
couldn't detect earlier in the CAD software. Due to this we are able to see a
significant improvement of quality levels in the design process.
Kamalakar Muralidhar
Asst. Manager – Design
L&T MPS
[The software] is allowing us to discover those hidden critical areas that
otherwise may have gone undetected.
Scott Lanski
Design Manager
Chrysler
[The software] helped us to reduce our part checking time by almost 60% while
ensuring robust quality of design.
Randy Scherger
Senior Tool Designer
Rockwell Automation
Tooling
Supply chain
Downstream Processes
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This analysis has helped us to identify critical issues during the design stage and
also has helped us to design feasible tools for the assembly process.
Hugo Cisneros
Global DFA Engineer
Jabil Circuits de Mexico
[The software] helped us to develop analysis … to perform and validate that
sheet metals or molded parts can be cleaned up in order to receive reliable parts
from vendors… We can identify, correct, fix or clean all features on a part that
has an issue and help, and educate customers for best practices in terms of
design.
Hugo Cisneros
Global DFA engineer
Jabil Circuits de Mexico
The results of tools aid us in improving our design reducing issues downstream.
Paul LaLinde
Principle Staff Engineer
Motorola Solutions
Capturing and Sharing Knowledge
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Earlier we were using a manual process for DFM reviews which involved
using checklists and knowledge from experienced engineers. The process
required lot of time from experienced engineers and still was error prone.
Also, the designer had difficulties in checking the design for issues related to
draft angle, wall thickness etc. due to limitations of the CAD software itself.
Kamalakar Muralidhar
Asst. Manager – Design
L&T MPS
This tool helps our design teams understand the process involved in
manufacturing. In other words, helps them understand how to design for
manufacturing. This leads to a significant reduction in design iterations due to
issues with manufacturability and reduction in design checking time.
SK. Pradeep Kumar
Director - E&T Capabilities
whirlpool
The Knowledge Based Enterprise
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Source: Duncan Greenman, Airbus UK
The Knowledge Based Enterprise
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Since 2005, Disher Design has employed GeomCaliper on every plastic part
design to ensure that we have optimized every possible area in our product
designs prior to tooling.
Mike Yandell
Design Manager
Disher Design & Development
What To Expect
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Rework reduction 5%-15%
Tooling savings 5%-12%
Productivity improvement 5%-10%
Collaboration efficacy 2%-7%
Scrap reduction 1%-2%
Warranty savings 1%-2%
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Where Do I Start?
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Optimized
•Simulation and
analysis tools
•Design for X
optimization
•Continually analyzed
and optimized
•Retire stale/incorrect
rules
Managed
•Enterprise-wide
knowledge base
•Cross-product tool
integration
•Automated
validation&
recommendations
Standardized
•DFX Program Office
established
•Integrated into PDP
•Design rules & best
practices applied
systematically
•Incl. manufacturing &
supplier capabilities
•Begin integration with
CAD tools
Formalized
•DFX metrics
established
•Design rules and
best practices
defined
•Little cross-product
sharing and
collaboration
Ad-Hoc
•No formal process
•Some rules of thumb;
used inconsistently
•Incorrect “best
practices” exist
Approach DFM systematically
Identify weaknesses to establish a baseline
Outline a continuous improvement plan
Establish an ROI framework
Build DFM into your product development process
Best Practices
Maintain cross-product centers of competence (COC)
Use advanced software tools for simulation, analysis and design validation
Maintain a “live” knowledge base of design rules and best practices
Automate decisions
Promote systems and data interoperability, including master data management and common taxonomies
Essential Guidance
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Learn More
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@JoeBarkai
www.JoeBarkai.com
www.dfmpro.geometricglobal.com
To request a free trial of Geometric DFMPro
The recorded webinar will be available next week
You will be notified via e-mail