DFMA

INTRODUCTION TO DESIGN FOR MANUFACTURE AND

ASSEMBLY (DFMA)

J.JAYARAMAN

CENTRE FOR AEROSPACE SYSTEMS DESIGN

ENGINEERING

INDIAN INSTITUTE OF TECHNOLOGY , BOMBAY

STRUCTURE OF THE PRESENTATION

WHY AND WHEN:

EARLY MANUFACTURING KNOWLEDGE IMPROVES PRODUCT SUCCESS

EXAMPLES OF BENEFITS

DFMA IN WORLD WAR II

WHAT:

WHAT IS INTEGRATED DESIGN AND MANUFACTURE

STRUCTURE OF THE PRESENTATION (CONTD.)

HOW:

HOW TO ACHIEVE INTEGRATED DESIGN AND MANUFACTURE

-BDI SOFTWARE

-FMECA

EXAMPLES:

- ACCELERATION SENSING UNIT

-WORKED EXAMPLE

-POWER SUPPLY OF LASER Tx HIGH VOLTAGE

CONCLUSION

BEST PRACTICES TO PRODUCT DEVELOPMENT

TECHNOLOGY DEVELOPMENT INTEGRATION DEMONSTRATION PRODUCTION

KNOWLEDGE POINT 1

TECHNOLOGIES

AND RESOURCES MATCH

REQUIREMENTS

PROGRAM LAUNCH

KNOWLEDGE POINT 2

DESIGN PERFORMS AS EXPECTED

PRODUCTION CAN MEET

COSTSCHEDULE

ANDQUALITY TARGETS

KNOWLEDGE POINT3

PRODUCT DEVELOPMENT

ATTAINMENT OD DESIGN AND

MANUFACTURING KNOWLEDGE WEAPON SYSTEM % OF DWGS. COMPLETED % OF CRITICAL MFG. PROGRAM

PRIOR TO MFG. PROCESSES IN CONTROL EXPERIENCE

AT PRODUCTION

BEST PRACTICEAT LEAST 90% DWGS.

COMPLETEDALL CRITICAL

PROCESSES IN STATISTICAL

CONTROL

MEET COST &SCHEDULE TARGETS

AIM-9X(AIR-AIR MISSILE) 95% UNKNOWN

4% UNIT COSTINCREASE1 MONTH

PRODUCTION DELAY

F-22 FIGHTER 26%44%

23% UNIT COSTINCREASE18 MONTH

PRODUCTION DELAY

ATTAINMENT OF DESIGN & MFG. KNOWLEDGE (contd.)

WEAPON SYSTEM % OF DWGS. COMPLETED % OF CRITICAL PROCESSES PROGRAM

PRIOR TO MFG. IN CONTROL AT PRODN. EXPERIENCE

F18 E/F FIGHTER58% * 78% NO UNIT COST

INCREASE3 MONTH

PRODUCTION DELAY

PATRIOT ADVANCED CAPABILITY

(PAC-3)MISSILE

21 % 35 %

159 % UNIT COST

INCREASE39 MONTH

PRODUCTION DELAY

ADVANCED THREAT

INFRAREDCOUNTER-

MEASURES/COMMON MISSILEWARNING SYSTEM

21%0 %

182 % UNITCOST

INCREASE34 MONTH

PRODUCTION DELAY

BENIFITS OF DFMA

THERE IS A MUCH BETTEER OPPORTUNITY TO MEET PREDICTED COST SCHEDULE AND QUALITY TARGETS WHEN THE MANUFACURING PROCESS DATA IS CAPTURED EARLY

BENEFITS OF DFMA (CONTD.)

F 18 E/F HAS 42% FEWER PARTS THAN C/D EVEN THOUGH IT IS 25% LARGER

REDUCED

-PRODUCTION COSTS

-DEFECTS

-REWORK

BY APPLYING DFMA BDI SOFTWARE & SOURCES OF VARIATION IN THE PROCESS

BENEFITS OF DFMA ( CONTD.)

TOMOHAWK CRUISE MISSILE

STRATEGIC TACTICAL

PARTS 11500 7500

FASTENERS 2500 800

CIRCUIT CARDS 45 22

CONNECTORS 160 45

ASSEMBLY/ TEST

HOURS 610 195

UNIT PRODUCTION

COST $1000,000 $500,000

ASSEMBLYTIME FOR BALL CAGE DEVICEREDUCED TO 15SEC

FROM 130 SEC.

8 SCREWS TO NOSCREWS

ASSEMBLY OPERATIONS FROM 83 TO

54

TOTAL ASSY.TIME 592SEC.TO 277 SEC.

DFMA METHODOF ELIMINATING

FASTENERS

RIBBON BASEPLATEDIABLO PRINTER

OLD DESIGN 77 PARTS

NEW DESIGN36 PARTS

COMPARISON OF ORIGINAL NEW DESIGNS OF RETICLE

ASSY.

ORIGINAL DESIGN REDESIGN IMPROVEMENT%

ASSY. TIME HRS 2.15 0.33 84.7

NO. OF DIFF. PARTS 24 8 66.7

TOTAL NO. OF PARTS 47 12 74.5

METAL FABN. TIME HRS. 12.63 3.65 71.1

WEIGHT LBS. 0.48 .26 45.8

PILOTS INSTRUMENT PANEL

LONG BOW APACHEAH-64D HELICOPTERBOEING COMPANY

ORIGINAL

OPTION 1

OPTION 2

PILOT’S INSTRUMENT PANEL

ORIGINAL PANEL NEW PANEL

( OPTION 1 )

PARTS COUNT 74 9

FABRICATION TIME HRS. 305 20

ASSY./INSTALLATION TIME HRS. 149/153 8/153

TOTAL TIME HRS. 697 181

WEIGHT KG. 3.0 2.74

COST $ 56000 15000

Advantages of DFMA Typical results of DFMA application Results of 88 published case studiesDecreases 51% parts count reduction 37% parts cost 50% time to market 64% in assembly time 57% in manufacturing assembly time 58% in assembly operations 69% in separate fasteners 68% in assembly defects 57% in service calls68% in improvement in quality and reliability

Benefits of DFMABenefits of DFMA

Shorter developmental schedules and reduced cycle times.

Better first article quality Development of robust product designs Easier transition of designs to production Better supplier product integration More effective risk management

McDonnel Douglas experience Reduce number of parts and fasteners used on aircraft It means fewer opportunities for defects For each fastener there is the chance that the hole will be

drilled in the wrong place or be the wrong size By reducing the number of fasteners – numbers of defects

reduced, therefore, produce a higher quality product Weight is critical. Fuel costs approximately $50,000 per

pound of aircraft weight over 6000 hrs of the life of the aircraft

There are 179000 on the FA-18 CD fasteners In previous models several parts were made of sheet metal

because machined parts were unable to reach minimum gage limits

With high speed machining – thinner gauge limits have become possible

ACCELERATION SENSING ASSEMBLY

OPTION-I OPTION-II

COMARISON TABLE ASA OPTIONS

1525NUMBER OF FABRICATED PARTS

8.3 Hours18.1 HoursMACHINING TIME

YESNOEMI GASKET PROVISION

254 x 117 x 78 mm254 x 117 x 86 mmSIZE

1.72 Kg1.92 KgMEASURED WEIGHT (W/O ELECTRONICS)

Rs 256.75Rs 559.17MACHINING COST

1.90 Kg

± 2.7 MINUTES

± 3.5 MINUTES

250 Hz

OPTION - I

548 HzNATURAL FREQUENCY

1.80 KgESTIMATED WEIGHT (W/O ELECTRONICS)

± 1.5 MINUTESMEASURED ACCURACY

± 1.5 MINUTESESTIMATED ACCURACY

OPTION - IIPARAMETER

DFMA IN WW II

WORLD WAR II EXPERIENCE:

US AVIATION INDUSTRY GREWW TEN FOLD

P-51 MUSTANG FIGHTER

- TO FACILITATE EASE OF MANUFACTURE

STABILISERS FINS WINGTIPS SQUARED OFF

- FUSELAGE – THREE SECTIONS- COMPLETE

PLUMBINGS, CABLE DISCONNECTS TO

FACILITATE ASSEMBLY AND DISASSEMBLY

FOR PACKING AND SHIPPING

DFMA IN WW II (CONTD.)DFMA INFLUENCE ON DESIGN OF GRUMMAN F-6F HELLCAT

- USED FEWER COMPOUND CURVES IN

EXTERNAL DESIGN-UGLY- SEVERELY

CLIPPED WINGS

- PRODUCED IN LARGE QUANTITIES

- 32 KPH SLOWER THAN F4U HERITAGE 1980

DFMA INFLUENCE PERMITTED SHIPMENT BY BOAT OR LAND. OUT WING PANELS AND EVEN TAIL ASSEMBLIES REMOVED AND REPLACED AT THE DESTINATION POINT.

SPITFIRE VS. MESSERCHMIDST

IN 1940 Me’s OUTNUMBERED SPITFIRES THREE TO ONE. DESIGN ATTRIBUTABLE TO DFMA PHILOSOPHY. Me’s 4000 LABOUR HOURS TO SPITFIRE 13000 HOURS

AIR WAR HISTORIANS DESIGNATE SPITFIRES AS THE BETTER AIRCRAFT, THE LONG AND SUCCESSFUL CAREER OF ME 109’s DURING ARAB ISRAELI WAR 1948 DEMONSTRATED THAT MAJOR ATTENTION TO DFMA PRODUCES EFFECTIVE AIRCRAFT DESIGN EVEN AS EARLY AS 40’s

SPITFIRE VS. MESSERCHMIDST.

SPITFIRE:

DESIGNED FOR AERODYANAMIC PERFORMANCE AND STRUCTURAL EFFICIENCY

BEAUTIFUL ELLIPTICAL WINGS CHOSEN FOR AERODYNAMIC PERFORMANCE WAS A NIGHTMARE TO MASS PRODUCE

DIFFICULT TO LEARN TO FLY, HIGHLY MANOEUVERABLE

WAS PRODUCED IN LARGE NUMBERS BECAME A MAJOR FORCE IN BATTLE OF BRITAIN AIR CAMPAIGN 1940-41

SPITFIRE VS. MESSERCHMIDST

MESSERCHMIDST

DESIGN WAS A DFMA CLASSIC

A MINIMUM OF COMPOUND CURVES USED IN THE EXTERIOR

RUDDER AND HORIZONTAL STABILISERS WERE SQUARED OFF FOR PRODUCTION EFFICIENCY

COCKPIT CANOPY WAS MADE ALMOST ENTIRELY OF FLAT GLASS

20 MM CANNON FIRED THROUGH A HOLLOW PROPELLER SHAFT TO OVERCOME COMPLEXITIESOF WING INSTALLATION AND TO ELIMINATE SIGHTING PARALLAX

INTEGRATED DESIGN AND MANUFACTURE

SIMULTANEOUSLY ADDRESS DESIGN FOR PERFORMANCE AND DESIGN FOR PRODUCTION

SYSTEMS ENGINEERING HAS ALIGNED DESIGN ENGINEERS IN REQUIREMENTS ANALYSIS, THE DEVELOPMENT OF FUNCTIONAL FLOWS etc.

INCLUDING THE ASPECTS OF MANUFACTURING PROCESS DEVELOPMENT IN THE SYSTEM ENGINEERING PROCESS HAS BEEN MORE DIFFICULT TO ACHIEVE

DESIGN HAS DIFFERENT MEANINGS

TO SOME IT IS AESTHETIC DESIGN

TO SOME IT MEANS ESTABLISHING THE BASIC PARAMETERS OF A SYSTEM

TO SOME IT IS DETIALING OF THE MATERIALS, SHAPES,AND TOLERANCE OF THE INDIVIDUAL PARTS OF THE PRODUCT

DFMA ADDRESSES THE LAST ASPECT OF PRODUCT DESIGNS

DFMA

THREE MAIN APPROACHES TO DESIGN FOR ASSEMBLY HAVE BEEN DEVELOPED AND USED Viz.:

DESIGN HEURISTICS

DESIGN RATINGS

DESIGN REVISION

DESIGN HEURISTICS

GENERAL SET OF RULES eg.:

MINIMIZE THE NUMBER OF PARTS & ASSEMBLY DIRECTIONS

AVOID PARTS THAT SHINGLE TANGLE etc.

HEURISTICS CAN BE APPLIED TO A DESIGNER’S THINKING PRIOR TO ACTUAL PRODUCT DEVELOPMENT OR ONCE AN ASSEMBLY IS COMPLETE

USED TO SIMPLIFY PRODUCT

DESIGN RATING

PROVIDE RATINGS FOR COMPONENTS AS WELL AS OVERALL DESIGN

ASSEMBLY RATINGS CAN BE CALCULATED

BDI HAS THEORETICAL HANDLING AND MATING RATINGS

OTHER DFA RATING METHODS PROVIDE DIFFERENT SCHEMES

DESIGN REVISION METHOD

COMBINATION OF HEURISTICS AND RATING METHOD eg. BDI

BDI COMBINES A COMPONENT RATING SCHEME WITH AN ASSEMBLY TIME AND COST ESTIMATION METRIC AS WELL AS SPECIFIC RULES IN AN ORDERED SEQUENCE FOR DECIDING HOW TO REVISE A DESIGN. THIS HAS ENABLED PRODUCT DESINERS IN MINIMISING ASSEMBLY SIMPLICITY

DFMA METHODOLOGY

WALKING THROUGH A CONCEPTUAL OR EXISTING DESIGN IN A VERY SPECIFIC PROCEDURE THROUGH OUT

THE PROCEDURE FOLLOWED AND THE DATA BASE SYSTEM ALLOWS A DESIGN ENGINEER OR CROSSFUNCTIONAL TEAM TO ANALYSE AND RATE PRODUCT DESIGNS FOR EASE OF ASSEMBLY, DESIGN EFFICIENCY AS WELL AS PREDICT PRODUCT ASSEMBLY AND MANUFACTURING COST

DFMA METHODOLOGY(CONTD.)

CAD RESULTED IN POWERFUL QUANTITATIVE OR ANALYTICAL TOOLS, PROVIDED BASIS FOR JUDGING A DESIGNER’S PERFORMANCE. DFMA HAS GIVEN MANUFACTURING ENGINEERS SUCH A TOOL.

DFMA IS ATTEMPTING TO FORESEE AT THE PRODUCT CONCEPTUAL DESIGN STAGE , WHAT MANUFACTURING ASSEMBLY AND QUALITY PROBLEMS WILL BE TO ARRIVE AT A BETTER PRODUCT

DFMA tools

Are tools for DFM & DFA

DFM TOOLS DFM ACTIVITY

OPTIMIZE

CONCEPT

SIMPLIFY ENSURE PROCESS

CONFORMANCE

OPTIMIZE PRODUCT FUNCTIONDFM TOOLS

DESIGN AXIOMS

DFM GUIDELINES

DESIGN FOR ASSY. METHOD

TAGUCHI METHOD

MFG. PROCESS DESIGN RULES

DESIGNERS TOOLKIT

COMPUTER AIDED DFM

GROUP TECHNOLOGY

FMEA

VALUE ANALYSIS

DFM METHODOLOGY COMPARISON (CONTD)

KEY TO ADVANTAGES A. NARROW RANGE OF POSSIBILITIESB. RESULTS IN INHERENT ROBUSTNESSC. READY REFERENCE TO BEST PRACTICESD. EMPHASISES EFFECTS OF VARIATIONSE. HELPS IDENTIFY AND PRIORITIZE CORRECTIVE ACTIONF. PROVIDES BOTH GUIDANCE AND EVALUATION G. CAN SHORTEN DESIGN /TOOLING CYCLEH. CAN REDUCE TOOLING AND FIXTURING COST

KEY TO DISADVANTAGES A. INTERPRETATION NOT ALWAYS SIMPLE B.. REQUIRES “BUY IN” ON PART OF USER C. EXCEPTIONS ARE NOT INDICATED D. RATES ONLY EASE OF ASSY.DOES NOT ADDRESS PART HANDLING OR OTHER RELATED MFG. PARAMETERS E. DEVELOPMENT REQUIRES INPUT FROM EXPERIENCED EXPERTS FAMILIAR WITH SPECIFIC PROCESS CAPABILITIES AND NEEDS F. TO BE USED ON A REGULAR BASIS IMPLEMENTATION MUST BE USER FRIENDLY G. MUST BE DEVELOPED AND/OR CUSTOMISED FOR EACH SPECIFIC APPLICATION H. OFTEN REQUIRES DIFFICULT TO OBTAIN INFORMATIONKEY TO APPLICATIONS

A. MECHANICAL AND ELECTROMECHANICAL DEVICES AND ASSEMBLIESB. ELECTRONIC DEVICES AND SYSTEM C. MANUFACTURING AND OTHER PROCESSESD. SOFTWARE INSTRUMENTATION AND CONTROL SYSTEM INTEGRATIONE. MATERIAL TRANSFORMATION PROCESSESF. SPECIFIED AND OR UNIQUE MANUFACTURING FACILITIES SUCH AS FLEXIBLE ASSEMBLY SYSTEMS

DFMA application areas

DFMA has been applied successfully to Structural design System design

Landing gear system Flight controls Electrical, electronic hydraulic systems Environment controls

COST AND EASE OF MODIFICATIONS

BENIFITS OF IMPROVED ASSY.

MANUAL DESIGN ASSEMBLY EFFICIENCY (%)( DFA INDEX )

IMPROVED ASSEMBLY DESIGN EFFICIENCY RESULTS IN INCREASED RELIABILITY

When to apply DFMA

WHEN CONCEPTUAL LAYOUTS ARE BEING MADE. THEN DESIGNER ENVISIONS AN ASSEMBLY EASY TO INSTALL THAT

REQUIRES MINIMUM NUMBER OF PARTS TO PERFORM THE REQUIREMENTS PREVIOUSLY ESTABLISHED

WHEN ASSEMBLY LAYOUTS ARE BEING MADE. DESIGNER IMPLEMENTS OPTIMISATION TO EASE OF MANUFACTURING , RELIABILITY AND MAINTAINABILITY

Who are using DFMA

Over 400 companies and institutions Aerospace companies

Allied signal Hughes Aircraft McDonnell Douglas Corpn.Have implemented DFMA philosophy throughouttheir product line Automotive industries Medical electronic equipment PC – industry and others

DFMA Team

Multidisciplinary teams Design engineers Manufacturing engineers Shop floor mechanics Suppliers reps Specialist in product support Maintainability Reliability

DFMA

BDI software Is used by manufacturing team members to

estimate and predict the savings that can be obtained.

Data are entered system does its analysis in different areas.

A complete listing of all the activities required to perform the assembly including

It provides complete overview of the tasks to be performed

DFMA TECHNIQUE

DESIGN CONCEPT

DESIGN FOR ASSEMBLY ( DFA )

SUGGESTIONS FOR SIMPLIFICATION FORPRODUCT STRUCTURE

SELECCCTION OF MATERIALS AND

PROCESSES AND EAZRLYCOST ESTIMATES

SUGGESTIONS FOR MORE ECONOMIC

MATERIALS ANDPROCESSES

BEST DESIGN CONCEPT

DESIGN FOR MANUFACTURE( DFM )

DETAIL DESIGN FOR MINIMUM MANUFACTURING

COST

PROTOTYPE PRODUCTION

BDI software It does an assembly analysis profile on a standard format where it theorizes the

number of tasks to be performed, fasteners required, connectors to be installed, candidates for elimination, acquisition of items not in reach or in stock, requisition of tools not in hand, standard operations, library of operations and recommendations.

All these activities are numbered and plotted. It automatically provides suggestions for improvement.

System provides suggestions for design and indicating every task with its time saving and its percentage reduction. It indicates specific instructions to perform the related tasks in order to obtain the suggested savings.

It also lists design for assembly analysis totals all parameters used for analysis such as total assembly time, totally assembly cost, total assembly weight, number of parts, sub assemblies theoretical minimum numbers of parts or unanalysed sub assemblies and the hourly labour rate.

All suggestions and comments included in the computer generated tables are automatically provided to aid the designers and manufacturing engineers to obtain a better view of the job

Questions asked in DFMA about each part in a product design

Does the part move with respect to other parts already assembled

Must the part be made from a different material or isolated from all other parts already assembled

These questions lead the reviewers to re-evaluate each part and process that has been specified

If a part does not meet any of these criteria – it is a candidate for elimination or consolidation with another part

Results of Design for Assembly (DFA) Analysis for the Motor Drive

Assembly Redesign

TYPICAL FUNCTIONAL FLOW

1.3.2.1.1CHARGE STORAGE

CAPACITOR

1.3.2.1.2RECEIVE PULSEINITIAE SIGNAL

1.3.2.1.3DISCHARGE CAPACITOR THROUGH LASER DIODE 1

1.3.2.1.4CREATE LASER PULSE ENERGY.

1.3.2.1.5CREATE LASER

PULSE SHAPE

1.3.2.1.6TRANSMIT PULSE THROUGH LENS

TYPICAL PROCESS FLOW

PRODUCE ACTIVE TRANSMITTER

P 1.1

P 1.2 PRODUCE ACTIVE

RECIEVER

P 1.3 PRODUCE PASSIVE

RECEIVER

P 1.4 PRODUCE FLEX.

ASSEMBLIES

P 1.5 PRODUCE PWB

ASSEMBLIES

ANDAND

P 1.6ASSEMBLE INTO UPPER HOUSING

ASSEMBLY

P 1.7PRODUCE LOWER

HOUSING ASSEMBLY

SEE NEXT SLIDE

TYPICAL PROCESS FLOW (CONTD)

P 1.3.1CODER

ATTACH

P 1.3.2CLEAN BOND

PADS

P 1.3.3WIRE BOND

CODER

P 1.3.4PICK AND PLACE

PbSe INTERCONNECT

STANDOFF

P 1.3.2CLEAN BOND PADS

P 1.3.5WIRE BOND

PbSe

P 1.3.6INSPECT

ACTIVITIES TO ACHIEVE

MFG. KNOWLEDGE IDENTIFY KEY SYSTEM CHARECTERISTICS AND CRITICAL

MANUFACTURING PROCESSES

DETERMINE PROCESS IS IN CONTROL AND CAPABLE

CONDUCT FMEA

SET RELIABILITY GROWTH PLAN AND GOALS

CONDUCT RELIABILITY GROWTH TESTING

CONDUCT REVIEW TO BEGIN PRODUCTION

Contd..

BEST APPROACH TO PRODUCT DEVELOPMENT

TECHNOLOGY DEVELOPMENT

SYSTEM

INTEGRATION & DEMONSTRATION PRODUCTION

KP1 KP2 KP3

TECHNOLOGY MATURITY

DESIGN MATURITY

PRODUCTION MATURITY

CONCLUSION

THE NEED FOR DFMA DURING EARLY STAGES OF PRODUCT DEVELOPMENT IS SEEN

TWO METHODS Viz. BDI AND FMECA APPROACHES APPEAR TO BE YIELDING EXCELLENT RESULTS.

A COMBINATION OF THE TWO IS LIKELY TO SERVE OUR PURPOSE BOTH IN MECHANICAL AND ELECTRONIC PRODUCTS

ACTIVITIES TO ACHIEVE STABLE DESIGN KNOWLEDGE

LIMIT DESIGN CHALLENGE

DEMONSTRATE DESIGN MEETS REQUIREMENTS

COMPLETE CRITICAL DESIGN REVIEWS

STAKE HOLDERS AGREE DRAWINGS COMPLETE AND PRODUCIBLE

REVIEW TO BEGIN INITIAL MANUFACTURING

PROCESS CAPABILITY INDEX & PROBABILITY OF A DEFECTIVE

PART

MFG. PROCESS CAPABILITY (Cpk) ASSOCIATED DEFECT RATE

Cpk .67 ( NOT CAPABLE) 1 IN 22 PARTS PRODUCED

Cpk 1.0 ( MARGINALLY CAPABLE )1 IN 370 PARTS PRODUCED

Cpk 1.33 ( INDUSTRY STD.) 1 IN 15152 PARTS PRODUCED

Cpk 2.0 ( INDUSTRY GROWTH GOAL) 1 IN 500,000,000 PARTS PRODUCED

ACTIVITIES TO ACHIEVE MFG. KNOWLEDGE

IDENTIFY KEY SYSTEM CHARECTERISTICS AND CRITICAL MFG. PROCESSES

DETERMINE PROCESSES IN CONTROL AND CAPABLE

CONDUCT FAILURE MODE AND EFFECTS ANALYSIS

SET RELIABILTY GROWTH PLAN AND GOALS

CONDUCT RELIABILITY GROWTH TESTING

REVIEW TO BEGIN PRODUCTION

EXAMPLES OF PROTOTYPES USED

PRODUCT PRODUCT PRODUCTION

INTEGRATION DEMONSTRATION

PROTOTYPE ENGG. PROTOS.VIRTUAL OR

PHYSICAL

PRODUCTION REPRESENTATIVE

PROTOTYPESINITIAL PRODUCTS

PURPOSE DEMONSTRATEFORM FIT

FUNCTION AND A STABLE DESIGN

DEMONSTRATE PRODUCT IS

CAPABLE RELIABLEAND MFG. PROCESSES

IN CONTROL

DEMONSTRATE READY FOR FULL

SCALE PRODUCTION

BUILD ENVIRONMENT

ENGINEERINGMFG. FIRST SET OF

PRODUCTION TOOLINGPRODUCTION ALL

RATE TOOLING

Advantages of DFMA

Ford $ 1.2 billion in ’87 using DFA alone GM 30-60% on certain projects in ’89 MD-11 cargo liner savings per aircraft $ 86,000, a

bulkhead – cost saving $4,000 McDonnel Douglas has ranged 36-96% parts

count reduction on several of its aircraft component assemblies

FA-18 CD bay shelf design savings 84% in number of parts 73% in cost 11% in weight 89% in assembly time

WHAT IS DFMA (CONTD.)

DFMA ENCOURAGES CONCURRENT ENGINEERING DURING PRODUCT DESIGN SO THAT PRODUCT QUALITIES RESIDE WITH BOTH THE DESINERS AND OTHER MEMBERS OF THE PRODUCTION TEAM

IT IS A COMMUNICATION TOOL FOR THE TEAM

IT IS A BENCH MARKING TOOL

IT DEFINES THE DESIGN AND MANUFACTURING CAPABILITIES OF SELF AND COMPETITOR

WHAT IS DFMA (CONTD.)

IT PROVIDES A NON-THREATENING WAY TO GET PEOPLE TALKING ABOUT A DESIGN WITHOUT FEELING LIKE OTHERS ARE ENCROACHING ON THEIR TERRITORY

EINSTEIN SAID “ THE BEST DESIGN IS THE SIMPLEST ONE THAT WORKS “. DFMA PROVIDES THE CHEAPEST WAY TO THAT GOAL

WHAT IS DFMA

DFMA IS AN EXACTING DESIGN REVIEW METHOD

IT IDENTIFIES:

-OPTIMAL PART DESIGN

-MATERIAL CHOICE

-ASSEMBLY AND FABRICATION OPERATIONS TO PRODUCE AN EFFICIENT AND COST EFFECTIVE PRODUCT

IT REVEALS THAT INITIAL IDEAS MAY NOT BE THE MOST EFFECTIVE (CONTD.)