A Short Intro On Design for manufacturing (DFM)

[marywiliams]

In manufacturing a product, the design is the first step and it is where most of the vital decisions are taken that affect the final cost of a product. The availability of amazing techniques such as analysis techniques has produced a revolution in the manufacturing industry, leading to better quality, reduced product cost, shorter time to market, few suppliers, lower inventory and lots of other improvements.



Design for Manufacturing is the process of designing parts, products or components for ease of manufacturing with an end goal of making a good product at a lower cost. And this is done by optimizing, simplifying and refining the design of the product.

There are five key principles are examined during a Design for Manufacturing (DFM).

1. Process
2. Design
3. Material
4. Environment
5. Compliance/Testing

Do you know that only 10% of the total product cost has been spent by the time a product has been designed? But, by that time, the product design has determined 80% of the cost of the product. This is because the design decides the manufacturability which finds a key part of the introduction and production cost of the product. Keep in mind that it is difficult for manufacturing companies to remove it once this cost is locked in. According to General Motors executives, “About 70% of the cost of manufacturing truck transmissions is determined in the design stage. Also, a study at Rolls-Royce found that design determines 80% of the final production costs of 2,000 parts.



Correctly-implemented DFM needs to include all the engineers, designers, contract manufacturer, and material supplier. This is because “cross-functional” Design for Manufacturing is to challenge the design to look at the design at all levels such as component, sub-system, system, and all levels to make sure the design does not have needless cost fixed in it and is well optimized. Including all the stakeholders together initial in the design process is easier particularly if you're developing a new product. However, challenging the original design is an essential element of a thorough DFM but even if you are dealing with an established product.

Errors in a design are repeated by replicating an existing or previous design. Therefore, you must:

• Look at the original pictures.
• Tear down the product.
• Explore your competitive products and lead users.
• Have some words with your contract manufacturer who may have solved the issue with a different client.
• Try to find out the other ways to make it better.

Remember a great DFM optimistically concludes by minimizing the complexity of the product design and satisfying the customer's needs for material, price, specification, and scheduling.