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Design for Manufacturing: A Development Practice for Lowering Production Costs - Prof. Ali, Study notes of Engineering

University of Illinois - Urbana-ChampaignEngineering
Prof. Ali A. Yassine

Design for manufacturing (dfm), a development practice that emphasizes manufacturing issues throughout the product development process. It covers the importance of understanding manufacturing costs, three methods to implement dfm, and the dfm process. The document also introduces design for assembly (dfa) and boothroyd-dewhurst software.

Typology: Study notes

Pre 2010

Uploaded on 02/24/2010

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Design for Manufacturing
Ali A. Yassine
Department of Industrial & Enterprise Systems Engineering
University of Illinois at Urbana Champaign
[email protected]
Planning
Planning
Product Development Process
Concept
Development
Concept
Development System-Level
Design
System-Level
Design Detail
Design
Detail
Design Testing and
Refinement
Testing and
Refinement Production
Ramp-Up
Production
Ramp-Up
How can we emphasize manufacturing issues
throughout the development process?
Design for Manufacturing Example:
GM 3.8-liter V6 Engine Definition
•Design for manufacturing (DFM) is a development
practice emphasizing manufacturing issues
throughout the product development process.
•Successful DFM results in lower production cost
without sacrificing product quality.
Understanding Manufacturing Costs
Manufacturing Cost
Components Assembly Overhead
Standard Custom Labor Equipment
and Tooling Support Indirect
Allocation
Raw
Material Processing Tooling
Three Methods to Implement DFM
1. Organization: Cross-Functional Teams
2. Design Rules: Specialized by Firm
3. Cost-Based Method
pf3

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Design for Manufacturing

Ali A. Yassine

Department of Industrial & Enterprise Systems Engineering University of Illinois at Urbana Champaign [email protected]

Planning Planning

Product Development Process

Concept Development

Concept Development System-Level Design

System-Level Design Detail Design

Detail Design Testing and Refinement

Testing and Refinement Production Ramp-Up

Production Ramp-Up

How can we emphasize manufacturing issues throughout the development process?

Design for Manufacturing Example:

GM 3.8-liter V6 Engine Definition

  • Design for manufacturing (DFM) is a development

practice emphasizing manufacturing issues

throughout the product development process.

  • Successful DFM results in lower production cost

without sacrificing product quality.

Understanding Manufacturing Costs

Manufacturing Cost

Components Assembly Overhead

Standard Custom^ Labor^

Equipment and Tooling Support Indirect Allocation

Raw Material Processing (^) Tooling

Three Methods to Implement DFM

1. Organization: Cross-Functional Teams

2. Design Rules: Specialized by Firm

3. Cost-Based Method

Design for Assembly Rules

Example set of DFA guidelines

from a computer manufacturer.

  1. Minimize parts count.
  2. Encourage modular assembly.
  3. Stack assemblies.
  4. Eliminate adjustments.
  5. Eliminate cables.
  6. Use self-fastening parts.
  7. Use self-locating parts.
  8. Eliminate reorientation of parts.
  9. Facilitate parts handling.
  10. Specify standard parts.

Design for Manufacturing (DFM)

Process

  1. Estimate manufacturing cost
  2. Reduce the costs of components
  3. Reduce the costs of assembly

( Boothroyd and Dewhurst method)

  1. Reduce the costs of supporting

fabrication

  1. Repeat

Estimating Manufacturing Costs

Manufacturing Cost

Components (^) Assembly Overhead

Standard Custom Labor Equipment and Tooling Support Indirect Allocation

Raw Material Processing Tooling

Material Costs

Manufacturing Costs Assembly Costs