LN10: Economic Design for

Manufacturing
EEE 452: Engineering Economics and
Management
Md. Naqib Imtiaz Hussain

Book: Strategic Management of Technological Innovation Chapter 10

 Story
• Future of design
• 3D printing impacting design of the future
technologies
• Video
 Lecture Outline
• How is design for manufacturing
• Infuse the following economic conditions into
design
– Save labor
– Save materials
– Have business objective in design
 Cost saving
• What process can influence the most on price
quality and cycle time?
 Design for Manufacturing
• Design for Manufacturing and Assembly (DFMA)
techniques to minimize product cost through
design and process improvements
• This is a process of proactively designing products
to (1) optimize all the manufacturing functions:
fabrication, assembly, test, procurement,
shipping, delivery, service, and repair, and (2)
assure the best cost, quality, reliability, regulatory
compliance, safety, time-to-market, and customer
satisfaction.
 DFA and DFM

• Design for Assembly (DFA)

– concerned only with reducing product assembly cost
– minimizes number of assembly operations
– individual parts tend to be more complex in design

• Design for Manufacturing (DFM)

– concerned with reducing overall part production cost
– minimizes complexity of manufacturing operations
– uses common datum features and primary axes
 The goal is to economize
• Both DFM and DFA seek to reduce material,
overhead, and labor cost.
• They both shorten the product development
cycle time.
• Both DFM and DFA seek to utilize standards to
reduce cost
 Economic Design Principles
• Minimize part count
• Design parts with self-locating features
• Design parts with self-fastening features
• Minimize reorientation of parts during assembly
• Design parts for retrieval, handling, & insertion
• Emphasize ‘Top-Down’ assemblies
• Standardize parts…minimum use of fasteners.
• Encourage modular design
• Design for a base part to locate other components
• Design for component symmetry for insertion
 A few DFM examples
• Provide self aligning and self locating parts
 A few DFM examples
• Make easy part to insert
 A few DFM examples
• Ensure visibility of handling and inserting
 A few DFM examples
• Design self attaching parts
 A few DFM examples
• Eliminate tangling and nesting
 A few DFM examples
• Reduce handling difficulty
 A few DFM examples
• Reduce handling time
• Handling Time: based on assembly process
and complexity of parts
– How many hands are required?
– Is any grasping assistance needed?
– What is the effect of part symmetry on assembly?
– Is the part easy to align/position?
 A few DFM examples
• Make it mistake proof
– Cannot assemble wrong part
– Cannot omit part
– Cannot assemble part wrong way around.
 A few DFM examples
• Eliminate components
 A few DFM examples
• Make parts symmetrical
 A few DFM examples
• Cost of fastening
 A few DFM examples
• Self fastening feature
 Cost vs Benefit of Manufacturing
Costs
Easy-to-price costs
Economic – land, planning, design
cost, construction cost
Not-so-easy to price costs
Environment – pollution (emission
cost), carbon cost, scenic values lost,
etc.
Economic – operation cost, insurance
cost, loss of property value, etc.
Benefits/value
Easy-to-price benefits
Economic – asset value, rental or sale
income, normal and enhanced capital
allowances
Not-so-easy-to-price benefits
Social – staff morale, comfort, etc.
Economic – productivity, hospital
recovery rates, savings in staff costs,
etc.
Environmental – savings in energy,
emissions, reduced flooding and
damage etc
Innovation to Manufacturing
DFM vs Saving
 Assignment 3
• Impact of 3D printing on economic design for
manufacturing
– 3~4 pages
– 10 independently verifiable citation
– Make solid introduction and conclusion