ME 474

Design for Manufacture and Modern Manufacturing

Strategies

Spring 2020
Instructor: Narasimha Boddeti
narasimha.boddeti@wsu.edu, Sloan 213
 Introduction
▪ What is manufacturing?
• Process(es) through which raw materials are transformed into a product
• Adds value to the input raw materials

Screw Gear Turbine Blade

Source: Wikipedia Source: Wikipedia Source: Wikipedia

All these products contain a single material - parts

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 Introduction
▪ What is manufacturing?
• Process(es) through which raw materials are transformed into a product
• Adds value to the input raw materials

Categories of Manufacturing Processes

Source: azom.com

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 Introduction
▪ What is manufacturing?
• Process(es) through which raw materials are transformed into a product
• Adds value to the input raw materials

Laptop Car Boeing Dreamliner Aircraft

Source: Wikipedia Source: Wikipedia Source: Wikipedia

These products contain multiple materials and multiple parts - assemblies

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 Introduction
▪ What is manufacturing?
• Process(es) through which raw materials are transformed into a product
• Adds value to the input raw materials

Welding Adhesive Bonding Mechanical Fasteners

Source: kau.edu.sa
Source: Wikipedia Source: open.edu

Examples of Joining Processes

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 History of Manufacturing
▪ Early products were hand-made by skilled craftsmen
▪ Hence the word manufacture = “manu factus” (Latin, made by hand)
▪ Industrial revolution in the 18th century introduced:
• Machines
• Concept of factory
▪ 1800’s process specialization
• Adam Smith – division of labor
• Eli Whitney – interchangeable parts
▪ Early 1900: Optimization (manufacturing systems)
• Economy of scale: cost reduction for high volume production
• Henry Ford’s Model T – assembly line
▪ 1950’s: Numerical control
• Automation
• Lean manufacturing, Just in time
• Six sigma
Ford Assembly Line
▪ Present day Source: Wikipedia

• Smart manufacturing

6 Source: 2.008 MIT, S. Kim

 History of Manufacturing

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 Modern Manufacturing

1. Chassis
2. Motherboard Assembled from several
3. CPU components/sub-assemblies
4. Graphics card
5. Display
6. Camera
7. Input devices
8. …

Laptop
Source: Wikipedia

A few trillion transistors in a modern CPU

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 Modern Manufacturing https://youtu.be/Tc0X92fZF1Y

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 Modern Manufacturing

About 30,000 parts in a modern car

(Source: Toyota.co.jp)

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 Modern Manufacturing https://youtu.be/RQHBR3rjGXM

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 Modern Manufacturing

About 2.3 million parts

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 Modern Manufacturing https://youtu.be/jiH3-rJ-iYc?t=10

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 Introduction
▪ Recall: Products provide a function and value to a consumer

Iron ore pellets

Source: Wikipedia

Steel block Gearbox

Source: amazon.com Source: Wikipedia

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Same input materials but different functions and value, i.e., different designs
 Introduction
▪ What is a design?
• Specifies different attributes of a product
▪ Aesthetics (e.g., size, shape, color)
▪ Function
▪ Performance
▪ …
▪ Cost
▪ What is the design process?
• “Engineering design is the systematic process of generating, evaluating and
specifying concepts that meet constraints and needs”

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 Product Realization Process

Design dictates cost

16 Poli, Design for Manufacturing: A Structured Approach

 Engineering Design
▪ Consists of four sequential but overlapping steps:
1. Conceptual design
▪ Identification of the physical principles by which the product functions
▪ And the principal parts, components or sub-assemblies
▪ Selection of materials and processes
2. Configuration design of parts/components
▪ Specification of standard part designs (e.g., cross-section of a beam, exact type of a
standard spring)
▪ Approximate dimensions
3. Parametric design
▪ Specification of exact dimensions, tolerances and materials (if not already assigned)
4. Detail design
▪ Final step where all the details needed for manufacturing are finalized

17 Poli, Design for Manufacturing: A Structured Approach

 Engineering Design

Design dictates cost

Figure 1.5, PDMA, Boothroyd et al

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 Engineering Design

Assembly is expensive

Design dictates cost

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Source: Sudhindra, MSRSAS
 Engineering Design
Design for function, performance and cost

Part or Component
Assembly Product
Manufacture

Design for Manufacturing

Design for Assembly (DFA) Design for X (DFX)
(DFM)

Do not consider downstream activities in the product development process

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 Design for X
▪ DFX:
• Developed by AT&T
• Process where the full lifecycle needs of the product are addressed during the
design stage
• Attempts to maximize all the desirable characteristics of a product, not just
function and aesthetics
• X could be:
▪ Cost
▪ Quality
▪ Serviceability
▪ Reliability
▪ Environment
▪ …
▪ Manufacturability
▪ Assembly

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 DFM & DFA
▪ DFM and DFA are complementary approaches
▪ When applied together, they are commonly referred to as DFMA
▪ DFMA could be the basis for concurrent engineering (as opposed to sequential engineering)
▪ DFMA enables early estimation of costs when it is easy to consider alternative designs

“Over-the-wall” approach Effects of DFMA and CE (HP)

Figure 1.6, PDMA, Boothroyd et al Figure 1.7, PDMA, Boothroyd et al

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 DFM & DFA
▪ DFM and DFA are complementary approaches
▪ When applied together, they are commonly referred to as DFMA
▪ DFMA could be the basis for concurrent engineering (as opposed to sequential engineering)
▪ DFMA enables early estimation of costs when it is easy to consider alternative designs

Design with DFMA

Figure 1.10, PDMA, Boothroyd et al

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 Overview of the Course
▪ Understand assembly considerations and assembly cost evaluations by
the design for assembly (DFA) method

▪ Understand basic manufacturing processes and the design for

manufacturing (DFM) implications of design choices for specific
manufacturing processes

▪ Learn modern manufacturing philosophies and practices

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 Course Outline
1. Introduction
2. Design for Assembly (DFA)
1. Manual
2. Automated
3. Design for Manufacturing (DFM)
1. Machining
2. Injection Molding
3. Metal Casting
4. Sheet Metal Working
4. Design for Advanced Manufacturing
Reference Textbook:
5. Topics in: Product Design for Manufacture and Assembly
1. Quality Control (3rd Edition) by
Boothroyd, Dewhurst and Knight
2. Lean Manufacturing Available online from the WSU library website
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 Course Details
▪ Lectures:
• Mon & Wed 9:10 – 10:00 AM, CARP 102
▪ Lab:
• Fri 9:10 – 10:00 AM, CARP 102
• Bring your own computer (Windows OS)
▪ Project (will announce details in two weeks)

▪ Grading:
• Homework – 20%
• Lab Assignments – 20%
• Mid-term Exam (open book) – 30%
• Group Project – 30%
Final Exam
▪ Office hours:
• Sloan 213, Friday 10:00 – 11:00 AM,
• Or, by appointment
• Email: Narasimha.Boddeti@wsu.edu

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