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Lecture 8 - Design For Manufacturing PDF
Lecture 8 - Design For Manufacturing PDF
INDU 440
INDU 440
Instructor: Dr. Ashok Kaushal 1
Concurrent Engineering in Aerospace
Agenda
INDU 440
Instructor: Dr. Ashok Kaushal 2
Design for Manufacturing
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Instructor: Dr. Ashok Kaushal 3
Design for Manufacturing
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Instructor: Dr. Ashok Kaushal 4
Definition
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Instructor: Dr. Ashok Kaushal 5
MECH 6941
Instructor: Dr. Ashok Kaushal 6
Product Development Process
INDU 440
Instructor: Dr. Ashok Kaushal 7
INDU 440
Instructor: Dr. Ashok Kaushal 8
Three Methods to Implement DFM
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Instructor: Dr. Ashok Kaushal 9
Design for Manufacturing Example:
GM 3.8-liter V6 Engine
INDU 440
Instructor: Dr. Ashok Kaushal 10
Original Air Intake
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Instructor: Dr. Ashok Kaushal 11
Design for Manufacturing
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Instructor: Dr. Ashok Kaushal 12
DFM Method
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Instructor: Dr. Ashok Kaushal 13
Manufacturing and Supply Chain System
(BORDERS)
Purchased
Components
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Instructor: Dr. Ashok Kaushal 14
Cost of Goods Breakdown
COST OF
GOODS
Factory Logistics
Costs Costs
Overhead
Components Assembly Freight Duties
(& Profit)
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Instructor: Dr. Ashok Kaushal 15
Component Costs
Standard Parts bought from Suppliers e.g. screws. motors, switches etc
INDU 440
Instructor: Dr. Ashok Kaushal 16
Design for Manufacturing
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Instructor: Dr. Ashok Kaushal 17
Component Costs
Standard Parts bought from Suppliers e.g. screws. motors, switches etc
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Instructor: Dr. Ashok Kaushal 18
Assembly Costs
Handling Time
+ Insertion Time
Assembly Time
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Instructor: Dr. Ashok Kaushal 19
Overhead Costs
Indirect Allocation – Cannot be directly linked to the product but still have
to be paid e.g. Cost of maintenance of building, security…
INDU 440
Instructor: Dr. Ashok Kaushal 20
Design for Manufacturing
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Instructor: Dr. Ashok Kaushal 21
Bill of Materials
e.g. Original Intake
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Instructor: Dr. Ashok Kaushal 22
Estimating the Costs of
Custom Components
Material Costs
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Instructor: Dr. Ashok Kaushal 23
Component
Manufacturing Costs
CNC Machining Cost
Examples
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Instructor: Dr. Ashok Kaushal 25
Component
Manufacturing Costs
Injection Molding
Examples
MECH 6941
Instructor: Dr. Ashok Kaushal 26
Component
Manufacturing Costs
Stamping
Examples
MECH 6941
Instructor: Dr. Ashok Kaushal 27
Component
Manufacturing Costs
Casting Cost Examples
Sand Casting
Investment
Casting
INDU 440
Instructor: Dr. Ashok Kaushal 28
Design for Assembly
–http://www.dfma.com
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Instructor: Dr. Ashok Kaushal 29
Design for Assembly Rules
Example set of DFA guidelines
(from a computer manufacturer)
INDU 440
Instructor: Dr. Ashok Kaushal 30
Method for Part Integration
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Instructor: Dr. Ashok Kaushal 31
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Instructor: Dr. Ashok Kaushal 32
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Instructor: Dr. Ashok Kaushal 33
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Instructor: Dr. Ashok Kaushal 34
Estimating the
Cost of Assembly
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Instructor: Dr. Ashok Kaushal 35
Typical Handling and Insertion
Times for Common
Components
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Instructor: Dr. Ashok Kaushal 36
Assembly Cost
e.g. PCV Valve
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Instructor: Dr. Ashok Kaushal 37
DFM Strategy is Contingent
Corporate
Strategy
Product
Strategy
Production
Strategy DFM
Strategy
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Instructor: Dr. Ashok Kaushal 38