Lecture 8 - Design For Manufacturing PDF

PRODUCT DESIGN AND DEVELOPMENT
INDU 440
Design for Manufacturing
Instructor: Dr. Ashok Kaushal , P.Eng

Concordia University
Dept. of Mechanical & Industrial Eng.
INDU 440
Instructor: Dr. Ashok Kaushal 1
Concurrent Engineering in Aerospace
Agenda
1. Lecture - “Design for Manufacturing”
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 Design for Manufacturing is part of Design for X.

 Design for X is an acronym for that designate various design
philosophies practiced by the design team
• Design for reliability,
• Design for manufacturing,
• Design for maintenance,
• Design for robustness,
• Design for Environment,
• Etc.
 DFM is the most common of the above and it addresses the
manufacturing cost.
 Manufacturing cost has a major impact on a product profitability
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 General Principles of DFX

• Detail-design decisions can have substantial impact on
product quality and cost.
• Development teams face multiple, and often conflicting,
goals.
• It is important to have metrics with which to compare
alternative designs.
• Dramatic improvements often require substantial
creative efforts early in the process.
• A well defined method assists the decision-making
process.
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Definition
 Design for manufacturing (DFM) is a development practice

emphasizing manufacturing issues throughout the product
development process.
 Successful DFM results in lower production cost and robust

supply chainwithout sacrificing product quality.
 The DFM process is one concurrent engineering technique that

is used to bring down-stream-life-cycle concerns to the forefront
of the NPD process
NPD = New Product Introduction
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MECH 6941
Product Development Process
Concept System-Level Detail Testing and Production

Planning Development Design Design Refinement Ramp-Up
How can we emphasize manufacturing issues

throughout the development process?
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Three Methods to Implement DFM
 Organization: Cross-Functional Teams
 Design Rules: Specialized by Firm
 CAD Tools: Boothroyd-Dewhurst Software
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Design for Manufacturing Example:
GM 3.8-liter V6 Engine
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Original Air Intake
Redesigned Air Intake
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 DFM process comprise 5 steps:

1. Estimate the manufacturing costs
2. Reduce the costs of components
3. Reduce the costs of assembly
4. Reduce the costs of supporting production
5. Consider the impact of DFM decisions on other factors
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DFM Method
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Manufacturing and Supply Chain System
Equipment Information Tooling
(BORDERS)
Raw Materials DISTRIBUTION

SYSTEM
transport Finished
Labor MANUFACTURING SYSTEM
Goods
Purchased
Components
Energy Supplies Services Waste
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Cost of Goods Breakdown
COST OF
GOODS
Factory Logistics
Costs Costs
Overhead
Components Assembly Freight Duties
(& Profit)
Equipment Indirect (Supplier

Standard Custom Labor Support
& Tooling Allocation Profit)
Materials handling, The salary of the

quality assurance, security guard and
Raw Equipment purchasing, the cost of
Processing Labor
Material & Tooling
shipping, receiving, maintenance to the
facilities, building and
equipment/tooling grounds
maintenance
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Component Costs
 Standard Parts bought from Suppliers e.g. screws. motors, switches etc
 Custom Parts – Made according to manufacturers design from raw

materials
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 Transportation costs are not included in the previous 2 models

but can be easily added.
 Fixed cost and variable is another way of calculation cost of a
product
 Fixed cost are the cost that do not change due to the
quantity of product made, example: salaries, rent, etc.
 Variable cost are the cost that do change in function of the
quantity of products manufactured: raw material, bolts, nuts,
etc.
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Component Costs
 Standard Parts bought from Suppliers e.g. screws. motors, switches etc
 Custom Parts – Made according to manufacturers design from raw

materials
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Assembly Costs
 Process of assembly incurs labor costs, tooling and equipment costs
To Compute Assembly Time
Handling Time
+ Insertion Time
Assembly Time
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Overhead Costs
 Support Costs – Support system required to manufacture the product

e.g. Material Handling, Quality Assurance, Shipping, Receiving….
 Indirect Allocation – Cannot be directly linked to the product but still have
to be paid e.g. Cost of maintenance of building, security…
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 To estimate cost of standard material you can get it by asking

the price from suppliers or by comparing to a similar part
 To estimate the cost of a custom part
• Single part = cost of raw material, processing and tooling
• Multiple parts = cost of each subcomponent + cost of
assembly + overhead
• Raw material cost = (weight of part + scrap allowance) * cost
per weight
• Processing costs = costs for the operator(s) of the
processing machinery + the cost of using the equipment
itself ($/hr)
• Processing time depends on operation and machine used
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Bill of Materials
e.g. Original Intake
• Cost estimation using the Bill of Material (BOM)
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Estimating the Costs of
Custom Components
Material Costs
Cost of material per

kilogram
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Component
Manufacturing Costs
CNC Machining Cost
Examples
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Component
Manufacturing Costs
Injection Molding
Examples
MECH 6941
Component
Manufacturing Costs
Stamping
Examples
MECH 6941
Component
Manufacturing Costs
Casting Cost Examples
Sand Casting
Investment
Casting
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Design for Assembly
 Key ideas of DFA:

– Minimize parts count
– Maximize the ease of handling parts
– Maximize the ease of inserting parts
• Benefits of DFA
– Lower labor costs
– Other indirect benefits
• Popular software developed by Boothroyd and Dewhurst.
–http://www.dfma.com
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Design for Assembly Rules
Example set of DFA guidelines
(from a computer manufacturer)
 Minimize parts count.

 Encourage modular assembly.
 Stack assemblies.
 Eliminate adjustments.
 Eliminate cables.
 Use self-fastening parts.
 Use self-locating parts.
 Eliminate reorientation.
 Facilitate parts handling.
 Specify standard parts.
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Method for Part Integration
 Ask of each part in a candidate design:

1. Does the part need to move relative to the rest of the
device?
2. Does it need to be of a different material because of
fundamental physical properties?
3. Does it need to be separated from the rest of the device to
allow for assembly, access, or repair?
• If not, combine the part with another part in the device.
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Estimating the
Cost of Assembly
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Typical Handling and Insertion
Times for Common
Components
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Assembly Cost
e.g. PCV Valve
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DFM Strategy is Contingent
Corporate
Strategy
Product
Strategy
Production
Strategy DFM
Strategy
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PRODUCT DESIGN AND DEVELOPMENT

Design for Manufacturing

Instructor: Dr. Ashok Kaushal , P.Eng

1. Lecture - “Design for Manufacturing”

 Design for Manufacturing is part of Design for X.

 General Principles of DFX

 Design for manufacturing (DFM) is a development practice

 Successful DFM results in lower production cost and robust

 The DFM process is one concurrent engineering technique that

Concept System-Level Detail Testing and Production

How can we emphasize manufacturing issues

 Organization: Cross-Functional Teams

 Design Rules: Specialized by Firm

 CAD Tools: Boothroyd-Dewhurst Software

Redesigned Air Intake

 DFM process comprise 5 steps:

Equipment Information Tooling

Raw Materials DISTRIBUTION

Energy Supplies Services Waste

Equipment Indirect (Supplier

Materials handling, The salary of the

 Custom Parts – Made according to manufacturers design from raw

 Transportation costs are not included in the previous 2 models

 Custom Parts – Made according to manufacturers design from raw

 Process of assembly incurs labor costs, tooling and equipment costs

To Compute Assembly Time

 Support Costs – Support system required to manufacture the product

 To estimate cost of standard material you can get it by asking

• Cost estimation using the Bill of Material (BOM)

Cost of material per

 Key ideas of DFA:

• Popular software developed by Boothroyd and Dewhurst.

 Minimize parts count.

 Ask of each part in a candidate design:

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