DFMA – Design for Manufacture

and Assembly

Shin Ta Liu
Ph.D. CSSBB, CQE, CRE
Principal Consultant
Lynx Systems
12529 Cloudesly Dr
San Diego, CA 92128
Web site: www.lynxsys.net
Email : shin@lynxsys.net
Phone: 858-366-4951

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 DFSS Process
DCDOV
Goals Tools
Obtain customers needs and wants Market/Customer Research, Kano
Define Translate customers needs and analysis, stakeholders analysis,
wants to VOC list operation cross walk

Concept Development Develop Design QFD. TRIZ, Axiomatic Design

Feature/functional requirements
based on VOC

Design Development Identify engineering and CTX, DFX, DOE, Taguchi

process parameters based on methods
the design features/functional
requirements

Optimize Design Identify optimal settings for the RSM, FMEA update, sensitivity
engineering and process analysis, Taguchi Methods
parameters based on the
performance, robustness,
production and other
requirements.

Verify Capability Establish the designed Verification/qualification tests,

product/process is capable of validation tests, simulation,
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meeting the design target and statistical analysis
requirements.
 DFMA process
Start

Design for Physical, Process structure,

Assembly transfer function specifications

Specify material,
Recommend improved
process and early
materials and process
cost estimate

Select the best

assembly process
structure

Design for Detailed Design for Minimum

Manufacture manufacturing costs

Prototype

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 DFMA Algorithm

• Determine criticality of a part

• a part is critical if
– - move relative to all other parts already
assembled, or
– - different material than all being assembled
– - separated from other parts assembled.
• Physical coupling of “un-critical” parts with a “critical
part”
• Reassess assembly time for new configured parts
• Analyze the manufacturability of new configured part

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DFMA Example

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 DFMA-Example 1 Analysis
• DFMA Worksheet for Datum Design
• Item • Number • Theoretical Part • Assembly Time(s) • Assembly Cost
Count (cents)
• Base • 1 • 1 • 3.5 • 2.9
• Bush • 2 • 0 • 12.3 • 10.2
• Motor Subassembly • 1 • 1 • 9.5 • 7.9
• Motor Screw • 2 • 0 • 21.0 • 17.5
• Sensor Subassembly • 1 • 1 • 8.5 • 7.1
• Setscrew • 1 • 0 • 10.6 • 8.8
• Standoff • 2 • 0 • 16.0 • 13.3
• End plate • 1 • 1 • 8.4 • 7.0
• End-plate screw • 2 • 0 • 16.6 • 13.8
• Plastic bush • 1 • 0 • 3.5 • 2.9
• Thread lead • - • - • 5.0 • 4.2
• Reorient • - • - • 4.5 • 3.8
• Cover • 1 • 0 • 9.4 • 7.9
• Cover Screw • 4 • 0 • 34.2 • 26.0
• TOTALS • 19 • 4 • 160.0 • 133.0

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 DFMA Example 1 Analysis

• Total actual assembly Time T1= 163 s

• Theoretical total part count is 4 and average
assembly time is 3 s. Theoretical assembly
time T2= 4 x 3 s = 12 s
• Calculate Design Efficiency :
• T2 12 s
    0.07362
T1 163s

•
• or 7.362%
•

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 DFMA Recommended
redesign

• Bushes are integral to the base

• Snap-on plastic cover replaces
standoff ,cover ,plastic bush, six screws.
• Using pilot point screw to fix the base,
which redesign to be self-alignment.

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DFMA- An Improved Design

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 DFMA Worksheet for an Improved Design

• Item • Number • Theoretical • Assembly • Assembly Cost

Part Count Time(s) (cents)
• Base • 1 • 1 • 3.5 • 2.9

• Motor Subassembly • 1 • 1 • 4.5 • 3.8

• Motor Screw • 2 • 0 • 12.0 • 10.0
• Sensor Subassembly • 1 • 1 • 8.5 • 7.1
• Setscrew • 1 • 0 • 8.5 • 7.1
• Thread leads • - • - • 5.0 • 4.2

• Plastic Cover • 1 • 0 • 4.0 • 3.3

• TOTALS • 7 • 4 • 46.0 • 38.4

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 DFMA Cost Differential Worksheet

• Old Design • New Design

• Item • Cost,$ • Item • Cost, $

• Base (Aluminum) • 12.91 • Base (nylon) • 13.43

• Bush(2) • 2.40

• Motor Screw(2) • 0.20 • Motor Screw(2) • 0.20

• Setscrew • 0.10 • Setscrew • 0.10

• Standoff(2) • 5.19

• Endplate • 5.89

• End-plate Screw • 0.20

• Plastic bush • 0.10

• Cover • 8.05 • Plastic Cover (include tooling) • 8.00

• Cover screw(4) • 0.40

• Totals • 35.44 • 21.73

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 DFMA –Calculate Total Saving

Total Saving =
Saving from Assembly Time Reduction
+ Saving from parts reduction
= $0.95 + $13.71
= $14.66

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 Improved Assembly Design Efficiency

• Total actual assembly Time T1= 46 s

• Theoretical total part count is 4 and average
assembly time is 3 s. Theoretical assembly
time T2= 4 x 3 s = 12 s
• Calculate Design Efficiency :
•
T2 12s
   0.26087
T1 46s
•
• or 26.087%
•

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 Design for Assemblability &
Manufacturability
-Summary

Design Guides:

• Minimize the number of setup and stages.

• Analyze the existing manufacturing and assembly function.
• Revisit the physical structure (of the design) which
customize to the local processing capability
• Apply the most appropriate (not latest) technology.
• Use Axiomatic design to create Modular design of the parts.
• Design for minimum number of parts using physical coupling
• Choose the appropriate material for easy manufacturing
• Apply the layer assembly principles.

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