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CONTENT
Introduction
Definition to design for manufacturing
Estimation of manufacturing costs
Reduction of cost in components, assembly
and supporting production
The impact of DFM on other factors
Casting Process
Powder Processing
Gypsum Factory
Joining Processing
Brazing
Adhesive
Assembly Process
Job Shop
Batch Flow
Assembly Line
Continuous Flow
CONTENT
Introduction
Definition to design for manufacturing
Estimation of manufacturing costs
Reduction of cost in components, assembly
and supporting production
The impact of DFM on other factors
DEFINITION
Design for manufacturing (DFM) is the material
and tooling cost issues throughout the product
development process.
Successful DFM results in lower production cost
without sacrificing product quality.
DFM Guidelines
1. Minimise total number of parts
Eliminate parts means great savings. Parts eliminated
cost nothing to make, assemble, store or service
The best way to eliminate parts is to make minimum part
count a requirement of the design
Combining two or more parts into one is another
approach
DFM Guidelines
2. Standardize Components
- Cost are minimized and quality is enhanced when
standard commercially available components are used in
the design
- Standardized parts will gives cost reduction through
quantity discounts, elimination of design effort, avoidance
of equipment and tooling costs and better inventory
control
DFM Guidelines
3. Use common parts across product lines
- Specify same material, parts and sub assemblies in each product
as much as possible. It provides economic of scales and easy
operator training and control.
- PDM (product data management) systems can be use to facilitate
similar design
DFM Guidelines
5. Aim to keep designs functional and simple
- The simplest design will usually the most reliable and
easiest to maintain.
- Do not specify more performance than is needed e.g
using heat treated alloy steel when a plain carbon steel
will achieve the required performance
DFM Guidelines
6. Designs Parts to be multi functional
- A good way to minimize part count is to design such parts
can fulfill more than one function leading to integral
architecture.
DFM Guidelines
7. Designs Parts for easy fabrication
- Choose least costly material that satisfies functional
requirement.
- In general material with higher strength have poor
workability or fabricability.
DFM Guidelines
8. Avoid excessively tight tolerances
- Tolerances must be set with great care. Specifying tighter
tolerances will increase cost.
- Designer must maintain credibility with manufacturing with
regard to tolerances.
DFM Guidelines
10. Utilize the Special characteristics of processes
- Be alert to special design that many processes provide.
- E.g Metal polymers can be provided with built in colour as
opposed to metal that need to be painted or plated.
3. Use subassemblies :
-Provides economies in assembly since there are fewer interfaces
in final assembly
-Product made from subassemblies are easier to repair by
replacing the defective subassembly
a) Design Mistakes
Mistakes attribute to the design process :
Ambiguous information on engineering drawing or
specifications Failure to properly use dimension and
tolerances.
Incorrect information. Mistakes in conversion units or wrong
calculations
Poorly developed design concept that does not fully provide
the need functionality. Hastily made design decision that
results poor performing product with low reliability or with
dangers to the safety of human or hazard for environment
c) Manufacturing Mistakes
Common mistakes in manufacturing parts :
Omitted operations : failure to perform a required step in the
process plan.
Omitted part : Forgetting to install a screw, gasket or washer
Wrong orientation of parts: A part inserted in propoer location
but wrong orientation
Misaligned part : Alignment not accurate to give proper fit
Wrong location of part : Part is oriented properly but wrong
location.
Selection of wrong parts : parts may look alike but different
sizes
c) Manufacturing Mistakes
Common mistakes in manufacturing parts :
Misadjustments : An operation is incorrectly adjusted
Commit prohibited action : safety violation failure to lock out
a power panel before hooking up a motor
Added material or parts : Failure to remove material. E.g
newspaper inside the fuel tank (used for painting protective)
or extra parts (screw inside engine)
Misread, mismeasure or misinterpret : error in reading
measurements, dimensions or understanding correct
information.
c) Human Mistakes
Human Mistakes
Safeguard
Inattentiveness
Forgetfulness
Inexperience
Misunderstanding
Poor Identification
CONTENT
Introduction
Definition to design for manufacturing
Estimation of manufacturing costs
Reduction of cost in components, assembly
and supporting production
The impact of DFM on other factors
Component Cost
Assembly Cost
Overhead Cost
CONTENT
Introduction
Definition to design for manufacturing
Estimation of manufacturing costs
Reduction of cost in components, assembly
and supporting production
The impact of DFM on other factors
Variable Cost
Variable costs are costs that vary with output. Generally variable costs increase at
a constant rate relative to labor and capital. Variable costs may include wages,
utilities, materials used in production
Cost
Unit Cost
Materials
5.7 kg aluminium
@$2.25/kg
12.83
Processing (casting)
3.53
Processing (Machining)
1.70
0.32
0.18
Fixed Cost
$12.09
$30.65
Cost
Unit Cost
Materials
12.83
Processing (casting)
3.53
Processing (Machining)
1.70
0.32
0.18
Fixed Cost
$12.09
$30.65
Question:
How do you reduce the cost per unit?
CONTENT
Introduction
Definition to design for manufacturing
Estimation of manufacturing costs
Reduction of cost in components, assembly
and supporting production
The impact of DFM on other factors
THE END