Design for Manufacturing

By Raghavendra(093303) Gangadhar(093304) Bhagwath(093306)

Design for X Topics

Design for Manufacturing Design for Production Design for Assembly Design for Recycling/Disposal

Design for Life Cycle

Prototyping

 Manufacturing cost is a key determinant of the economic success of a product since such success depends on the profit margin earned on each sale of the product and on how many units of the product the firm can sell. Profit margin is the difference between the manufacturers selling price and the cost of making the product. Economically successful design is thus about ensuring high product quality while minimizing manufacturing costs and DFM is one method of achieving this

DFM requires cross-functional team

DFM utilizes information of several types:
Sketches, drawings, product specifications, and design alternatives. A detailed understanding of production and assembly processes Estimates of manufacturing costs, production volumes, and ramp-up timing. DFM efforts commonly draw upon expertise from manufacturing engineers ,cost accountants and production personnel, in addition to product designers. DFM is performed throughout the Development process.

DFM Method
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.

DFM Method
Proposed Design Estimate the Manufacutring Costs

Reduce the Costs of Components

Reduce the Costs of Assembly

Reduce the Costs of Supporting Production

Consider the Impact of DFM Decisions on Other Factors

Recompute the Manufacturing Costs

Good enough ? Y

Acceptable Design

Estimate the Manufacturing Costs

Equipment Information Tooling

Raw Materials Labor Purchased Components

Manufacturing System

Finished Goods

Energy

Supplies

Services

Waste

INPUT-OUTPUT MODEL OF A MANUFACTURING SYSTEM

Definition of Manufacturing Cost:

Sum of all the expenditures for the inputs of the system

(i.e. purchased components, energy, raw materials, etc.)

and for disposal of the wastes produced by the system

Unit manufacturing cost is computed by dividing the

total manufacturing costs for some period(usually a

quarter or by a year) by the number of units of the

product manufactured during that period.

Elements of the Manufacturing Cost of a Product

Manufacturing Cost

Components

Assembly

Overhead

Standard

Custom

Labor

Equipment and Tooling

Support

Indirect Allocation

Raw Material

Processing

Tooling

Fixed Costs vs. Variable Costs

Fixed Costs incurred in a predetermined amount, regardless of number of units produced (i.e. setting up the factory work area or cost of an injection mold) Purchasing injection mold is example of fixed cost. Variable Costs incurred in direct proportion to the number of units produced (i.e. cost of raw materials) Cost of raw materials is example of variable cost.

ESTIMATING COSTS OF STANDARD COMPONENTS

The costs of standard components are estimated by either Comparing each part to a substantially similar part the firm is already is producing or purchasing in comparable volumes or Soliciting price quotes from vendors or suppliers.

ESTIMATING COSTS OF CUSTOM COMPONENTS

When the custom component is a single part , we estimate its cost by
adding up the costs of raw materials ,processing and tooling. The raw materials costs can be estimated by computing the mass of

the part, allowing for some scrap, and multiplying by the cost per unit
mass of the raw material.

 Processing costs include costs for the operator(s) of the processing machinery as well as the cost of using the equipment itself. Tooling costs are incurred for the design and fabrication of the cutters,molds,dies or fixtures required to use certain machinery to fabricate parts ESTIMATING THE COST OF ASSEMBLY Manual assembly costs can be estimated by summing the estimated time of each assembly operation and multiplying by a labor rate. Assembly operations require from about 4 seconds to about 60 seconds each, depending upon the size of the parts , the difficulty of the operation , and the production quantities .

ESTIMATING THE OVERHEAD COSTS

Most firms assign overhead charges by using overhead rates( also called burden rates). Overhead rates are typically applied to one or two cost drivers. Cost drivers are parameters of the product which are directly measurable. Overhead charges are added to direct costs in proportion to the drivers. Under the ABC approach , a firm utilizes more and different cost drivers and allocates all indirect costs to the associated cost drivers where they fit best. As a result , the firm may have overhead rates applied to various dimensions of product complexity

 EXAMPLE REPRESENTING CALCULATION OF MANUFACTURING COST

Reduce the Cost of Components

Understand the Process Constraints and Cost Drivers Redesign Components to Eliminate Processing Steps Choose the Appropriate Economic Scale for the Part Process Standardize Components and Processes Adhere to Black Box Component Procurement

Understand the Process Constraints and Cost Drivers

Redesign costly parts with the same performance while avoiding high manufacturing costs. Work closely with design engineersraise awareness of difficult operations and high costs.

Redesign Components to Eliminate Processing Steps

Reduce the number of steps of the production process Eliminate unnecessary steps. Use substitution steps, where applicable. Analysis Tool Process Flow Chart and Value Stream Mapping

Choose the Appropriate Economic Scale for the Part Process

Economies of Scale As production volume increases, manufacturing costs usually decrease. Fixed costs divided among more units. Variable costs are lower since the firm can use more efficient processes and equipment.

Standardize Components and Processes

Economies of Scale The unit cost of a component decreases as the production volume increases. Standard Componentscommon to more than one product Analysis tools group technology and mass customization

Adhere to Black Box Component Procurement

Customers Requirement

BLACK BOX

Out Put

Black boxonly give a description of what the component has to do, not how to achieve it. Successful black box design requires clear definitions of the functions, interfaces, and interactions of each component.

Reduce the Costs of Assembly

Design for Assembly (DFA) index
Integrated Parts (Advantages and Disadvantages)

Maximize Ease of Assembly

Consider Customer Assembly

The Assembly from Heaven*

Can be assembled one-handed by a blind person wearing a boxing glove Is stable and self-aligning

Tolerances are loose and forgiving

Few fasteners Few tools and fixtures Parts presented in the right orientation Parts asymmetric for easy feeding Parts easy to grasp and insert

Design for Assembly Index

(Theoretical minimum number of parts) x (3 seconds) DFA index = Estimated total assembly time

Determining the Theoretical Minimum Number of Parts

Does the part need to move relative to the rest of the assembly? Must the part be made of a different material from the rest of the assembly for fundamental physical reasons? Does the part have to be separated from the assembly for assembly access, replacement, or repair?

Integrated Part Design

Home Hot Water System Family Part

Comparison between Assembled & Integrated Parts

Advantages of Integrated Parts

Do not have to be assembled Often less expensive to fabricate rather than the sum of each individual part Allows critical geometric features to be controlled by the part fabrication process versus a similar assembly process

Disadvantages of Integrated Parts

Conflict with other sound approaches to minimize costs Not always a wise strategy

Maximize Ease of Assembly

Part is inserted from the top of the assembly Part is self-aligning Part does not need to be oriented Part requires only one hand for assembly Part requires no tools Part is assembled in a single, linear motion Part is secured immediately upon insertion

Consider Customer Assembly

Customers will tolerate some

assembly
Design product so that customers

can easily and assemble correctly

Customers will likely ignore

directions

DFMA Example

DFMA-Example 1 Analysis

DFMA Worksheet for Datum Design

Item
Base Bush

Number
1 2

Theoretical Part Count

1 0

Assembly Time(s)
3.5 12.3

Assembly Cost (cents)

2.9 10.2

Motor Subassembly Motor Screw

Sensor Subassembly Setscrew Standoff End plate End-plate screw Plastic bush Thread lead Reorient Cover Cover Screw TOTALS

1 2
1 1 2 1 2 1 1 4 19

1 0
1 0 0 1 0 0 0 0 4

9.5 21.0
8.5 10.6 16.0 8.4 16.6 3.5 5.0 4.5 9.4 34.2 160.0

7.9 17.5
7.1 8.8 13.3 7.0 13.8 2.9 4.2 3.8 7.9 26.0 133.0

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 163 s
or 7.362%

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.

DFMA- An Improved Design

DFMA Worksheet for an Improved Design

Item
Base

Number
1

Theoretical Part Count

1

Assembly Time(s)
3.5

Assembly Cost (cents)

2.9

Motor Subassembly Motor Screw Sensor Subassembly Setscrew Thread leads

1 2 1 1 -

1 0 1 0 -

4.5 12.0

3.8 10.0 7.1 7.1 4.2

8.5
8.5 5.0

Plastic Cover

4.0

3.3

TOTALS

46.0

38.4

DFMA Cost Differential Worksheet

.

Old Design
Item
Base (Aluminum) Bush(2)

New Design Item

Base (nylon)

Cost,$
12.91 2.40

Cost, $
13.43

Motor Screw(2)
Setscrew Standoff(2) Endplate End-plate Screw Plastic bush Cover Cover screw(4) Totals

0.20
0.10 5.19 5.89 0.20 0.10 8.05 0.40 35.44

Motor Screw(2)
Setscrew

0.20
0.10

Plastic Cover (include tooling)

8.00

21.73

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 12 s 0.26087 T1 46 s

or 26.087%

DFMA Calculate Total Saving

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

Proposed Design

Estimate the Manufacutring Costs

Reduce the Costs of Components

Reduce the Costs of Assembly

Reduce the Costs of Supporting Production

Consider the Impact of DFM Decisions on Other Factors

Recompute the Manufacturing Costs

Good enough ? Y

Acceptable Design

3.Reduce the Costs of Supporting Production

Reduction in no of parts- reduction in inventory. Reduction in assembly content- reduces no of workers Standardizing no of parts- reduces demands on engineering support and quality control.

Minimize Systemic Complexity

Production system consist- many suppliers, parts,people,processes. Needs to be monitered.Comlexicity is driven by design. Minimize Systemic Complexity (inputs, outputs, and transforming processes) Use smart design decisions

Error Proofing
Anticipate possible failure modes Take appropriate corrective actions in the early stages Use color coding to easily identify similar looking, but different parts

5.Consider the Impact of DFM Decisions on Other Factors

Development Time Development Cost Product Quality External Factors
Component reuse Life cycle costscost of toxic disposal. warranty period cost.

Conclusion
DFM is aimed at reducing manufacturing cost while simultaneously improving product quality,development time, and development cost.

References
Ulrich, K. & Eppinger, S. (2000). Product Design and Development. Boston, MA: Irwin McGraw-Hill. Product Design for Assembly, Geoffrey Boothroyd and Peter Dewhurst, 1991, Boothroyd Dewhurst Inc.

Thank you