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DFM Design Principles

The document discusses strategies for reducing manufacturing costs through design for manufacturing (DFM) principles. It recommends simplifying designs by using fewer parts and standard components, liberal tolerances, and materials easy to process. Close collaboration with manufacturing engineers is advised to understand cost drivers and avoid expensive production steps. Standardizing common designs and leveraging economies of scale can further reduce costs.

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Cherun Chesil
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© © All Rights Reserved
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Download as PDF, TXT or read online on Scribd
36 views

DFM Design Principles

The document discusses strategies for reducing manufacturing costs through design for manufacturing (DFM) principles. It recommends simplifying designs by using fewer parts and standard components, liberal tolerances, and materials easy to process. Close collaboration with manufacturing engineers is advised to understand cost drivers and avoid expensive production steps. Standardizing common designs and leveraging economies of scale can further reduce costs.

Uploaded by

Cherun Chesil
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Sasi Kumar Gera

Scientist/Engineer ‘E’
NIELIT, Aurangabad
 Mechanical engineering designs generally
include off-the-shelf components and
fabricated parts.

 Knowing the strengths and limitations of the


fabrication techniques makes for higher
quality and more cost competitive designs.
1. Simplicity
2. Standard Materials and Components
3. Standardized Design of the Product
4. Liberal Tolerances
5. Use Materials that are Easy to Process
6. Teamwork with Manufacturing Personnel
7. Avoidance of Secondary Operations
8. Design to Expected Level of Production
9. Utilize Special Process Characteristics
10. Avoid Process Restrictiveness
 Description: minimize the number of parts,
intricate shapes, and manufacturing
operations
 Motivation: generally provides reduced cost,
improved reliability, easier servicing, and
improved robustness
 Example: Braun Lift
 Description: Use standard off-the-shelf parts
and widely available materials

 Motivation: eases purchasing, simplifies


inventory management, and avoids tooling
investments

 Example: Screws
 Description: For similar products, specify the
same materials, parts, and subassemblies as
much as possible.

 Motivation: provides economies of scale,


simplifies operations, and simplifies inventory
management

 Example: Braun Lift


 Description: make tolerances as forgiving as
possible

 Motivation: tight tolerances are expensive (in


a non-linear fashion)
(Fig in the next slide)
 Description: take advantage of materials that
have been developed for easy processibility

 Motivation: while material may cost more, it


will often provide lower overall cost

 Example: “Free-Machining” Grades, Many


polymer grades are tuned to a process
 Description: collaborate with the people who
will be producing your product (the earlier the
better)

 Motivation: they provide a unique body of


knowledge and useful insights

 Example:
 Description: minimize the need for secondary
operations

 Motivation: secondary operations (e.g.


deburring, inspection, painting, and heat
treating) can be as expensive as the primary
manufacturing operation

 Example: Pre-painted steel, investment


casting
 Description: understand and take advantage
of the special capabilities of various
manufacturing processes

 Motivation: can often eliminate


manufacturing operations and reduce the
number of parts

 Example: injection molding snap fits and


living hinges
 Description: on part drawings, specify only
the final characteristics needed; do not
specify the process to be used

 Motivation: potential cost savings


Proposed Design

Estimate the Manufacutring


Costs

Reduce the Costs of Reduce the Costs of Reduce the Costs of


Components Assembly Supporting Production

Consider the Impact of DFM


Decisions on Other Factors

Recompute the
Manufacturing Costs

Good
N
enough
?
Y

Acceptable Design
 Estimate the manufacturing 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.
Equipment Information Tooling

Raw Materials

Labor
Manufacturing System Finished Goods
Purchased
Components

Energy Supplies Services Waste


 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
Manufacturing Cost

Components Assembly Overhead

Equipment Indirect
Standard Custom Labor Support
and Tooling Allocation

Raw
Processing Tooling
Material
 Component Costs (parts of the product)
 Parts purchased from supplier
 Custom parts made in the manufacturer’s own plant or by
suppliers according to the manufacturer’s design specifications

 Assembly Costs (labor, equipment, & tooling)

 Overhead Costs (all other costs)


 Support Costs (material handling, quality assurance,
purchasing, shipping, receiving, facilities, etc.)
 Indirect Allocations (not directly linked to a particular product
but must be paid for to be in business)
 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)

 Variable Costs – incurred in direct proportion


to the number of units produced (i.e. cost of
raw materials)
 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
Redesign costly parts with the same
performance while avoiding high
manufacturing costs.

Work closely with design engineers—raise


awareness of difficult operations and high
costs.
 Reduce the number of steps of the
production process
 Will usually result in reduce costs
 Eliminate unnecessary steps.
 Use substitution steps, where applicable.
 Analysis Tool – Process Flow Chart and Value
Stream Mapping
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.
 Black box—only 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.
 Economies of Scale – The unit cost of a
component decreases as the production
volume increases.

 Standard Components—common to more


than one product

 Analysis tools – group technology and mass


customization

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