Class Details
- Class Name:
- Design for Manufacturability and Assembly (DFM/DFA)
- Audience:
- Anyone involved in product design, manufacturing engineering, and manufacturing management, including design engineers, product engineers, manufacturing engineers, process engineers, quality engineers, and mechanical engineers.
- Duration:
- 3 Day Course
- Language:
- English
Learning Objectives
- Understand how DFM impacts product cost and quality
- Identify ways to simplify your product and dramatically reduce part count
- Understand the six principles of mistake-proofing (poka-yoke) and how to proactively apply it
- Learn the principles of design for assembly for both mechanical and electronic products
- Obtain detailed guidelines of DFM covering fabrication processes used by your company
- Learn by doing through a series of exercises
- See hundreds of examples of good and bad design for manufacturability
- Learn how to optimize tolerances to enhance manufacturability
- Determine the 10 key steps to DFM implementation
- Learn a practical methodology for analyzing the manufacturability of your company's products
- Obtain practical DFM feedback on your existing products or products under development
Outline At-a-Glance
1. DESIGN FOR MANUFACTURABILITY/ ASSEMBLY (DFM/A)
- DFM/A Introduction
- Design Impact on Cost
- DFM/A Fallacies vs. Reality
2. DESIGN FOR ASSEMBLY
- Principles of Design for Assembly
- Simplicity - Minimize Part Count and Consolidate Part Functions
- Minimize Parts Exercise
- Commonality and Standardization - Minimize Part Variety
- Commonality and Standardization Approach and Method
- Mistake-Proof Fabrication and Assembly - The Six Mistake-Proofing Principles and the Relative Benefit
- Mistake-Proofing Approach and Methodology
- Mistake-Proofing Exercise - Identify Mistake-Proofing Opportunities
- Assembly Process Framework
- Design for Parts Feeding & Handling
- Automated Assembly Handling and Feeding
- Design for Part Orientation
- Design for Location and Insertion
- Axes of Assembly, Reorientation & Blind Assembly
- Top Down, Uni-Axis Assembly
- Self-Fixturing vs. Production Fixtures
- Joining & Fastening Guidelines
- Finishing, Adjustment & Calibration
- DFA Considerations to Facilitate Inspection
- Applying DFA to Packaging - The Final Assembly Step
- Design for Assembly Analysis Exercise
3. DFM/A FOR ELECTRONICS
- Use of DFM/A Guidelines for Boards
- Simplify the Assembly Process - Mixing Technology and Board Sides
- Reduce Thermal Cycles
- Board Size and Penalization Guidelines
- PCB Layout Guidelines
- Component Selection Guidelines
- Avoid Manual Assembly
- Other Component Considerations
- DFM/A Assessment for Boards
- Automated Design Rules Checking
4. DESIGN FOR MANUFACTURABILITY
- DFM Framework
- Material and Process Evaluation
- Material and Process Evaluation Exercise
- Raw Material Standardization
- General DFM Guidelines
- Machining Guidelines and Examples
- Manufacturability Analysis Exercise
- Sheet Metal and Stamping Guidelines and Examples
- Injection Molding Guidelines and Examples
- Casting Guidelines and Examples
- Minimize Finishing Requirements
- Design for the Supply Chain
5. PROCESS CAPABILITY AND TOLERANCES
- What is Process Capability and the Effect on Manufacturability
- Variation and Specifications
- Parameter and Tolerance Objectives
- Statistical Process Capability and Capabilities Indices - Cp and Cpk
- Effect of Tolerances
- Tolerance Optimization
6. DFM/A AND THE DEVELOPMENT PROCESS
- DFM/A Process Steps
- Early Manufacturing Involvement
- Early Supplier Involvement
- DFM/A Collaboration Tools and Methods
- Role of Solids and Assembly Models in DFM/A Evaluation
- How to Effectively Consider Design Alternatives to Address DFM/A Issues
- Product Cost Models to Estimate Costs & Evaluate Design Alternatives
- Developing Design Guidelines
- Formal DFM/A Analysis & Assessment
- Design for Manufacturability and Assembly (DFM/A)
- Conducting Design Reviews to Address DFM/A
- Capturing Issues with Build Reports
- Closing the Loop with a Final Production Review
- DFM/A Performance Measurement & Metrics
7. SUMMARY
- 10 Steps to DFM/A
- DFM/A Survey Results
- Sources of Further Information
- Questions and Discussion
8. DFM/A ANALYSIS OF COMPANY PRODUCT OR ASSEMBLY (DAY 3 WORKING LAB)
- Transitioning from the Workshop to Product Design - Exercise Objectives
- Introduction of Analysis Methodology and DFM/A Worksheet
- Team Analysis of Company Products or Assemblies
- Team Consideration of DFM/A Improvements
- Team Reporting Out and Exercise Discussion
9. CONCLUDING QUESTIONS AND DISCUSSION
Job Roles