Design for Manufacturing & Assembly (DFM/DFA)

Design for Manufacturing and Assembly (DFM+A), pioneered by Boothroyd and Dewhurst, has been used by many companies around the world to develop creative product designs that use optimal manufacturing and assembly processes. Correctly applied, DFM+A analysis leads to significant reductions in production cost, without compromising product time-to-market goals, functionality, quality, serviceability, or other attributes. In this two-day seminar, you will not only learn the Boothroyd Dewhurst Method, you will actually apply it to your own product design!

This seminar will include information on how DFM+A fits in with QFD, concurrent engineering, robust engineering, and other disciplines. In addition, there will be a brief demonstration of computer software tools, which simplify the DFM+A analysis.

Each participant will receive and use the hard-bound authoritative reference textbook, Product Design for Manufacture and Assembly, written by Geoffrey Boothroyd, Peter Dewhurst and Winston Knight.

What Will You Learn

By attending this seminar, you will be able to:
  • Perform Design for Assembly (DFA) Analysis using the BDI Manual (Worksheet) Method
  • Perform DFM Analysis (manufacturing cost estimation)
  • Apply Design for Service (DFS) Principles
  • Reduce your company's production costs by analyzing and eliminating the factors that greatly affect the time, cost, and quality of manufacturing, assembly and service processes 
  • Utilize effective analysis, brainstorming, and trade-off techniques for redesigning assemblies and subassemblies

Is This Course For You

Product designers, product engineers, or manufacturing engineers will benefit by attending this seminar. Individuals involved in a new or ongoing product development process will also benefit by learning how to help synchronize and optimize fabrication and assembly activities. This course is most effective when attended by product development team members; however, this is not a requirement for attendance.

NOTE: You are strongly encouraged to bring a sample or drawing of one of your own designs to analyze during the workshop on Day Two. You are also asked to bring a calculator capable of making simple calculations.

Materials Provided

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Course Requirements

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  • What is DFM+A
    • The history of DFM+A
    • The various "Design fors"
    • Why companies are using DFM+A
    • DFM+A success stories
    • DFM+A benefits
    • Key factors in ensuring DFM+A success
  • DFA Good Design Principles
    • The Boothroyd Dewhurst Design for Manual Assembly Method
    • Using the manual handling and insertion tables
    • Determining theoretical minimum part count
    • Filling in the BDI DFA worksheet
    • Computing the DFA Index
  • DFA Baseline Analysis Exercise (Pneumatic Piston)
  • Redesign Project (Pneumatic Piston Assembly)
    • Developing design concepts
    • Identifying conservative and "stretch" designs
    • Selecting the best DFA concept
    • Analysis of redesign
    • Presentation of team results
  • General Approach to Manufacturing Cost Estimation
    • Manufacturing cost drivers
    • Estimating piece cost
    • Cost calculation exercise
  • BDI Design for Manufacture (DFM) Cost Estimation
    • Injection molding cost algorithms
    • Sample calculation
    • Exercise (analyzing part from pneumatic piston)
  • BDI DFM Cost Estimation (continued)
    • Review of die casting and/or sheet metal stamping cost algorithms
  • Design for Service (DFS) Assessment
    • Two main approaches
    • Life cycle considerations
    • DFS exercise
  • BDI DFM/A Software Toolkit Demonstration
    • DFA module
    • Injection molding or other module
  • DFM+A Workshop Checklist
  • Brainstorming Guidelines
  • DFM+A Workshop Project (approximately 4 hours)
    • Project selection (from those brought to class)
    • Team identification
    • Baseline analysis
    • Redesign development
    • Development of project reports (illustrations, action plan, possible roadblocks, etc.)
    • Presentations of team results
  • Institutionalizing DFM+A in Your Organization
    • How DFM+A fits in with other strategies
    • Lessons learned from other companies
    • Ideal workplace implementation plan
  • Video Presentation on Goal Setting (time permitting)
  • Wrap Up
  • Course Evaluation