Design for Manufacturing & Assembly

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. This seminar will include information on how DFM+A fits in with QFD, Concurrent Engineering, Robust Engineering, and other disciplines.

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.

You are also asked to bring a calculator capable of making simple calculations.

What Will You Learn

Upon successful completion of this course, 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

You should attend if you are a product designer, product engineer, or manufacturing engineer. Individuals involved in a new or ongoing product development process will benefit by learning how to help synchronize and optimize fabrication and assembly activities. This course is most effective when attended by product development teams. However, this is not a requirement for attendance.

Materials Provided

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Course Requirements

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  • Welcome and Introduction
  • 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)
  • Brief Design for Service (DFS) Overview
  • DFM+A Workshop Checklist
  • Institutionalizing DFM+A in Your Organization
    • How DFM+A fits in with other strategies
    • Lessons learned from other companies
    • Ideal workplace implementation plan
  • Wrap Up
  • Course Evaluation