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
- 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
Materials Provided
Course Requirements
Topics
- 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