Design for Manufacture and Assembly (DFM/DFA)

This seminar provides both a functional understanding of the principles involved in conducting a Design for Manufacture/Design for Assembly (DFM/DFA) study and the process for implementing a DFM/DFA culture into the organization. DFM/DFA principles can apply to both manual and automated processes resulting in significant cost savings through not only simpler designs with fewer components but also analyses workstation setup and workflow, part orientations during build, and design considerations such as component placement, tolerancing and servicing considerations. Related topics include: ergonomic considerations, error-proofing vs. mistake-proofing, and tooling considerations.

Actual examples from the mobility industry are used to support the lecture and participants conduct a full DFM/DFA study which includes completing the DFM/DFA worksheet, calculation of Design Efficiency for Manufacturing, and understanding the challenges of implementing a DFM/DFA culture.

What Will You Learn

Upon completion of this course, you will be able to:
  • Recognize and list the benefits of the DFM/DFA method in creating product designs which support manufacturing processes leading to short- and long-term product cost savings
  • Identify the elements of a design for manufacturing strategy that optimizes manufacturing efficiency without sacrificing product functionality.
  • Outline the use of specific robust design techniques to ensure a proper balance of functional design and ease of manufacturing
  • Determine the criteria to select designs suitable as DFM/DFA candidates
  • Compare and contrast the two major types of DFM/DFA studies; Boothroyd and Dewhurst and Lucas Assembly Method
  • List the essential steps of an effective Design for Manufacture study
  • Define design for manufacturing (DFM) methods to overcome manufacturing difficulties associated with the product design
  • Define design for assembly (DFA) considerations to address production issues such as workstation design and layout, tool selection, ergonomics, and equipment and fixture design
  • Construct DFM/DFA worksheets and calculate design efficiency using an instructor provided project

Is This Course For You

Product Engineers, Designers and Managers, Manufacturing and Tooling Engineers, and Project Managers who desire to understand DFM/DFA as a product design tool to increase manufacturability of product assemblies. The course is best suited for individuals in the manufacturing industry and is beneficial to OEMs and Tier suppliers.

Materials Provided

This data is not available at this time

Course Requirements

This data is not available at this time

Topics

Day One
  • Introduction to DFM/DFA and DFM/DFA objectives
    • DFM, DFA and Product Life Cycle
    • Six Steps of the DFM/DFA Life Cycle Model
    • DFM and DFA advantages and challenges in a Product Development environment
  • Design Considerations
    • Creating the DFM/DFA Environment
    • Guidelines for selecting DFM candidates
    • Integrating FMEA and DFM/DFA
    • Material Selection process
    • Project Cost Estimation
    • DFM Worksheet, Tables and Terms Defined
    • Minimizing part count using the Minimum Part Criteria
    • Finalizing the Critical Design Characteristics
    • DFM introductory project
Day Two
  • Design Considerations (cont)
    • Operator Interface Considerations - Handling, Insertion, and Fastening issues
    • Calculating initial design efficiencies
    • Prioritizing Design Improvement efforts using the Worksheet codes
    • Finalizing DFM project
  • Process Considerations
    • Workplace Layout
    • Methods of Assembly
    • Lean Production Metrics
    • Errorproofing
  • Introduction to DFM Concurrent Costing
  • Total cost savings through DFM and DFA