Design For Manufacturability

What you will learn

What is the main idea behind Design for
Manufacturability?
Where is it used?
Why is it used?
How can products be designed using this
concept?
How can a manufacturing process be planed to
use DFM?
How does DFM save money?

Introduction
What is the main idea behind Design for
Manufacturability?
The definition of Design for Manufacturability (DFM)
is the general engineering art of designing products
in such a way that they are easy to manufacture.

Where is DFM used?

DFM is utilized in many industries ranging from
industrial products, microelectronics, scientific
instruments, and the aerospace industry

DFM with respect to Product Design

Objective
To design a product that can be easily, efficiently,
and cost effectively be manufactured
To reduce overall cost of a product warranty,
engineering changes, factory floor space,
unnecessary parts, and service

How
Reduce the total number
of parts
Modular design
Standard components
Multi-functional parts
Multi use parts
Ease of Fabrication

Avoid Separate
Fasteners
Minimize Assembly
Directions
Maximize compliance
Minimize handling

Design for Manufacturing DFM

Series of guidelines for producing
a product easily and profitably

Simplification - Minimize parts

Standardization
Design parts for multiple
applications

Use modular design

Simplify operations

See
http://www.citeman.com/4995-dfm-principles-dfm-design-for-manufacturi
ng/

Reduce the Total Number of Parts

Designing a product with less parts means less
-

Purchases
Inventory
Handling
Processing Time
Development Time
Equipment
Engineering Time

- Assembly Difficulty
- Service Inspection
- Testing

LEADS TO A CHEAPER
PRODUCT

Develop a Modular Design

Using modules simplifies the manufacturing
process
Allows for the use of standard components
Allows for tests to be conducted prior to the
product being assembled

Use of Standard Components

Standard components less expensive than
custom-made
Testing already completed
No need for development

Design Parts to be MultiFunctional

Reduce the total number of parts required
Reduce manufacturing time
Reduce inventory required
Example A part that acts as a heat dissipating element
and as a structural support

Design Parts for Multi-use

Using parts for the same or different operations
multiple times in a product
Reduces the number of parts that need to be
developed
Less machines - Less usage of factory floor
space

Design for Ease of Fabrication

Material Selection
Avoid
Post process operations (painting, polishing)
Excessive tolerance requirements

Avoid Separate Fasteners

Fasteners reduce manufacturing efficiency
Expensive due to operations required to produce
fasteners
Instead use snap fits

Minimize Assembly Directions

Optimal assembly of a product occurs in one
direction
Preferred direction is from above using gravity to
assist in the manufacturing process

Maximize Compliance
Errors in insertion due to positioning and
dimensional variability cause damage to parts
and to machinery
Use tapers, chamfers and moderate radii to
ease insertion
Example utilization of a rigid base and tactile
and visual sensors in assembly

Minimize Handling
Positioning, orienting, and fixing a part are time
consuming and costly
Use external guiding features to orient the part
Ideally the part should be placed one time

Concurrent Engineering
The process of designing the product and the
manufacturing process simultaneously to
increase the efficiency and reduce the time to
launch a product

DFM with respect to Manufacturing

Processes

Manufacturing Processes

Casting, foundry, or molding

Forming or metalworking
Machining
Joining and Assembly
Surface Treatments
Rapid Prototyping
Heat Treating

Casting Design & Processes

Design Considerations
Shrinkage, Parting Line,
Draft
Section Changes
Features
Holes
Ribs
Fillets

Processes
Permanent Metal Mold
Expendable Sand Mold
Centrifugal
Plaster Mold
Ceramic Mold
Investment Casting
Die Casting

Forming & Metalworking Processes

Extrusions
Powder Metallurgy
Forging
Stampings
Fine-blanked Parts
Spring & Wire Parts
Spun Metal
Upset
Rotary-Swaged
Tube & Section Bends
Electroformed Parts
Cold Extrusion
Rolled Form
Metal Injection Molding (MIM)

Extruded Parts
Eliminate Irregularities
Use standard cross
sections
Eliminate secondary
drawing operation;
eliminates additional
tooling, handling, and
cost.

Powder Metallurgy
Undesired Features Steps, Inserts, Screw Threads, Sharp Corners,
Spherical Surfaces
Limitations Holes, Inserts, Knurls, Lettering
Desired features - Small radii, No draft.

Forged Parts
Features of Reduced
Size
Radii are necessary
Draft
Parting Line
Perpendicular to the
axis of motion
If not, no more than 75

Machining Processes

Milling
Planing, Shaping, Slotting
Broaching
Flame-Cutting
Electrochemical
Chemical

Machined Parts
General Guidelines
If possible, avoid machining at all costs; the most
expensive form of manufacturing
Parts must be easily fixtured and must be rigid enough to
withstand the forces of clamping; thin walls and deep
pockets must be avoided.
Difficult to machine materials must be avoided.
Avoid features such as tapers, undercuts, projections,
sharp corners.

DFM with respect to Cost Management

Cost Management
(Design)

The machines + processes used

The materials used
The form of the materials
The quantity being manufactured
The dimensional tolerances + strength
The design and shape
The desired quality of the final product

Cost Management
(Manufacturing)

Number of workers
Escalation
Risk
Contingency or management reserve
Travel and transfer of materials/products
Fees + profit

Cost Management
(Solutions)
Substitute for less expensive materials
Assign a person with greater expertise or more
experience to perform or help with the
project/activity to get it done more efficiently
Reduce the scope or requirements of the work
package or for specific activities
Improve methods or technology

DFM Case Study: Car Engine

Presented by Ryan Loggins

Overview
A car engine is a very complex product with
many parts
Due to the large magnitude of the automotive
industry, it is very important that these parts are
easy to manufacture and as least expensive as
they can be.
It is also important that these parts can be easily
and quickly assembled

Engine for a 2010 Corvette ZR1

Design
It normally takes between three and five years to
design a car engine
The design team consists of several engineers
These engineers usually stay on the same page in
terms of the overall design of the engine.
But what about the people who are responsible for
designing the processes to produce that engine
Or what about the people who are responsible for
putting that engine together
It is important to keep in mind the entire production
process when designing a good of this magnitude

DFM for Manufacturing Processes

When designing a car engine it is important to
keep in mind how the parts you are designing
are going to be produced
The manufacturing engineers need to be able to
take your design and design the processes
used to create each and every part
This can be done by:
Creating the most simple parts possible
Using a material that is easily manufacturable

DFM for Assembly

The harder a product is to assemble:
The longer it takes to produce
The more likely the chance that something
will go wrong
In most cases, it costs more to produce

DFM for Quality Control

As the design for a part gets more complicated:
The harder it is to keep high quality standards
The more complex the manufacturing process has
to be
The more critical dimensions the design has,
therefore greater frequency of sampling and
inspections has to occur

Conclusion
To review:
Design for Manufacturability is a concept that is
used in many industries
Its purpose is to make it easier to manufacture
products on large scales
By adjusting both the product design and the
production design, the ability to produce parts can
be greatly improved
This increase in efficiency will also reduce costs

Questions?