Product Design and Development

Karl T. Ulrich and Steven D. Eppinger

2nd edition, Irwin McGraw-Hill, 2000.
Design for Manufacturing Chapter Table of Contents
1. Introduction
2. Development Processes and Organizations
3. Product Planning
4. Identifying Customer Needs
5. Product Specifications
Teaching materials to accompany: 6. Concept Generation
Product Design and Development 7. Concept Selection
Chapter 11 (13 new) 8. Concept Testing
9. Product Architecture
Karl T. Ulrich and Steven D. Eppinger
10. Industrial Design
2nd Edition, Irwin McGraw-Hill, 2000.
11. Design for Manufacturing
12. Prototyping
13. Product Development Economics
14. Managing Projects

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Design for Manufacturing Example:

Product Development Process GM 3.8-liter V6 Engine

Concept System-Level Detail Testing and Production

Planning Development Design Design Refinement Ramp-Up

How can we emphasize manufacturing issues

throughout the development process?

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 Intake Manifold Definition
• Design for manufacturing (DFM) is a development
practice emphasizing manufacturing issues
throughout the product development process.

• Successful DFM results in lower production cost

without sacrificing product quality.

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Understanding Manufacturing Costs

Manufacturing Cost

Components Assembly Overhead

Equipment Indirect
Standard Custom Labor Support
and Tooling Allocation

Raw
Processing Tooling
Material

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 Determining Costs BOM Original Assembly
• Component Costs
– Standard Parts – volume
– Custom components
• Materials, labor, tooling
• Assembly Costs – study, experience
– Alignment, insertion
• Overhead Costs
– Easiest estimate is percent of part cost
– Missed fixed costs – caught by better accounting

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Three Methods to Implement DFM

Original Manifold Casting
1. Organization: Cross-Functional Teams

2. Design Rules: Specialized by Firm

– includes “DFA”, Design for Assembly

3. CAD Tools: Boothroyd-Dewhurst Software

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 Design for Assembly Rules Design for Assembly
Example set of DFA guidelines
from a computer manufacturer. • Key ideas of DFA:
1. Minimize parts count. –Minimize parts count
2. Encourage modular assembly. –Maximize the ease of handling parts
3. Stack assemblies. –Maximize the ease of inserting parts
4. Eliminate adjustments.
• Benefits of DFA
5. Eliminate cables.
6. Use self-fastening parts. –Lower labor costs
7. Use self-locating parts. –Other indirect benefits
8. Eliminate reorientation. • Popular software developed by
9. Facilitate parts handling. Boothroyd and Dewhurst.
10. Specify standard parts. –[Link]

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To Compute Assembly Time

Method for Part Integration
• Ask of each part in a candidate design:
Handling Time 1. Does the part need to move relative to the rest of
the device?
+ Insertion Time
2. Does it need to be of a different material because
of fundamental physical properties?
Assembly Time 3. Does it need to be separated from the rest of the
device to allow for assembly, access, or repair?
• If not, combine the part with another part in the
device.

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 New PCV Assembly New Casting-Molding

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New Molding New Molding

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 Intake Manifold Design Intake Manifold BOM

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DFMA design improvement example

DFA Software

B
START: FINISH:
• 3 parts • 2 parts
• Requires a • 3 parts • 2 parts • Integrated
screwdriver fastener &
• Requires a • 2 parts • Integrated cradle
• Needs careful rivet gun fastener &
alignment • Integrated cradle • Can be hand-
• Alignment fastener & pressed into
• Time- not as cradle (A • Requires place—even
consuming delicate becomes B) machine to by end
• Assembly press part into consumer—
• Requires place and can be
time less machine to removed
secure the
head of the
Product cost = $0.66
fastener Product cost = $0.38
Assembly time = 20.92 seconds Assembly time = 8.82 seconds

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 DFM Strategy is Contingent
Definition of DFMA
Corporate
Strategy “The goal of DFMA analysis is to determine what a
Product product should really cost to make.
Strategy
“DFMA software gives engineers tools for deciding
Production where cost is necessary in a design and where cost
Strategy DFM can be removed without compromising product
Strategy function.”
Nick Dewhurst
Executive Vice President

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The three main uses of The three main uses of

DFMA DFMA
Increase competitive advantage:
Improve product while reducing
cost: Study competitors’ products,
determine quality and quantify
Help the design team simplify
manufacturing and assembly
the product, improve quality,
difficulties, and create a superior
reduce manufacturing and
product
assembly costs, and quantify
improvements

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 The three main uses of Typical Product Cost
DFMA Breakdown
Hold suppliers accountable: Labor
4%
Use as a “should-cost” tool
to provide cost predictions, Overhead
24%
analyze and discuss Part Costs
supplier bids and contracts, 72%

and hold outside suppliers

to a higher standard
Boothroyd Dewhurst, Inc 2005

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