DFM.ppt
- 2. 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?
- 3. 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
- 4. DFM with respect to Product Design Presented by Rick Forney
- 5. 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
- 6. 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
- 7. Reduce the Total Number of Parts • Designing a product with less parts means less - Purchases - Assembly Difficulty - Inventory - Service Inspection - Handling - Testing - Processing Time - Development Time - Equipment LEADS TO A CHEAPER - Engineering Time PRODUCT
- 8. 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
- 9. Use of Standard Components • Standard components less expensive than custom-made • Testing already completed • No need for development
- 10. Design Parts to be Multi-Functional • 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
- 11. 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
- 12. Design for Ease of Fabrication • Material Selection • Avoid – Post process operations (painting, polishing) – Excessive tolerance requirements
- 13. Avoid Separate Fasteners • Fasteners reduce manufacturing efficiency • Expensive due to operations required to produce fasteners • Instead use snap fits
- 14. 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
- 15. 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
- 16. 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
- 17. 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
- 18. DFM with respect to Manufacturing Processes Presented by Caleb Pan
- 19. Manufacturing Processes • Casting, foundry, or molding • Forming or metalworking • Machining • Joining and Assembly • Surface Treatments • Rapid Prototyping • Heat Treating
- 20. 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
- 21. 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)
- 22. Extruded Parts • Eliminate Irregularities • Use standard cross sections • Eliminate secondary drawing operation; eliminates additional tooling, handling, and cost.
- 23. Powder Metallurgy • Undesired Features – Steps, Inserts, Screw Threads, Sharp Corners, Spherical Surfaces • Limitations – Holes, Inserts, Knurls, Lettering • Desired features - Small radii, No draft.
- 24. Forged Parts • Features of Reduced Size • Radii are necessary • Draft • Parting Line – Perpendicular to the axis of motion – If not, no more than 75°
- 25. Machining Processes • Milling • Planing, Shaping, Slotting • Broaching • Flame-Cutting • Electrochemical • Chemical
- 26. 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.
- 27. DFM with respect to Cost Management Presented by C. Spencer Whittingham
- 28. 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
- 29. Cost Management (Manufacturing) • Number of workers • Escalation • Risk • Contingency or management reserve • Travel and transfer of materials/products • Fees + profit
- 30. 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
- 31. DFM Case Study: Car Engine Presented by Ryan Loggins
- 32. • 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 Overview
- 33. Engine for a 2010 Corvette ZR1
- 35. • 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 Design
- 36. • 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 Manufacturing Processes
- 37. • 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 Assembly
- 38. • 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 DFM for Quality Control
- 39. Conclusion • To review: – Design for Manufacturability is a concept that is used in many industries – It’s 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
Editor's Notes
- #29: Cost management is a very important and crucial part when designing products for manufacturing. There are many things that affect the cost of a manufactured product such as: some machines are more efficient – they can make the work go by faster and they will produce less waste some materials are cheaper than others and they have higher tolerance levels some materials are better manufactured in different forms or at different temperatures it is sometimes more beneficial to manufacture a greater quantities at once as the same machines and processes can be used with no delay for setup the dimension of a material can affect its tolerance levels or also its strength the design and shape of a material will affect what processes must be used for its manufacturing depending on how high the quality of the final product is required to be, different processes are used and more extensive work takes place with each product Cost management is very important when it comes to meeting quality standards as these two are very closely interrelated.
- #30: there needs to be a balance between the number of workers and the amount of work that needs to be completed there needs to be a consideration for the escalation of prices during the duration of the project there are many things that could go wrong and this needs to be addressed during the budget planning process there needs to be a contingency plan to address a situation where things can go wrong travel for representatives and workers must be addressed as well as the transportation of the various materials and products there are various fees to be addressed such as costs of materials and wages for workers; also, a profit has to be made to make it worth the contractors time
- #31: Examples: find a supplier who can provide the same materials but at lower costs hire subcontractor with greater experience who can get the work completed quicker and at a better rate using 1 coat of paint instead of 2 as long as quality is not affected using automatic paint spraying equipment – lowers costs and duration of activity as opposed to using rollers and brushes