1. INTRODUCTION TO DESIGN FOR MANUFACTURE AND ASSEMBLY (DFMA)
J.JAYARAMAN
CENTRE FOR AEROSPACE SYSTEMS DESIGN
ENGINEERING
INDIAN INSTITUTE OF TECHNOLOGY , BOMBAY

2. STRUCTURE OF THE PRESENTATION
WHY AND WHEN:
EARLY MANUFACTURING KNOWLEDGE IMPROVES PRODUCT SUCCESS
EXAMPLES OF BENEFITS
DFMA IN WORLD WAR II
WHAT:
WHAT IS INTEGRATED DESIGN AND MANUFACTURE

3. STRUCTURE OF THE PRESENTATION (CONTD.)
HOW:
HOW TO ACHIEVE INTEGRATED DESIGN AND MANUFACTURE
-BDI SOFTWARE
-FMECA
EXAMPLES:
- ACCELERATION SENSING UNIT
-WORKED EXAMPLE
-POWER SUPPLY OF LASER Tx HIGH VOLTAGE
CONCLUSION

4. BEST PRACTICES TO PRODUCT DEVELOPMENT
TECHNOLOGY
DEVELOPMENT
INTEGRATION
DEMONSTRATION
PRODUCTION
KNOWLEDGE
POINT3
KNOWLEDGE
POINT 1
KNOWLEDGE
POINT 2
TECHNOLOGIES
AND RESOURCES
MATCH
REQUIREMENTS
PROGRAM
LAUNCH
PRODUCTION
CAN MEET
COST
SCHEDULE
AND
QUALITY
TARGETS
DESIGN PERFORMS
AS EXPECTED

6. ATTAINMENT OD DESIGN AND MANUFACTURING KNOWLEDGE
WEAPON SYSTEM % OF DWGS. COMPLETED % OF CRITICAL MFG PROGRAM
PRIOR TO MFG PROCESSES IN CONTROL EXPERIENCE
AT PRODUCTION
MEET COST &
SCHEDULE
TARGETS
AT LEAST 90% DWGS.
COMPLETED
ALL CRITICAL
PROCESSES
IN STATISTICAL
CONTROL
BEST PRACTICE
AIM-9X
(AIR-AIR MISSILE)
95%
4% UNIT COST
INCREASE
1 MONTH
PRODUCTION
DELAY
UNKNOWN
44%
23% UNIT COST
INCREASE
18 MONTH
PRODUCTION
DELAY
26%
F-22 FIGHTER

7. ATTAINMENT OF DESIGN & MFG. KNOWLEDGE (contd.)
WEAPON SYSTEM % OF DWGS. COMPLETED % OF CRITICAL PROCESSES PROGRAM
PRIOR TO MFG IN CONTROL AT PRODN EXPERIENCE
F18 E/F FIGHTER
78%
NO UNIT COST
INCREASE
3 MONTH
PRODUCTION
DELAY
58% *
PATRIOT
ADVANCED
CAPABILITY
(PAC-3)
MISSILE
159 % UNIT
COST
INCREASE
39 MONTH
PRODUCTION
DELAY
21 %
35 %
ADVANCED
THREAT
INFRARED
COUNTER-
MEASURES/
COMMON MISSILE
WARNING SYSTEM
21%
182 % UNIT
COST
INCREASE
34 MONTH
PRODUCTION
DELAY
0 %

8. BENIFITS OF DFMA
THERE IS A MUCH BETTEER OPPORTUNITY TO MEET PREDICTED COST SCHEDULE AND QUALITY TARGETS WHEN THE MANUFACURING PROCESS DATA IS CAPTURED EARLY

9. BENEFITS OF DFMA (CONTD.)
F 18 E/F HAS 42% FEWER PARTS THAN C/D EVEN THOUGH IT IS 25% LARGER
REDUCED
-PRODUCTION COSTS
-DEFECTS
-REWORK
BY APPLYING DFMA BDI SOFTWARE & SOURCES OF VARIATION IN THE PROCESS

10. BENEFITS OF DFMA ( CONTD.)
TOMOHAWK CRUISE MISSILE
STRATEGIC TACTICAL
PARTS
FASTENERS
CIRCUIT CARDS
CONNECTORS
ASSEMBLY/ TEST
HOURS
UNIT PRODUCTION
COST $1000, $500,000

11. ASSEMBLYTIME FOR
BALL CAGE DEVICE
REDUCED TO 15SEC
FROM 130 SEC.
8 SCREWS TO NO
SCREWS
DFMA METHOD
OF ELIMINATING
FASTENERS
ASSEMBLY
OPERATIONS
FROM 83 TO 54
TOTAL ASSY.
TIME 592SEC.
TO 277 SEC.

12. RIBBON BASEPLATE
DIABLO PRINTER
OLD DESIGN 77 PARTS

13. NEW DESIGN
36 PARTS

16. COMPARISON OF ORIGINAL NEW DESIGNS OF RETICLE ASSY.
ORIGINAL DESIGN REDESIGN IMPROVEMENT%
ASSY. TIME HRS
NO. OF DIFF. PARTS
TOTAL NO. OF PARTS
METAL FABN. TIME HRS
WEIGHT LBS

17. ORIGINAL
OPTION 1
PILOTS INSTRUMENT
PANEL
LONG BOW APACHE
AH-64D HELICOPTER
BOEING COMPANY
OPTION 2

18. PILOT’S INSTRUMENT PANEL
ORIGINAL PANEL NEW PANEL
( OPTION 1 )
PARTS COUNT
FABRICATION TIME HRS
ASSY./INSTALLATION TIME HRS / /153
TOTAL TIME HRS
WEIGHT KG
COST $

19. Advantages of DFMA Typical results of DFMA application
Results of 88 published case studies
Decreases
51% parts count reduction
37% parts cost
50% time to market
64% in assembly time
57% in manufacturing assembly time
58% in assembly operations
69% in separate fasteners
68% in assembly defects
57% in service calls
68% in improvement in quality and reliability

20. Benefits of DFMA
Shorter developmental schedules and reduced cycle times.
Better first article quality
Development of robust product designs
Easier transition of designs to production
Better supplier product integration
More effective risk management

21. McDonnel Douglas experience
Reduce number of parts and fasteners used on aircraft
It means fewer opportunities for defects
For each fastener there is the chance that the hole will be drilled in the wrong place or be the wrong size
By reducing the number of fasteners – numbers of defects reduced, therefore, produce a higher quality product
Weight is critical. Fuel costs approximately $50,000 per pound of aircraft weight over 6000 hrs of the life of the aircraft
There are on the FA-18 CD fasteners
In previous models several parts were made of sheet metal because machined parts were unable to reach minimum gage limits
With high speed machining – thinner gauge limits have become possible

22. ACCELERATION SENSING ASSEMBLY
OPTION-I
OPTION-II

23. COMARISON TABLE ASA OPTIONS15 25
NUMBER OF FABRICATED PARTS
8.3 Hours
18.1 Hours
MACHINING TIME
YES NO
EMI GASKET PROVISION
254 x 117 x 78 mm
254 x 117 x 86 mm
SIZE
1.72 Kg
1.92 Kg
MEASURED WEIGHT (W/O ELECTRONICS) Rs Rs
MACHINING COST
1.90 Kg
± 2.7 MINUTES
± 3.5 MINUTES
250 Hz
OPTION - I
548 Hz
NATURAL FREQUENCY
1.80 Kg
ESTIMATED WEIGHT (W/O ELECTRONICS)
± 1.5 MINUTES
MEASURED ACCURACY
ESTIMATED ACCURACY
OPTION - II
PARAMETER

24. DFMA IN WW II WORLD WAR II EXPERIENCE:
US AVIATION INDUSTRY GREWW TEN FOLD
P-51 MUSTANG FIGHTER
- TO FACILITATE EASE OF MANUFACTURE
STABILISERS FINS WINGTIPS SQUARED OFF
- FUSELAGE – THREE SECTIONS- COMPLETE
PLUMBINGS, CABLE DISCONNECTS TO
FACILITATE ASSEMBLY AND DISASSEMBLY
FOR PACKING AND SHIPPING

25. DFMA IN WW II (CONTD.)
DFMA INFLUENCE ON DESIGN OF GRUMMAN F-6F HELLCAT
- USED FEWER COMPOUND CURVES IN
EXTERNAL DESIGN-UGLY- SEVERELY
CLIPPED WINGS
- PRODUCED IN LARGE QUANTITIES
- 32 KPH SLOWER THAN F4U HERITAGE 1980
DFMA INFLUENCE PERMITTED SHIPMENT BY BOAT OR LAND. OUT WING PANELS AND EVEN TAIL ASSEMBLIES REMOVED AND REPLACED AT THE DESTINATION POINT.

26. SPITFIRE VS. MESSERCHMIDST
IN 1940 Me’s OUTNUMBERED SPITFIRES THREE TO ONE. DESIGN ATTRIBUTABLE TO DFMA PHILOSOPHY. Me’s 4000 LABOUR HOURS TO SPITFIRE HOURS
AIR WAR HISTORIANS DESIGNATE SPITFIRES AS THE BETTER AIRCRAFT, THE LONG AND SUCCESSFUL CAREER OF ME 109’s DURING ARAB ISRAELI WAR 1948 DEMONSTRATED THAT MAJOR ATTENTION TO DFMA PRODUCES EFFECTIVE AIRCRAFT DESIGN EVEN AS EARLY AS 40’s

27. SPITFIRE VS. MESSERCHMIDST.
DESIGNED FOR AERODYANAMIC PERFORMANCE AND STRUCTURAL EFFICIENCY
BEAUTIFUL ELLIPTICAL WINGS CHOSEN FOR AERODYNAMIC PERFORMANCE WAS A NIGHTMARE TO MASS PRODUCE
DIFFICULT TO LEARN TO FLY, HIGHLY MANOEUVERABLE
WAS PRODUCED IN LARGE NUMBERS BECAME A MAJOR FORCE IN BATTLE OF BRITAIN AIR CAMPAIGN

28. SPITFIRE VS. MESSERCHMIDST
DESIGN WAS A DFMA CLASSIC
A MINIMUM OF COMPOUND CURVES USED IN THE EXTERIOR
RUDDER AND HORIZONTAL STABILISERS WERE SQUARED OFF FOR PRODUCTION EFFICIENCY
COCKPIT CANOPY WAS MADE ALMOST ENTIRELY OF FLAT GLASS
20 MM CANNON FIRED THROUGH A HOLLOW PROPELLER SHAFT TO OVERCOME COMPLEXITIESOF WING INSTALLATION AND TO ELIMINATE SIGHTING PARALLAX

29. INTEGRATED DESIGN AND MANUFACTURE
SIMULTANEOUSLY ADDRESS DESIGN FOR PERFORMANCE AND DESIGN FOR PRODUCTION
SYSTEMS ENGINEERING HAS ALIGNED DESIGN ENGINEERS IN REQUIREMENTS ANALYSIS, THE DEVELOPMENT OF FUNCTIONAL FLOWS etc.
INCLUDING THE ASPECTS OF MANUFACTURING PROCESS DEVELOPMENT IN THE SYSTEM ENGINEERING PROCESS HAS BEEN MORE DIFFICULT TO ACHIEVE

30. DESIGN HAS DIFFERENT MEANINGS
TO SOME IT IS AESTHETIC DESIGN
TO SOME IT MEANS ESTABLISHING THE BASIC PARAMETERS OF A SYSTEM
TO SOME IT IS DETIALING OF THE MATERIALS, SHAPES,AND TOLERANCE OF THE INDIVIDUAL PARTS OF THE PRODUCT
DFMA ADDRESSES THE LAST ASPECT OF PRODUCT DESIGNS

31. DFMA
THREE MAIN APPROACHES TO DESIGN FOR ASSEMBLY HAVE BEEN DEVELOPED AND USED Viz.:
DESIGN HEURISTICS
DESIGN RATINGS
DESIGN REVISION

32. DESIGN HEURISTICS GENERAL SET OF RULES eg.:
MINIMIZE THE NUMBER OF PARTS & ASSEMBLY DIRECTIONS
AVOID PARTS THAT SHINGLE TANGLE etc.
HEURISTICS CAN BE APPLIED TO A DESIGNER’S THINKING PRIOR TO ACTUAL PRODUCT DEVELOPMENT OR ONCE AN ASSEMBLY IS COMPLETE
USED TO SIMPLIFY PRODUCT

33. DESIGN RATING PROVIDE RATINGS FOR COMPONENTS AS WELL AS OVERALL DESIGN
ASSEMBLY RATINGS CAN BE CALCULATED
BDI HAS THEORETICAL HANDLING AND MATING RATINGS
OTHER DFA RATING METHODS PROVIDE DIFFERENT SCHEMES

34. DESIGN REVISION METHOD
COMBINATION OF HEURISTICS AND RATING METHOD eg. BDI
BDI COMBINES A COMPONENT RATING SCHEME WITH AN ASSEMBLY TIME AND COST ESTIMATION METRIC AS WELL AS SPECIFIC RULES IN AN ORDERED SEQUENCE FOR DECIDING HOW TO REVISE A DESIGN. THIS HAS ENABLED PRODUCT DESINERS IN MINIMISING ASSEMBLY SIMPLICITY

35. DFMA METHODOLOGY
WALKING THROUGH A CONCEPTUAL OR EXISTING DESIGN IN A VERY SPECIFIC PROCEDURE THROUGH OUT
THE PROCEDURE FOLLOWED AND THE DATA BASE SYSTEM ALLOWS A DESIGN ENGINEER OR CROSSFUNCTIONAL TEAM TO ANALYSE AND RATE PRODUCT DESIGNS FOR EASE OF ASSEMBLY, DESIGN EFFICIENCY AS WELL AS PREDICT PRODUCT ASSEMBLY AND MANUFACTURING COST

36. DFMA METHODOLOGY(CONTD.)
CAD RESULTED IN POWERFUL QUANTITATIVE OR ANALYTICAL TOOLS, PROVIDED BASIS FOR JUDGING A DESIGNER’S PERFORMANCE. DFMA HAS GIVEN MANUFACTURING ENGINEERS SUCH A TOOL.
DFMA IS ATTEMPTING TO FORESEE AT THE PRODUCT CONCEPTUAL DESIGN STAGE , WHAT MANUFACTURING ASSEMBLY AND QUALITY PROBLEMS WILL BE TO ARRIVE AT A BETTER PRODUCT

37. DFMA tools
Are tools for DFM & DFA

38. ENSURE PROCESS CONFORMANCE OPTIMIZE PRODUCT FUNCTION
DFM TOOLS
DFM ACTIVITY
OPTIMIZE
CONCEPT
SIMPLIFY
ENSURE PROCESS CONFORMANCE
OPTIMIZE PRODUCT FUNCTION
DFM TOOLS
DESIGN AXIOMS
DFM GUIDELINES
DESIGN FOR ASSY. METHOD
TAGUCHI METHOD
MFG. PROCESS DESIGN RULES
DESIGNERS TOOLKIT
COMPUTER AIDED DFM
GROUP TECHNOLOGY
FMEA
VALUE ANALYSIS

40. DFM METHODOLOGY COMPARISON (CONTD)
KEY TO ADVANTAGES
NARROW RANGE OF POSSIBILITIES
RESULTS IN INHERENT ROBUSTNESS
READY REFERENCE TO BEST
PRACTICES
EMPHASISES EFFECTS OF
VARIATIONS
HELPS IDENTIFY AND PRIORITIZE
CORRECTIVE ACTION
PROVIDES BOTH GUIDANCE AND
EVALUATION
CAN SHORTEN DESIGN /TOOLING
CYCLE
CAN REDUCE TOOLING AND
FIXTURING COST
KEY TO DISADVANTAGES
A. INTERPRETATION NOT ALWAYS SIMPLE
B REQUIRES “BUY IN” ON PART OF USER
C. EXCEPTIONS ARE NOT INDICATED
D. RATES ONLY EASE OF ASSY.DOES NOT
ADDRESS PART HANDLING OR OTHER
RELATED MFG. PARAMETERS
E. DEVELOPMENT REQUIRES INPUT FROM
EXPERIENCED EXPERTS FAMILIAR WITH
SPECIFIC PROCESS CAPABILITIES AND
NEEDS
F. TO BE USED ON A REGULAR BASIS
IMPLEMENTATION MUST BE USER
FRIENDLY
G. MUST BE DEVELOPED AND/OR
CUSTOMISED FOR EACH SPECIFIC
APPLICATION
H. OFTEN REQUIRES DIFFICULT TO OBTAIN
INFORMATION
KEY TO APPLICATIONS
MECHANICAL AND ELECTROMECHANICAL DEVICES AND ASSEMBLIES
ELECTRONIC DEVICES AND SYSTEM
MANUFACTURING AND OTHER PROCESSES
SOFTWARE INSTRUMENTATION AND CONTROL SYSTEM INTEGRATION
MATERIAL TRANSFORMATION PROCESSES
SPECIFIED AND OR UNIQUE MANUFACTURING FACILITIES SUCH AS
FLEXIBLE ASSEMBLY SYSTEMS

41. DFMA application areas
DFMA has been applied successfully to
Structural design
System design
Landing gear system
Flight controls
Electrical, electronic hydraulic systems
Environment controls

42. COST AND EASE OF MODIFICATIONS

43. BENIFITS OF IMPROVED ASSY.
MANUAL DESIGN ASSEMBLY EFFICIENCY (%)
( DFA INDEX )
IMPROVED ASSEMBLY DESIGN EFFICIENCY RESULTS IN INCREASED RELIABILITY

44. When to apply DFMA
WHEN CONCEPTUAL LAYOUTS ARE BEING MADE. THEN DESIGNER ENVISIONS AN ASSEMBLY EASY TO INSTALL THAT
REQUIRES MINIMUM NUMBER OF PARTS TO PERFORM THE REQUIREMENTS PREVIOUSLY ESTABLISHED
WHEN ASSEMBLY LAYOUTS ARE BEING MADE. DESIGNER IMPLEMENTS OPTIMISATION TO EASE OF MANUFACTURING , RELIABILITY AND MAINTAINABILITY

45. Who are using DFMA Over 400 companies and institutions
Aerospace companies
Allied signal
Hughes Aircraft
McDonnell Douglas Corpn.
Have implemented DFMA philosophy throughout
their product line
Automotive industries
Medical electronic equipment
PC – industry and others

46. DFMA Team Multidisciplinary teams Design engineers
Manufacturing engineers
Shop floor mechanics
Suppliers reps
Specialist in product support
Maintainability
Reliability

47. DFMA
BDI software
Is used by manufacturing team members to estimate and predict the savings that can be obtained.
Data are entered system does its analysis in different areas.
A complete listing of all the activities required to perform the assembly including
It provides complete overview of the tasks to be performed

48. MINIMUM MANUFACTURING DESIGN FOR MANUFACTURE
DFMA TECHNIQUE
DESIGN CONCEPT
SUGGESTIONS FOR
SIMPLIFICATION FOR
PRODUCT STRUCTURE
DESIGN FOR ASSEMBLY
( DFA )
SELECCCTION OF
MATERIALS AND
PROCESSES AND EAZRLY
COST ESTIMATES
SUGGESTIONS FOR
MORE ECONOMIC
MATERIALS AND
PROCESSES
BEST DESIGN CONCEPT
DETAIL DESIGN FOR
MINIMUM MANUFACTURING
COST
DESIGN FOR MANUFACTURE
( DFM )
PROTOTYPE
PRODUCTION

49. BDI software
It does an assembly analysis profile on a standard format where it theorizes the number of tasks to be performed, fasteners required, connectors to be installed, candidates for elimination, acquisition of items not in reach or in stock, requisition of tools not in hand, standard operations, library of operations and recommendations.
All these activities are numbered and plotted. It automatically provides suggestions for improvement.
System provides suggestions for design and indicating every task with its time saving and its percentage reduction. It indicates specific instructions to perform the related tasks in order to obtain the suggested savings.
It also lists design for assembly analysis totals all parameters used for analysis such as total assembly time, totally assembly cost, total assembly weight, number of parts, sub assemblies theoretical minimum numbers of parts or unanalysed sub assemblies and the hourly labour rate.
All suggestions and comments included in the computer generated tables are automatically provided to aid the designers and manufacturing engineers to obtain a better view of the job

50. Questions asked in DFMA about each part in a product design
Does the part move with respect to other parts already assembled
Must the part be made from a different material or isolated from all other parts already assembled
These questions lead the reviewers to re-evaluate each part and process that has been specified
If a part does not meet any of these criteria – it is a candidate for elimination or consolidation with another part

55. Results of Design for Assembly (DFA) Analysis for the Motor Drive Assembly Redesign

57. TYPICAL FUNCTIONAL FLOW
CHARGE STORAGE
CAPACITOR
RECEIVE PULSE
INITIAE SIGNAL
DISCHARGE CAPACITOR
THROUGH LASER DIODE 1
CREATE LASER
PULSE ENERGY.
CREATE LASER
PULSE SHAPE
TRANSMIT PULSE
THROUGH LENS

58. TYPICAL PROCESS FLOW P 1.1 PRODUCE ACTIVE TRANSMITTER P 1.2
RECIEVER
P 1.3
PRODUCE PASSIVE
RECEIVER
AND
P 1.6
ASSEMBLE INTO
UPPER HOUSING
ASSEMBLY
P 1.7
PRODUCE LOWER
HOUSING ASSEMBLY
AND
P 1.4
PRODUCE FLEX.
ASSEMBLIES
SEE NEXT SLIDE
P 1.5
PRODUCE PWB
ASSEMBLIES

59. TYPICAL PROCESS FLOW (CONTD)
WIRE BOND
CODER
P 1.3.1
CODER
ATTACH
P 1.3.2
CLEAN BOND
PADS
P 1.3.4
PICK AND PLACE
PbSe
INTERCONNECT
STANDOFF
P 1.3.2
CLEAN BOND PADS
P 1.3.6
INSPECT
P 1.3.5
WIRE BOND
PbSe

62. ACTIVITIES TO ACHIEVE MFG. KNOWLEDGE Contd..
IDENTIFY KEY SYSTEM CHARECTERISTICS AND CRITICAL MANUFACTURING PROCESSES
DETERMINE PROCESS IS IN CONTROL AND CAPABLE
CONDUCT FMEA
SET RELIABILITY GROWTH PLAN AND GOALS
CONDUCT RELIABILITY GROWTH TESTING
CONDUCT REVIEW TO BEGIN PRODUCTION
Contd..

63. BEST APPROACH TO PRODUCT DEVELOPMENT
SYSTEM
INTEGRATION & DEMONSTRATION
TECHNOLOGY DEVELOPMENT
PRODUCTION
KP3
KP1
KP2
TECHNOLOGY MATURITY
DESIGN MATURITY
PRODUCTION MATURITY

64. CONCLUSION
THE NEED FOR DFMA DURING EARLY STAGES OF PRODUCT DEVELOPMENT IS SEEN
TWO METHODS Viz. BDI AND FMECA APPROACHES APPEAR TO BE YIELDING EXCELLENT RESULTS.
A COMBINATION OF THE TWO IS LIKELY TO SERVE OUR PURPOSE BOTH IN MECHANICAL AND ELECTRONIC PRODUCTS

65. ACTIVITIES TO ACHIEVE STABLE DESIGN KNOWLEDGE
LIMIT DESIGN CHALLENGE
DEMONSTRATE DESIGN MEETS REQUIREMENTS
COMPLETE CRITICAL DESIGN REVIEWS
STAKE HOLDERS AGREE DRAWINGS COMPLETE AND PRODUCIBLE
REVIEW TO BEGIN INITIAL MANUFACTURING

66. PROCESS CAPABILITY INDEX & PROBABILITY OF A DEFECTIVE PART
MFG. PROCESS CAPABILITY (Cpk) ASSOCIATED DEFECT RATE
1 IN 22 PARTS PRODUCED
Cpk .67 ( NOT CAPABLE)
Cpk 1.0 ( MARGINALLY CAPABLE )
1 IN 370 PARTS PRODUCED
Cpk ( INDUSTRY STD.)
1 IN PARTS PRODUCED
Cpk 2.0 ( INDUSTRY GROWTH
GOAL)
1 IN 500,000,000 PARTS PRODUCED

67. ACTIVITIES TO ACHIEVE MFG. KNOWLEDGE
IDENTIFY KEY SYSTEM CHARECTERISTICS AND CRITICAL MFG. PROCESSES
DETERMINE PROCESSES IN CONTROL AND CAPABLE
CONDUCT FAILURE MODE AND EFFECTS ANALYSIS
SET RELIABILTY GROWTH PLAN AND GOALS
CONDUCT RELIABILITY GROWTH TESTING
REVIEW TO BEGIN PRODUCTION

68. EXAMPLES OF PROTOTYPES USED
PRODUCT PRODUCT PRODUCTION
INTEGRATION DEMONSTRATION
ENGG. PROTOS.
VIRTUAL OR
PHYSICAL
PRODUCTION
REPRESENTATIVE
PROTOTYPES
PROTOTYPE
INITIAL PRODUCTS
PURPOSE
DEMONSTRATE
FORM FIT
FUNCTION AND
A STABLE DESIGN
DEMONSTRATE
PRODUCT IS
CAPABLE RELIABLE
AND MFG. PROCESSES
IN CONTROL
DEMONSTRATE
READY FOR FULL
SCALE PRODUCTION
MFG. FIRST SET OF
PRODUCTION TOOLING
PRODUCTION ALL
RATE TOOLING
ENGINEERING
BUILD
ENVIRONMENT

70. Advantages of DFMA Ford $ 1.2 billion in ’87 using DFA alone
GM 30-60% on certain projects in ’89
MD-11 cargo liner savings per aircraft $ 86,000, a bulkhead – cost saving $4,000
McDonnel Douglas has ranged 36-96% parts count reduction on several of its aircraft component assemblies
FA-18 CD bay shelf design savings
84% in number of parts
73% in cost
11% in weight
89% in assembly time

71. WHAT IS DFMA (CONTD.)
DFMA ENCOURAGES CONCURRENT ENGINEERING DURING PRODUCT DESIGN SO THAT PRODUCT QUALITIES RESIDE WITH BOTH THE DESINERS AND OTHER MEMBERS OF THE PRODUCTION TEAM
IT IS A COMMUNICATION TOOL FOR THE TEAM
IT IS A BENCH MARKING TOOL
IT DEFINES THE DESIGN AND MANUFACTURING CAPABILITIES OF SELF AND COMPETITOR

72. WHAT IS DFMA (CONTD.)
IT PROVIDES A NON-THREATENING WAY TO GET PEOPLE TALKING ABOUT A DESIGN WITHOUT FEELING LIKE OTHERS ARE ENCROACHING ON THEIR TERRITORY
EINSTEIN SAID “ THE BEST DESIGN IS THE SIMPLEST ONE THAT WORKS “. DFMA PROVIDES THE CHEAPEST WAY TO THAT GOAL

73. WHAT IS DFMA DFMA IS AN EXACTING DESIGN REVIEW METHOD IT IDENTIFIES:
-OPTIMAL PART DESIGN
-MATERIAL CHOICE
-ASSEMBLY AND FABRICATION OPERATIONS TO PRODUCE AN EFFICIENT AND COST EFFECTIVE PRODUCT
IT REVEALS THAT INITIAL IDEAS MAY NOT BE THE MOST EFFECTIVE (CONTD.)