Design for Manufacturing and Assembly (DFMA).pptx

Design for Manufacturing and Assembly (DFMA)
Design for Manufacturing and Assembly (DFMA) is an engineering approach that focuses on designing products in a way that simplifies both manufacturing and assembly processes. The goal is to reduce production costs, minimize waste, improve product quality, and shorten time-to-market.

1. Key Principles of DFMA
DFMA consists of two main components:

Design for Manufacturing (DFM): Focuses on designing parts to be easily and cost-effectively manufactured.
Design for Assembly (DFA): Focuses on simplifying the assembly process to reduce time and labor costs.
Principles of DFM
Minimize the Number of Parts: Reduce complexity by integrating functions into fewer parts.
Use Standardized Components: Avoid custom parts when standard parts are available.
Design for Efficient Material Use: Optimize raw material usage to minimize waste.
Select Cost-Effective Manufacturing Processes: Choose processes that balance cost, quality, and production speed.

1. SHARAD INSTITUTE OF TECHNOLOGY, COLLEGE OF ENGINEERING, YADRAV- ICHALKARANJI (Kolhapur) An ‘A’ Grade Institute Accredited by NAAC NBA Accredited Programmes Prepared by Mr. Ashish A. Desai Assistant Professor Mechanical Department Design for Manufacturing and Assembly (DFMA) Part -I

2. LEARNING OBJECTIVES To know the importance of Design for Manufacturing and Assembly To understand Principles of DFM  

3. LEARNING OUTCOMES able to explain the importance of Design for Manufacturing and assembly able to a ware about designing the components  

4. Internal Organization has the most over Price, Quality, & Cycle Time?

5. Design for Manufacturing and Assembly • Design for manufacturing (DFM) is design based on minimizing the cost of production and/or time to market for a product, while maintaining an appropriate level of quality. A primary strategy in DFM involves minimizing the number of parts in a product. •Design For Assembly (DFA) involves making attachment directions and methods simpler.

6. Sequence of Analysis

7. Difference between DFA and DFM

8. DFMA Study

9. Design for Manufacturing

10. Sketches, drawings, product specifications, and design alternatives. A detailed understanding of production and assembly processes Estimates of manufacturing costs, production volumes, and ramp-up timing. In connection with look at process, design, Material, and Environment, Testing etc. Gathering DFM Information

11. Process DFM took into consideration the quantity of parts being made, the material being used, the complexity of the surfaces, the tolerances required and whether there were secondary processes required

12. Design Design is essential. The actual drawing of the part or product has to conform to good manufacturing

13. MATERIAL

14. ENVIRONMENT   The part/product must be designed to withstand the environment it will be subjected to. All the form in the world won’t matter if the part can’t function properly under its normal operating conditions.

15. Testing All products must comply with safety and quality standards. Sometimes these are industry standards, others are third-party standards and some are internal, company-specific standards

16. Principles of DFM

17. Major DFM Objective

18. 1.Estimate the cost of Manufacturing

19. 1.Estimate the cost of Manufacturing

20. 1.Estimate the cost of Manufacturing

21. Understand the Process Constraints and Cost Drivers Redesign Components to Eliminate Processing Steps Choose the Appropriate Economic Scale for the Part Process Standardize Components and Processes Adhere to “Black Box” Component Procurement 2.Reduce the Cost of Components

22. Redesign costly parts with the same performance while avoiding high manufacturing costs. E.g. EDM –for close tolerances Work closely with design engineers—raise awareness of difficult operations and high costs. Understand the Process Constraints and Cost Drivers

23. Redesign Components to Eliminate Processing Steps Reduce the number of steps of the production process Will usually result in reduce costs Eliminate unnecessary steps. Use substitution steps, where applicable. Analysis Tool – Process Flow Chart and Value Stream Mapping Avoid the paint to aluminum parts, A net shape part formulated by molding, forging ,extrusion etc.

24. Redesign Components to Eliminate Processing Steps Example:- Redesign

25. 3.Reduce cost of Assembly Part is inserted from the top of the assembly Part is self-aligning Part does not need to be oriented Part requires only one hand for assembly Part requires no tools Part is assembled in a single, linear motion Part is secured immediately upon insertion

26. Minimize Systemic Complexity (inputs, outputs, and transforming processes) Use smart design decisions Error Proofing ( PokaYoke ) Anticipate possible failure modes Take appropriate corrective actions in the early stages Use color coding to easily identify similar looking, but different parts 4.Reduce the Costs of Supporting Production

27. 5. Consider the Impact of DFM Decisions on Other Factors Development Time Development Cost Product Quality External Factors -Component reuse -Life cycle costs

28. Guidelines for DFM

29. Thank You