The Design for Serviceability Workshop covers practical knowledge to apply DFS

DESIGN  FOR  SERVICEABILITY  WORKSHOP

DRM Associates

© 2008 DRM Associates

DRM Associates
New Product Development Training
Training Experience
DFM Consulting
PD Toolkit (DFA Software)
Mistake-Proofing By Design Workshop
Design for the Life Cycle
Design for Manufacturability Paper
Design for Assembly Guidelines
Design for Manufacturability Guidelines
Product Development Forum
NPD Body of Knowledge

This three-day, practical, hands-on workshop covers the principles of design for serviceability and maintainability illustrating these principles with numerous examples of good and bad application examples. The workshop includes exercises to reinforce understanding of principles. The final exercise uses one or more of your company's products to analyze its serviceability and identify changes to improve the serviceability of the design.

1. INTRODUCTION TO DESIGN FOR SERVICEABILITY (DFS)

  • Introduction to Design for Serviceability
  • The Five Service Process Drivers as a Framework for Analysis
  • Determining Service Requirements - A Basis for Planning
  • Developing a Service Strategy
  • Considering Levels of Repair Strategies
  • Identifying Serviceable Items and Maintenance Procedures
  • Design for Serviceability Objectives
    • Reducing Service Requirements and Frequency
    • Facilitating Diagnosis
    • Minimizing the Time and Effort to Disassemble, Repair/ Replace, and Reassemble the Product as Part of the Service Process
    • Reducing Costs of Service Parts

2. DESIGN FOR RELIABILITY AND DURABILITY

  • Design for Reliability
  • Tools to Analyze and Improve Reliability During Development
  • Reliability Prediction
  • Failure Modes and Effects Analysis (FMEA)
  • Failure Reporting and Corrective Action System (FRACAS)
  • Design Strategies and Techniques to Improve Reliability
  • Design for Durability
  • Design Strategies and Techniques to Improve Durability

3. DESIGN FOR SERVICEABILITY OVER-ARCHING PRINCIPLES

  • Three Overarching Principles - Simplification, Standardization and Mistake-Proofing
  • Simplification Elements
    • Product Architecture
    • Modular Design
    • Interconnections
    • Assembly Design & Minimum of Parts
  • Criteria for Minimum Parts
  • Minimize Parts Exercise
  • Standardization - Minimize Part Variety
  • Standardization - Minimize Hand Tools
  • Standardization Approach and Method
  • Mistake-Proof Assembly (Poke Yoke)
  • The Six Mistake-Proofing Principles
    • Elimination
    • Replacement
    • Prevention
    • Facilitation
    • Detection
    • Mitigation
    • Examples of the Six Mistake-Proofing Principles
  • Mistake-Proofing Exercise - Identify Mistake-Proofing Opportunities

4. DESIGN FOR SERVICEABILITY PROCESS AND PRINCIPLES

  • Design for Serviceability Process
  • Principles Organized by the Service Process Step
  • Diagnosibility - Principles, Approaches and Human Factors Considerations
  • Consideration of Service Preparation Steps - Instructions, Marking and Labeling, Hand Tools, & Other Factors
  • Accessability and Ergonomics
  • Factors to Consider in Designing for Safe Serviceability
  • Minimize Disassembly Steps to Access Replaceable/Repairable Items
  • Disassembly Considerations
    • Unfastening: Fastening and Attachment Methods and Considerations
      • Threaded Fastener Considerations & Guidelines
      • Integral Attachment (Snap-Fit Assembly) Guidelines
    • Interconnections: Disconnection and Removal
    • Minimize Weight and Handling
    • Minimize Disassembly and Assembly Motions
    • Design for Minimum and Common Service Tools
    • Part Robustness and Handling
    • Design for Ease of Disassembly and Removal
  • Repair and Replacement Considerations
    • Replacement Standards
    • Service Parts
    • Cleaning and Refurbishment
  • Reassembly Considerations
    • Design for Ease of Reassembly
    • Part or Module Handling and Orientation
    • Part or Module Insertion and Location
    • Self-Locating and Self-Fastening Features
    • Reconnection Considerations
    • Avoid Calibration and Adjustments
  • Service Model Implications
  • Case Studies and Benefits
  • Design for Reassembly Exercise

5. DFS PROCESS AND METRICS

  • DFS Process Steps
  • Early Service Involvement
  • Advance Quality Planning (AQP)
  • Developing and Using Serviceability Design Guidelines and Checklists
  • Conducting Design Reviews to Address DFS
  • DFS Evaluation - Analyzing Prototypes
  • Performance Measurement & Metrics

6. SUMMARY

  • 8 Steps to DFS
  • Key Success Factors
  • Sources of Further Information
  • Questions and Discussion

7. DFS ANALYSIS OF COMPANY ITEM(S)

  • Exercise Objectives
  • Analysis Methodology 
  • DFS Team Analysis Exercise
  • Review of Team Findings  
  • Questions and Discussion

©2004 DRM Associates, email: kcrow@aol.com