Design for Manufacturability/Assembly Workshop

This practical, hands-on workshop is three days in length. It includes over 240 examples of good and bad design for manufacturability and assembly practices. Exercises are used throughout to reinforce understanding of DFM/A principles.┬áThe workshop concludes with an exercise to analyze your company’s assemblies to introduce a practical DFM/A analysis methodology. The workshop includes one day on-site prior to the workshop to customize it to your products and processes.

1. DESIGN FOR MANUFACTURABILITY/ ASSEMBLY (DFM/A)

  • DFM/A Introduction
  • Design Impact on Cost
  • DFM/A Fallacies vs. Reality

2. DESIGN FOR ASSEMBLY

  • Principles of Design for Assembly
  • Simplify Product Architecture
    • Modularity and Structure with Architecture
    • Partitioning, Collocation, and Orientation Effect on Interconnections
    • Modular Design vs. Integral Design
  • Simplicity – Minimize Part Count
  • Minimize Parts Exercise
  • Standardization – Minimize Part Variety
  • Standardization Approach and Method
  • Mistake-Proof Assembly – The Six Mistake-Proofing Principles and the Relative Benefit
    • Elimination Principle and Examples
    • Replacement Principle and Examples
    • Prevention Principle and Examples
    • Facilitation Principle and Examples
    • Detection Principle and Examples
    • Mitigation Principle and Examples
  • Mistake-Proofing Approach and Methodology
  • Mistake-Proofing Exercise – Identify Mistake-Proofing Opportunities
  • Assembly Process Framework
  • Design for Parts Feeding & Handling
  • Design for Part Orientation
    • Considering and Applying Symmetry vs. Asymmetry
    • Measuring Symmetry – Alpha, Beta and Combined Symmetry
  • Design for Location and Insertion
  • Minimize Flexible Parts
  • DFA Considerations with Gaskets, Interconnections, & Connectors
  • Axes of Assembly, Reorientation & Blind Assembly
  • Top Down, Uni-Axis Assembly
  • Self-Fixturing vs. Production Fixtures
  • Joining & Fastening Guidelines
    • Integral Attachment (Self-Fastening & Snap-Fit Assembly) Guidelines
    • Threaded Fastener Considerations & Guidelines
    • Adhesive Joining Guidelines
    • Welding Guidelines
    • Other Fastening Methods and Guidelines
  • Finishing, Adjustment & Calibration
  • DFA Considerations to Facilitate Test and Inspection
  • Applying DFA to Packaging – The Final Assembly Step
  • Case Studies and Benefits – Aerospace, Automotive, Electronics, Mechanical Machinery
  • Design for Assembly Analysis Exercise

2. DESIGN FOR AUTOMATED ASSEMBLY (optional module)

  • Production Considerations for Manual, Flexible Automation and Hard Automation
  • Cost / Benefit Analysis of Automation
  • Design for Feeding Guidelines
  • Feeding Systems & Orientation
  • Flexible Automation
    • Design for Robotic Assembly Guidelines
    • Design for Vision System Guidelines
    • Gripper Design Guidelines

3. DFM/A FOR ELECTRONICS (optional module)

  • Use of DFM/A Guidelines for Boards
  • Simplify the Assembly Process – Mixing Technology and Board Sides
  • Reduce Thermal Cycles
  • Board Size and Panelization Guidelines
  • PCB Layout Guidelines
    • Panel Considerations and Keep-Out Area
    • Tooling Hools
    • Fiducials
    • Through-Holes and Vias
    • Trace Width and Spacing
    • Pad Layout and Component Spacing
    • Test Point Access
  • Component Selection Guidelines
  • Avoid Manual Assembly
  • Other Component Considerations
  • DFM/A Assessment for Boards
  • Automated Design Rules Checking

4. DESIGN FOR MANUFACTURABILITY

  • DFM Framework
  • Material and Process Evaluation
  • Material and Process Evaluation Exercise
  • Raw Material Standardization
  • General DFM Guidelines
  • Machining Guidelines and Examples
  • Manufacturability Analysis Exercise
  • Sheet Metal and Stamping Guidelines and Examples
  • Injection Molding Guidelines and Examples
  • Casting Guidelines and Examples
  • Minimize Finishing Requirements

5. PROCESS CAPABILITY AND TOLERANCES

  • What is Process Capability
  • Variation and Specifications
  • Parameter and Tolerance Objectives
  • Statistical Process Capability
    • Normal Distribution
    • Capabilities Indices – Cp and Cpk
    • Capability Index Exercises
    • Six Sigma Capability and Defects per Million
  • Effect of Tolerances
  • Tolerance Analysis
    • Worst Case
    • Root Sum of Squares (RSS)
  • Tolerance Optimization

6. DFM/A AND THE DEVELOPMENT PROCESS

  • DFM/A Process Steps
    • During Concept Development Phase
    • During Design Phase
    • During Validation and Pilot Phase
    • During Production Launch Phase
  • Early Manufacturing Involvement
  • DFM/A Collaboration Tools and Methods
  • Role of Solids and Assembly Models in DFM/A Evaluation
  • How to Effectively Consider Design Alternatives to Address DFM/A Issues
  • Product Cost Models to Estimate Costs & Evaluate Design Alternatives
  • Early Supplier Involvement
  • Developing DFM/A Guidelines
  • Formal DFM/A Analysis & Assessment
  • DFM/A Manual and Software Tools
  • Conducting Design Reviews to Address DFM/A
  • Capturing Issues with Build Reports
  • Closing the Loop with a Final Production Review
  • DFM/A Performance Measurement & Metrics

7. SUMMARY

  • 10 Steps to DFM/A
  • DFM/A Survey Results
  • Sources of Further Information
  • Questions and Discussion

8. DFM/A ANALYSIS OF COMPANY PRODUCT OR ASSEMBLY

  • Transitioning from the Workshop to Product Design – Exercise Objectives
  • Introduction of Analysis Methodology and DFM/A Worksheet
  • Team Analysis of Company Products or Assemblies
  • Team Consideration of DFM/A Improvements
  • Team Reporting Out and Exercise Discussion
  • Concluding Questions and Discussion