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 at least one day on-site prior to the workshop to customize it to your products and processes.

This workshop is conducted onsite for individual clients and customized to the nature of the client’s products and production processes with client examples to illustrate the various DFM/A principles.

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 Holes
    • 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