Design Proposal ⇒ Check List ⇒ Record Note in AP List ⇒ Use Grading Matrix ⇒ Summary Report
A sound DFM have a very crucial role in determining the product cost as it was calculated that 70% cost of the product was determined by design phase decisions like material selection, process mapping, and product assembly whereas equipment’s and tools selection, process planning responsible for 20% cost total cost of the product. There are certain below Basic principles and guidelines for product DFM and DFM FA (Final Assembly).
- Try to minimize no of components during the bill of material (BOM) Creations.
- Try your best to use maximum standard and commercially available components in the marketplace.
- Use common parts numbers in the product manufacturing process to avoid multiple handling or fixture designing.
- Selection of existing parts so that is easy to assemble and minimize the process no of steps.
- Use modular design to easy for manufacturing activities like inspection, assembly, packaging, maintenance, redesigning etc.
- Minimize handling of product and try to Avoid separate fasteners.
- Try to Eliminate or reduce the Adjustments requirements
- Minimize assembly directions during manufacturing flow.
- Eliminate product features or process steps for that customer not willing to pay or having no value addition.
Required few sorts of inputs or information to start and workout sound DFM product design and development: –
- Product Sketches, drawings, layouts, product specifications, and design alternatives if any possible.
- A detailed description and understanding of Manufacturing and assembly processes applicable steps.
- Applicable Test and functional requirements of the product.
- Estimates of manufacturing costs, tentative production volumes, and ramp-up timing period.
The major Factors responsible for determining the cost of a product during manufacturing Process adaptation
- Components Costs as per BOM (Raw material cost of the product)
- Component purchased from different vendors and supplier.
- Dedicated Customized component developments by suppliers according to the product design specifications requirements.
- Assembly Costs of Product (labor, equipment, tooling, Jig fixtures, space etc.)
- Overhead Costs involved (all other product related costs)
- Support Costs (material handling, quality assurance, purchasing, training, shipping, receiving, facilities, etc.)
- Indirect cost contributors (not directly linked to a particular product but must be paid for to be in business expenses)
Redesign all costly parts with the same specifications and performance to reduce the cost of the product. work closely with CFT team members to focus on optimization of complicated and high-cost operations on regular basis.To Reduce the no of steps in a manufacturing process and eliminate over processing steps. Better options to value stream mapping and process flow charts to optimize the process.
Thus the Design for manufacturing (DFM) is a very effective and helpful tool to quantify the manufacturing and assembly difficulties, deviations and leads to the helpful in product cost reduction, limiting the quality defects and minimizing the delivery time in the market to introduce.