Design for Manufacturability BtP ti P lBest Practices Panelmydlc.com/pmi-mn/PRES/2010D10_DesignForManufctr_Panel.pdf · Design for Manufacturability BtP ti P lBest Practices Panel

Design for Manufacturability Design for Manufacturability B t P ti P lB t P ti P lBest Practices PanelBest Practices Panel

ModeratorModeratorModeratorModeratorWayne Wayne LindholmLindholm

PanelistsPanelistsKim JohnsonKim Johnson

KyleKyle BjorkBjorkKyle Kyle BjorkBjorkGreg Greg BurneskeBurneskeRich WaltersRich WaltersRich WaltersRich Walters

DFM DefinedDFM DefinedDesign for manufacturability is the process of proactively

designing products to . . .

(1) Optimize all the manufacturing functions: plan, design, fabricate, assemble, test, procure, ship, g , , , , p , p,deliver, and service.

(2) Assure the best: cost, quality, reliability, regulatory li f t ti t k t d tcompliance, safety, time-to-market, and customer

satisfaction.

B k "D i F M f bili d C E i i “ C i h © 2010 b D id M A dBook: "Design For Manufacturability and Concurrent Engineering“ Copyright © 2010 by David M. Anderson

DFM + ConcurrencyDFM + ConcurrencyConcurrency is the practice of concurrently developing

products and their manufacturing processes.

• If existing processes are to be utilized, then the product must be design for these processes.p g p

• If new processes are utilized, then the product andthe process must be developed concurrentlyp p y

Book: "Design For Manufacturability and Concurrent Engineering“ Copyright © 2010 by David M. Anderson

PMBOK PMBOK AlignmentAlignment•• Chapter 8 Project QualityChapter 8 Project Quality ManagementManagement•• Chapter 8, Project Quality Chapter 8, Project Quality ManagementManagement

–– 8.1 Quality Planning 8.1 Quality Planning –– Identifying which quality standards are Identifying which quality standards are relevant to the project and determining how to satisfy themrelevant to the project and determining how to satisfy themp j g yp j g y

–– 8.1.2 8.1.2 Tools & TechniquesTools & Techniques•• 1 Cost1 Cost--benefit analysisbenefit analysis.1 Cost.1 Cost benefit analysisbenefit analysis•• .2 Benchmarking.2 Benchmarking•• .3 Design of experiments.3 Design of experiments

4 C t f lit (COQ)4 C t f lit (COQ)•• .4 Cost of quality (COQ).4 Cost of quality (COQ)•• .5 Additional quality planning tools.5 Additional quality planning tools

–– Design for manufacturabilityDesign for manufacturability

PMBOK AlignmentPMBOK Alignment

PMI/PDMA Design For Manufacturability

DFM & Low Volume ProductionOctober 18, 2010

Today’s PresenterToday s Presenter• Bachelors of Science Degree in

M h i l E i i d f thMechanical Engineering degree from the University of Minnesota.

• 24 years of product design, sourcing,24 years of product design, sourcing, and manufacturing experience.

• 12 Years with TSI Incorporated.• 12 Years with Malco Products, Inc.• Currently work in the Malco Design &

Deliver Group Kyle BjorkDeliver Group. y j

Malco Products, Inc.a co oducts, cFounded 1950

160 Employee/Owners160 Employee/Owners

Malco ProductsMalco Products is a product business.

Hand tools andHand tools and accessories.

The Malco Design & Deliver Group is the brandGroup is the brand

name for our service business.

The MALCO DESIGN & DELIVER GROUP

Market Research

The MALCO DESIGN & DELIVER GROUP

ConceptualizationD iDesignEngineeringg ee gPrototypingDocumentationManufacturingManufacturing

Today’s Objectives1. Understand why low volume production

Today s Objectivesy p

is important.2. Discuss some of the key low volume

processes that are available.3. Look at how DFM has changed with low

volume productionvolume production.4. Discuss the role of Information

Technology in low volume production.gy p

Why Design for Low Volume?Why Design for Low Volume?• Specialty/niche products.p y p• Test marketing a new product.• Demand (in units) is small• Demand (in units) is small.• Customers require customized products.

What’s Low VolumeA few parts to

a few thousand parts… a few thousand parts.

Low Volume & DFMLow Volume & DFM• One of the keys to being successful

in designing low volume products is to understand and select the appropriate manufacturing processmanufacturing process.

• The process you select will impact how you design your partdesign your part.

• New and improved technologies are making low volume manufacturingmaking low volume manufacturing more viable.

• DFM guidelines are changing!DFM guidelines are changing!

Manufacturing ProcessesManufacturing Processes• Subtractive Processes

– Multiple operations take material away. – Machining, grinding, cutting.

• Net Shape Processes– Part is produced in one operation– Part is produced in one operation.– Molding, casting, stamping.

• Additive Processes• Additive Processes– Builds parts one layer at a time.– SLA, SLS, DMLS, FDM, 3D printing.S , S S, S, , 3 p t g

Additive ProcessesAdditive Processes• SLA (Stereo lithography Apparatus) ( g p y pp )• SLS (Selective Laser Sintering)

DMLS (Di t M t l L Si t i )• DMLS (Direct Metal Laser Sintering)• FDM (Fuse Deposition Modeling) ( use epos o ode g)• 3D Printing

Additive ProcessesAdditive Processes• Additive process were traditionally used for Rapid

Prototyping.• Equipment and materials are continuously

improvingimproving.• Additive processes are now being used for

production (Rapid Manufacturing or Direct Digitalproduction (Rapid Manufacturing or Direct Digital Manufacturing).

• SLA & SLS are better choices for production parts.

• Additive processes can be used to produce t litooling.

Advantages of Additive ProcessesAdvantages of Additive Processes• No tooling.• Quick.• Easy to make changes.y g• Easy to customize. • Can have zero-draft, undercuts, thick walls, , , ,

hollows, very complex geometry.• Can even combine multiple parts into one p p

part. • Can do things traditional process can’t!

Example SLS Tube ClampExample SLS Tube Clamp

Low Volume ProcessesLow Volume ProcessesAlternatives For Injection Moldingj g• Additive processes – i.e. SLA, SLS• Aluminum injection mold tooling• Aluminum injection mold tooling• Urethane castings

Can use additive processes to assist in building tooling– Can use additive processes to assist in building tooling.

Low Volume ProcessesLow Volume ProcessesAlternatives For Die Castingg• Sand casting• Investment casting• Investment casting

Casting patterns can be made from rapid prototyped parts.

Other Low Volume ProcessesOther Low Volume Processes

• Laser CuttingLaser Cutting

• Plasma Cutting

Water Jet Cutting• Water Jet Cutting

Other Low Volume ProcessesOther Low Volume Processes

• Laser EtchingLaser Etching

• Digital Pad Printing

Digital Printing• Digital Printing

Selecting The Right ProcessSelecting The Right Process• Evaluate product requirements.p q

• Consider your timeframe.y

• Look at the total costLook at the total cost.– Setup charges

Tooling cost– Tooling cost– Piece part cost

Lead Time– Lead-Time

Production Jigs/FixturesProduction Jigs/Fixtures• Low volume processes can also be used p

to create production jigs and fixtures.• Use existing CAD geometry from productUse existing CAD geometry from product

to quickly design jigs and fixtures.• Entire jig/fixture could be made from one• Entire jig/fixture could be made from one

part.Ver eas to adj st or replicate• Very easy to adjust or replicate.

Information TechnologyInformation Technology• Low volume production is a digital world.p g• Technology is critical to most low volume

processes.processes.• Consider both hardware and software.

Pl f fil t f i• Plan for file transfers, conversion, translation, and management.

• Consider all technology needs as soon as possible.

Low Volume Case Study #1Low Volume Case Study #1• Client had a product idea for an entirely p y

new market.• Wanted to be able to produce productsWanted to be able to produce products

in low volumes to help build the market.• Wanted to be able to ramp up in phases• Wanted to be able to ramp up in phases

as the market developed and volumes increasedincreased.

• Was willing to accept a higher cost for low volumeslow volumes.

Low Volume Case Study #1Low Volume Case Study #1

Solid SLS Handle Hollow SLS Handle

Final Handle Using Multiple Molded Parts

Low Volume Case Study #2Low Volume Case Study #2• Malco Products wanted to be able to

produce customized products and packaging in low volumes.p g g

• Packaging materials typically have high setup costs making low volume orderssetup costs making low volume orders prohibitively expensive.


Used a digital printing press Example of a printed sheetUsed a digital printing press to produce insert card images on 12” x 18” card stock

Example of a printed sheet with 6 insert cards.

stock.


Use a small rotary die Insert card is placed into aUse a small rotary die cutter to cut out insert cards.

Insert card is placed into a clamshell package and product is stapled to the outsideoutside.


Clamshell packaging and Digital printer can also beClamshell packaging and product can be modified with a small laser cutter/etcher

Digital printer can also be used to create custom labels.

cutter/etcher.

QUESTIONSQUESTIONS

For More Information Contact:For More Information Contact:

Kyle BjorkKyle BjorkChief Sales Engineer

The Malco Design & Deli er Gro pThe Malco Design & Deliver Group

13355 George Weber Drive Suite C13355 George Weber Drive, Suite CRogers, MN 55374

Toll Free [email protected]

www.MalcoD2group.Com

Bringing Innovative Solutions…On Board

5660 Technology Circle • Appleton, WI 54914 • [email protected] • www.teamsmt.com

SMT OverviewSMT Overview

Design and manufacturing of custom electronic productsDesign and manufacturing of custom electronic products

Spec-to-production or a la carte service

Solutions from one-off products to high volume productionSolutions from one off products to high volume production

No proprietary products

Customers own all design IPg

Simplicity and attention to detail – our keys to success!



Product Life Cycle CapabilitiesProduct Life Cycle Capabilities

RapidPrototype Solutions

“RPS”

ProductDevelopment

RPS

U.S.Manufacturingg

Product Support Center

OffshoreManufacturingSuppo t Ce te

Higher LevelAssembly

“HLA”

a u actu g


Bringing Innovative Solutions…On BoardBringing Innovative Solutions…On Board

SMT OverviewSMT Overview


Bringing Innovative Solutions…On BoardBringing Innovative Solutions…On Board

Markets/Industries ServedMarkets/Industries ServedMarkets/Industries ServedMarkets/Industries Served

Customer Mix5%

10%25%5%

45%10%

Medical Telecom Ind. Controls

Automotive Consumer Military



Electronics AssemblyElectronics Assembly 4 DFM Areas4 DFM AreasElectronics Assembly Electronics Assembly -- 4 DFM Areas4 DFM Areas

Design for manufacturability – printed circuit board substrate

Design for manufacturability – circuit board assembly

Design for assembly – completed product

Design for testability

Circuit board assembly

Complete product


Bringing Innovative Solutions…On Board Bringing Innovative Solutions…On Board

DFMDFM PCB SubstratePCB SubstrateDFM DFM –– PCB SubstratePCB Substrate

PCB fabrication is a 2-D photo-lithographic process

PCB is built in layersPCB is built in layers

Each layer has artwork etched




DFM rules are set by the PCBDFM rules are set by the PCB manufacturing process

Very rigid rules

Feature size

Trace widths

Spacing

Drill patterns

L t kLayer stack-ups

Standard thicknesses




DFM rules are set by the PCB manufacturing process

Standard panel sizes

Step and repeat utilization



DFMDFM PCB AssemblyPCB AssemblyDFM DFM –– PCB AssemblyPCB Assembly

Automated placement (pick & place)Automated placement (pick & place)

Eliminate hand placed parts

Minimize thru-hole (this is aMinimize thru hole (this is a different soldering process

Optimize placement patterns



DFMDFM PCB AssemblyPCB AssemblyDFM DFM –– PCB AssemblyPCB Assembly

Heat transfer for solderabilityHeat transfer for solderability

Assure solder reflow by achieving proper temperature

iover time

Minimize shadowing and eliminate heat sinks

Soldering process drives DPMO

DPMO = Defects Per Million Opportunities



DFADFA Complete ProductComplete ProductDFA DFA –– Complete ProductComplete Product

Minimize component countMinimize component count

Development of fixtures for repeatability and throughput

Design snap features

Eliminate wire harnesses

Design for testability

Connectors

Built-in Self-Test (BIST)

Programming and serialization



Design for TestDesign for TestDesign for TestDesign for Test

Electronic products get 100% functional test plus low level testing and inspection

b i d li i4 basic test modalities

AOI – Automated Optical Inspection

X rayX-ray

ICT - In-circuit Test

Functional TestFunctional Test



Design for TestDesign for Test AOIAOIDesign for Test Design for Test -- AOIAOI

AOI A d O i lAOI – Automated Optical Inspection

Missing components

Component markings

Limited solder inspection

No electrical test



Design for TestDesign for Test XX RayRayDesign for Test Design for Test –– XX--RayRay

X-ray

Inspection of hidden ld j isolder joints

Limited throughput –often used on audit basis

Reserved for most complex assemblies



Design for TestDesign for Test ICTICTDesign for Test Design for Test –– ICTICT

In-Circuit Test

Verifies component i ipresence, orientation,

function

High-speed, good g p gthroughput

Best bang-for-buck



Design for TestDesign for Test Functional TestFunctional TestDesign for Test Design for Test –– Functional TestFunctional Test

Functional Test

High-level functionality h kcheck

Programming

Does not catch low levelDoes not catch low-level manufacturing issues

Verifies user perspective



Design for TestDesign for TestDesign for TestDesign for Test

4 basic test modalities – No single test modality catches all problems



Design for TestDesign for Test

Test types are Additive – with the goal to achieve 100% coverage – no escapes

ICT 100% coverage(NO

achieve 100% coverage no escapes

In line AOI may only (NO Escapes)

In-line AOI may only catch 60% of defects

JTAG/Boundary ScanFunctional



Design for Test Design for Test -- DPMODPMO

Process DPMO 50

Boards/Job 500

Solder Joints/board 2,935

Components/board 419

Defect Opportunities/board 3,354

Defect Opportunities/Job 1,677,000

Defective Solder Joints/Job 83

Defective Boards/Job 83

Assume AOI/X-ray is 70% effective @ DPMO = 50; 25 escapes/job



Thank You!



Who We Are:Unlike design firms that make things beautiful and leave them to you to figure out how to make themUnlike design firms that make things beautiful and leave them to you to figure out how to make them work, we tackle the science first, finding the best way to bring the idea to life. We see so many different challenges from so many different industries that we’re constantly inventing new technologies or applying existing technologies to new categories. Our “science first” approach and broad view of the world means we get to solutions that others can’t.

Key beliefs and practices to improve Design for Manufacturing

Uncomplexification – The business• Really crushing the important things ... removing the others. Prioritize goals. • Just ask the end user/customer through professional design research. Find out what is

important Just because you have a process in house doesn't make it relevantimportant. Just because you have a process in house doesn t make it relevant.• Don’t let too much process approval stand in the way. Keep groups small, assign

responsibility and hold them accountable.

Integration – The environment and process• Teams of diverse/cross‐functional experts, cross‐industry experience/ p , y p• Innovate first based on goals, start with addressing problems to find the good ideas early as

possible – tooth brush example• Getting it done‐ iterative “learning” prototypes• Low cost, low risk ways to validate

Supplier Relations‐ The communication of capabilities•Pushing vendors to meet needs (communication) – make it smaller than a quarter•Holding the line for design intent (important details)•Selecting vendors based on specific capabilities, design to match the vendor's capabilities

Documents

Design for Manufacturability BtP ti P lBest Practices Panelmydlc.com/pmi-mn/PRES/2010D10_DesignForManufctr_Panel.pdf · Design for Manufacturability BtP ti P lBest Practices Panel