Design for Manufacturability

Raise engineer’s design skill level Improve quality of design

Improve quality of documentation Enable higher quality, more cost

effective manufacturing Produce products more easily

PRG/TBC 2

Simultaneous, Early Consideration Of All Design Goals & Constraints

Optimizes Efficiencies From Initial Concept Through Product Life.

Results In Lowest Total Cost & Shortest Time To Market.

PRG/TBC 3

Business Challenge

Elect. Design

Ind./Mech. Design

Software Dev.

Proj. Mgmt.

Bus. Process

Test Dev.

Proto Mfg. Packaging/ Logistics

Vol. Mfg.

Quality/ Reliability

Fulfillment/Repair

Finance Mktg/Sales

HR

Cust. Reqn’ts

Prod. Def.

Business Challenge

Lack of Technical Expertise: Internal resources often lack sufficient or appropriate technical expertise to support projects.

Project Management and Integration: Internal resources have limited bandwidth to manage multiple outside partners effectively.

Resource Availability: Internal resources are not always available in the timeframe required to meet project needs.

SpreadsheetsEmailsFaxes

Cha

nges

BOMs

New Part Requests

Engineering

?

Manufacturing

• Product Revisions?

• Current BOM?

• New Part Signoffs?

• Contract Manufacturers tied into change control?

Product is not what customer wants Costs are too high Product is not manufacturable or supportable Unable to achieve compliance (ISO, FDA, RoHS, etc.) Missed business plan targets

Product Design Costs 5% Of Total Product. Product Design Determines 70% Of Total. To Reduce Costs - Focus On Design. Allocate/Move Resources “Upstream”.

PRG/TBC 8

Product Design◦ Inventory cost impact◦ Engineering

documentation◦ Customer service costs◦ Quality risks◦ Material & direct labor◦ Administrative costs◦ Customer response

time◦ Capital equipment

costs

PRG/TBC 10

PRG/TBC 11

Launch

DEVELOPMENT STAGES

COST

Cost of changes multipliesBy 10 with each step

10 100 1000 10,000

Process Challenges

Guidelines for Assembly

Fundamental Considerations

PRG/TBC 12

American Airlines

◦ Fleet of 12 different aircraft = 11 x cost

Southwest

◦ Fleet of 737 aircraft = streamlined cost

PRG/TBC 14

REDESIGN FOR TITER PLATE ASSEMBLY Existing Design: Redesign: 33 piece part items 19 piece part items 98 pieces of hardware (Includes 34 rivets) 38 pieces of hardware Time estimate to install the additional 64 screws at 15 seconds per screw is 16 minutes. COMPONENTS DIS-ASSEMBLED FOR SIDE BY SIDE COMPARISON

EXISTING TITER COMPONENTS

PRG/TBC 15

REDESIGN FOR TITER PLATE ASSEMBLY

Detail 1: Qty 10 machined components with qty 4 standard bearings. Replaced with qty 2 machined components with qty 2 standard bearings.

PRG/TBC 16

REDESIGN FOR TITER PLATE ASSEMBLY Detail 4: Qty 1 machined component. Replaced with qty 1 simplified fabricated component.

Product Lifecycle Management (PLM)◦ Supports the extended enterprise

Customers, design, and supply partners◦ Integrates

People Processes Business systems and information

17

• A set of capabilities that enables an enterprise to:– Manage its products and related

services throughout the entire business lifecycle

Total Business Consulting Group 18

Manufacturing

Planning

Full Production

Service andSupport

Concept andPlanning

Design and Engineering

PLM provides a data platform for managing forward processing of data, AND recycling it back for subsequent products.

CAD/CAE

Web, Excel, Visio, etc.

PDM

cPDVisualization

SCM/SRM

CRM

ERP/MRP

What is Product Lifecycle Management (PLM)?

Traditional serialized product development process◦ When does the Mfg./Production Engineer see the

final design?◦ What happens next?

Changes begin How many changes do you initiate?

◦ How do we classify the changes? Mandatory vs. phase-in

PRG/TBC Group 22

• Resistance– Lack of familiarity and

FEAR• Global Issues

– Distance/language• Lack of Champion

– Driving force• Lack of

Measurement– Where are we?– What is the ROI?

23

PRG/TBC 24

Q and A