DESIGN FOR MANUFACTURABILITY:

A Proactive Approach to Product Design and Plastics Manufacturing

Product Development>> Developing a new product involves

many moving parts

>> Preparation is a vital part of the product development process and sets up the rest of the project for success

>> This preparation lays the groundwork for Designing for Manufacturability

What Is Designing for ManufacturabilityDesigning for Manufacturability (DFM) is an interdisciplinary team effort through which design goals are thoroughly reviewed

Designing for Manufacturability>> The DFM process helps mold makers

and manufacturers ensure:

> Product quality

> Durability

> Cost efficiency

>> DFM is the cornerstone of every project EVCO Plastics undertakes

Why Is DFM Important?>> The design planning stage is the most opportune

time in the development process to consider how the end user wants the product to function

>> A better understanding of how it will be used allows for:

> A more robust design

> A higher quality advantage

> Greater efficiency

Why Is DFM Important?Product plan and design typically lock in 70% of what the actual product cost will be

Identifying cost-efficient materials and development plans needs to take place prior to production

The DFM process works

because it solves problems

up-front, avoiding unexpected

costs and delays.

DFM and Competitive Advantage DFM plays an important role in client competitive advantage

> Offers potential cost savings on capital equipment and piece price

> Early considerations for materials selection, including alternate options, can give a speed advantage and ensure high quality

DFM and Competitive AdvantageOne example of a checkpoint in the DFM process is Failure Mode Effect Analysis (FMEA)

> Method of calculating the likelihood of product failure, in what area and at what level of seriousness

> Takes place after initial design is complete

> Helps identify potential pitfalls in making the part

DFM and Improved EfficiencyMaterial selection consideration, including alternate options, takes place at the start of the DFM process

> Speeds up overall process as kinks are worked out ahead of time

> Solves problems up-front

DFM and EVCO PlasticsEVCO Plastics is deeply entrenched in DFM and follows five key considerations to ensure success:

1. Part design and customer involvement

2. Mold design

3. Molding process

4. Quality assurance

5. Automation

With early checkpoints,

DFM improves overal l

eff iciency

Program Management EVCO’s DFM process begins with an initial one- to four-hour meeting; from there, planning and production are set into motion:

1. Timeline established

2. Customers send electronic design files

3. EVCO reviews files internally and creates a feedback document to present to customer

4. EVCO provides prototype as needed for testing

5. After approval, EVCO moves forward with production

DESIGN SAMPLING & PRODUCTIONPART APPROVAL PROCESS

TOOLING LEAD TIME

ISSUE PO/START MOLD BUILDING

QUALITY PLANNING

AUTOMATION DESIGN AND BUILD

METROLOGY PLANNING

CUSTOMER APPROVAL& PRODUCTION START-UP

Production and Development Timeline

DFM in ActionSituation: a large paper company came to EVCO Plastics to partner on a concept for a napkin dispenser, originally made out of sheet metal

The customer wanted to make the switch to plastic and incorporate new features

DFM in Action>> EVCO Plastics held a series of client meetings with

their marketing, design, purchasing and quality staff to present different options and costs

>> EVCO Plastics factored in options including material type, timing for making and assembling parts, purchased component options and tooling

>> At each meeting EVCO Plastics worked withthe customer to review decisions that wouldimpact budget without compromising quality and functionality

DFM in Action>> When the customer selected the preliminary design,

EVCO Plastics developed an SLA prototype

>> The prototype allowed the client to see what the part would look like and how it would function

>> Quality planning discussions and part performance took place at the same time

DFM in ActionThrough DFM, EVCO Plastics was able to:

> Cut 30% out of the price > Cut 30% from the overall tooling budget> Incorporate desired features to dispenser

Through DFM, EVCO cut 30%

out of the cl ient’s part price

About EVCO PlasticsEVCO Plastics is a leading plastic manufacturing company with nine manufacturing facilities strategically located throughout the world. With an emphasis on design for manufacturability, strategic engineering and innovative technology, EVCO is recognized as a global leader in custom plastic injection molding. EVCO was founded in 1964, employs over 900 people and operates 140 injection molding machines ranging from 28 to 3,500 tons. For more information on EVCO, visit www.evcoplastics.com, facebook.com/evcoplastics or twitter.com/evcoplastics