Design for Manufacture and Assembly

e-Brochure

Edition: 01 September 2006

Boothroyd Dewhurst, Inc.

Design for Manufacture and Assembly
Boothroyd Dewhurst in Europe, the Middle East & Africa is served by:Design IV PO Box 194 Hereford HR2 0YG Great Britain Tel. +44 1981 550-400 Fax. +44 8700 516-506 sales@design-iv.com www.design-iv.com

DFMA is a registered trademark of Boothroyd Dewhurst, Inc.

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Table of Contents

Boothroyd Dewhurst_________________________________________________ 3 DFMA - Cost Reduction through Improved Design ________________________ 3 Design for Assembly Software ________________________________________ 5 Design for Manufacture Software ______________________________________ 8 On-site DFMA Workshops ___________________________________________ 13 DFMA software users ______________________________________________ 15

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Boothroyd Dewhurst
Boothroyd Dewhurst DFMA software tools and services allow companies to develop products with fewer parts at lower cost and with higher quality than was previously possible. Our disciplined approach to product development provides an early and accurate understanding of product cost and the capability to manage cost during the product development process. We put manufacturing information in the hands of design teams. Companies in many industries all over the world have been using DFMA software tools and services since 1983. Our clients aim for competitive advantage in their marketplace, and they understand the importance of creating products that are simple in structure, low in cost, and high in quality. Our goal is to help companies stimulate the creativity, innovation, and teamwork necessary for the development of world-class products.

DFMA - Cost Reduction through Improved Design

During the development stages of a new product, cost and cost drivers certainly deserve careful consideration. Yet they tend to be neglected, especially when designers lack a reliable method of managing and understanding them. If your goal is to improve your products without increasing your costs, the lack of cost detail during design can really hold you back. Design teams often find themselves relying on historical manufacturing and assembly costs recorded for previous or similar versions of a product, for example, or on supplier best estimates. Usually, designers have no way of accurately quantifying whether the specific innovation they are contemplating will increase or reduce overall product cost. The Design for Manufacture and Assembly suite of software gives you tools you can use anytime during the product development cycle to analyze and understand the cost effects of your design decisions. From the earliest conceptual stages of design, DFMA software equips you with quick and accurate cost information. The software also provides a way to work creatively and objectively with your suppliers to find new avenues for improving design efficiency and profitability. Cost understanding throughout the product development process can be best explained in three discreet steps.

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Cost reduction through product simplification: During the early stages of design, control of part count is paramount to maintaining cost targets. Design for Assembly (DFA) software tools help you simplify products by focusing the attention of design teams on part count and part count reduction. Product simplification is achieved through the application of our industry-tested minimum part count criteria. The analysis allows you to determine the theoretical minimum number of parts that must be in the design for the product to function as required. When you identify and eliminate unnecessary parts, you eliminate unnecessary manufacturing and assembly costs. Suppliers are a rich source of feedback during product simplification, particularly if one of your options is to consolidate multiple parts into one part with multiple features. As a design matures, DFA tools help avoid part proliferation and ensure that costs do not creep back into the product. Cost understanding using should-cost: The potential for cost reduction continues when you select the optimal material and manufacturing process for each part in your design. Using Design for Manufacture (DFM) software tools, you achieve a thorough understanding of the primary cost drivers associated with manufacturing your product and establish a benchmark for what your product "should cost." Central to the shouldcosting approach is accumulating real information about manufacturing costs and noting where specific costs arise in your design. Large costs in product development are associated with design manufacturability, so sharing should-costing information with suppliers can make your collaboration more fruitful. Supplier verification: Once your design is complete and it's time for purchasing to work with suppliers, the should-cost approach of DFM Concurrent Costing becomes invaluable. The design team can turn over to purchasing a costed bill of material that has true science behind it. Each part description can include a breakdown identifying what the setup, material, process, and tooling costs should be. The purchasing engineer and the supplier can then begin to facilitate discussions about predicted cycle times and costs, rather than get bogged down in arguments over margins and profits.
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Design for Assembly Software

Manufacturers today must deliver quality products to customers faster and at less cost. To hit this mark, designers in every industry from automotive, aerospace and telecommunications to medical devices and consumer goods rely on Design for Assembly (DFA) software from Boothroyd Dewhurst, Inc. Simplicity pays off Design for Assembly is a methodology for evaluating part designs and the overall design of an assembly. It is a quantifiable way to identify unnecessary parts in an assembly and to determine assembly times and costs. Using DFA software, product engineers assess the cost contribution of each part and then simplify the product concept through part reduction strategies.

These strategies involve incorporating as many features into one part as is economically feasible. The outcome of a DFA-based design is a more elegant product with fewer parts that is both functionally efficient and easy to assemble. The larger benefits of a DFA-based design are reduced part costs, improved quality and reliability, and shorter development cycles.

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With DFA software, you can: Create Products that are functionally efficient and easier to assemble Estimate assembly costs for alternative designs Reduce manufacturing and assembly costs Shorten overall development time for your organisation

The link to Design for Manufacture DFA complements Design for Manufacture (DFM). Engineers use DFA software to reduce the assembly cost of a product by consolidating parts into elegant and multifunctional designs. DFM software allows the design engineer to quickly judge the cost of producing the new design and to compare it with the cost of producing the original assembly. Used together, DFM and DFA software gives engineers an early cost profile of product designs, providing a basis for planning and decision-making. Such analyses, when performed at the earliest stages of concept design, have the potential to greatly influence manufacturing and other life-cycle costs before they are locked in. Benefits of DFA for Product Designers Product engineers know that 85% of manufacturing costs are determined in the early stages of design. They also know that making informed design decisions during the concept stages avoids costly corrections later on. DFA software helps Estimate assembly difficulty. Establish a rating for your product design in terms of its assembly difficulty. The software rates each part according to how it is grasped, oriented and moved for insertion and how it is inserted and fastened. Support decision-making. The software provides objective, consensus-building information so your team can examine all the potential design solutions and select the most effective approach. Benchmark existing products. The DFA index, a measure of assembly efficiency, serves as a basis for quantitatively comparing design alternatives or even against competing products, irrespective of size or complexity. Add focus to design reviews. DFA analysis can guide the progress of a design, verifying improvement as it evolves. As redundant parts or operations and assembly difficulties are eliminated, the assembly efficiency scores noticeably improve.

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Sharpens design skills. The software helps designers establish the theoretical minimum number of parts for a product. In the process, engineers identify design concepts that reduce unnecessary complexity and cost.

Integrate design and manufacturing. The DFA approach gives an overall structure for making design changes. Used together, DFA and DFM enables engineers to select appropriate and cost-effective shape-forming processes for components.

See fast results from the start. DFA software promotes systematic thinking about every part in an assembly. After entering the name and part number for the product, the first step is to identify all the components in the design, together with any special handling operations by creating a Structure Chart.

Then populate the Chart by choosing from menu options such as add part and add operation. To save time, the software also allows cut and paste from existing DFA analyses. Even import an existing bill of materials in order to create the Structure Chart, and easily import part dimensions from existing CAD models. Part costs estimated with DFM software can also be simply and quickly added. For each item in the design, answer a series of DFA questions, such as must each item in turn in the chart be separate from all others in the assembly. Specify securing methods, part dimensions, and any handling, insertion or fetching difficulties for each part. The answers establish the assembly time and cost for each item in a design, updating a results table as each question is answered. Multiple Structure Charts allow results comparisons. Separate picture and memo fields allow an image of each part to be displayed along with any comments. With a completed DFA analysis for several designs, comparison reports and graphs help summarise the results. Systematic use of DFA opens new doors to innovation and creativity and fosters overall improvement in product design practices.

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Design for Manufacture Software

DFM software is a concurrent engineering analysis tool for generating cost estimates for parts and tooling at the concept stages of design. The software isolates the major cost drivers associated with a wide range of processes for part manufacture and finishing. Used as an analysis tool during part design, DFM software guides product engineers as they investigate alternative materials and processes for producing parts and helps them to select the most cost-efficient design. Given the large number of process technologies and materials available, few design engineers have detailed knowledge of all the major shape-forming processes. Consequently, engineers tend to design for manufacturing processes with which they are familiar. DFM methodology encourages individual engineers and concurrent development teams to investigate additional processes and materials and to develop designs that may be more economical to produce. With more information about viable processes and materials, users can quantify manufacturing costs for competing design alternatives and decide which design is best.

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Design teams can import, view, and obtain 3-D geometrical information from (STL, DXF, OBJ, IGES, and VRML files, in addition to a variety of native CAD files) their solid models created in all the major CAD/CAM systems, including Pro/E, Catia, Unigraphics, I-DEAS, AutoCAD, SolidWorks, and many others using Solid Concepts SolidView viewer. When the CAD file opens, part dimensions, weight, volume, number of surfaces and other measurements automatically update in DFM software. As the product engineer selects different materials and manufacturing processes for the part, the DFM software uses the imported 3-D part geometry to calculate estimated manufacturing costs. Cost estimates are immediately displayed once the material and process are chosen and the envelope dimensions of the part entered. Modifying the process data defaults to reflect the details of the part and manufacturing environment provide an accurate part cost. DFM offers different processes and materials that help guide teams in material and process selection during the early stages of design:

*Machined/Cut from Stock includes Turning, Facing, Grinding, Boring, Drilling, Cut-off, Tapping, Reaming, Threading, Milling, Broaching, and more
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An expanding library of secondary operations includes information on the plating of plastics and on trimming and hole punching for blow moulding, machining, painting, packaging, inspection, and much more. Cost-estimating activities during design, encourages engineers to choose the most cost-effective shape-forming process for a part and to consider how individual part features might be modified to optimise manufacturing costs. DFM software is a valuable analysis tool both at the concept stage of part design and later during detailed design decisions. A key benefit of DFM software is the quick generation of an initial cost estimate at any stage of design in just a few simple steps. The Link to Design for Assembly DFM complements Design for Assembly (DFA). Engineers use DFA software to reduce the assembly cost of a product by consolidating parts into elegant and multifunctional designs. DFM software then allows the design engineer quickly to judge the cost of producing the new design and to compare it with the cost of producing the original assembly. Used together, DFM and DFA software give engineers an early cost profile of product designs, providing a basis for planning and decision-making. Such analysis, when performed at the earliest stages of concept design, has the potential to greatly influence manufacturing and other life cycle costs before they are locked in.

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A New Software Tool for DFM DFM Concurrent Costing allows you to develop rapid estimates of the cost to manufacture a part. The software puts 20 years of industry-validated research into the hands of the designer or the concurrent engineering team. Your organization can benefit from using DFM Concurrent Costing as: A Highly Accurate Cost-Estimator - Gain quick insight into the tremendous cost impact of even simple changes to part dimensions. DFM Concurrent Costing provides a fast, accurate way to review evolving designs for cost efficiency by quickly simulating the use of alternate materials and comparing various shape-forming processes. An Aid to Concurrent Engineering - Shorten product development cycles by working collaboratively on cost decisions. Because DFM Concurrent Costing is so easy to use, designers and manufacturing engineers can work closely with personnel from marketing, finance and purchasing to analyze alternative materials and process options. A Useful Design Tool - Redesign existing products for better quality and manufacturability while still adhering to manufacturing cost requirements. DFM Concurrent Costing effectively aids redesign by offering quick testing of alternate materials and processes. An Effective Vendor-Negotiating Aid - Evaluate vendor quotes by comparing the information the software provides on such items as total cost, cycle time, machine size and die cost. DFM Concurrent Costing gives even non-specialists a foundation for meaningful discussions with vendors. A Competitive Benchmarking Tool - Compare your designs with competitors products to determine market feasibility and to target costs. Because of its accuracy in predicting costs, DFM Concurrent Costing adds advantage to companies seeking to enter competitive industries. Make Your Sketch The Rest Is Easy - DFM Concurrent Costing starts in the analysis window, where you enter the part name, part number, life volume, and overall envelope
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shape for the part. You then enter basic information about the part dimensions and select the material and manufacturing process to be used. The Process Chart on the left side of the window shows in file tree format the material and processes you have chosen. As you proceed, the software guides you by indicating which materials and processes are compatible, possible, or incompatible. Context-sensitive help provides background information and diagrams for shape-forming processes. Engineers, purchasing professionals, and other decision makers on the product development team will appreciate having this manufacturing knowledge at their fingertips. Once you make material and process choices, the Responses Panel on the right side of the window displays default values that are used to calculate an approximate cost estimate for producing the part. You customize the cost estimate by changing the defaults and entering moredetailed part geometry and values specific to your own manufacturing site. A Geometry Calculator included in the software helps you insert part geometry. You can also edit the geometry by entering data from a solid modelling program. Each time you edit a given default value, such as part volume, average machine rate, tolerance, or number of cavities, and then click on the Calculate button, the Results Panel updates with a more accurate cost estimate. The software gives the steps in each manufacturing process, so that you can identify all costs. For example, hot chamber die-casting includes both the die casting process and the trimming operation, so DFM Concurrent Costing gives cost values for each step. The software also allows you to fine-tune a cost estimate by adding secondary operations such as die threading or finishing. Finally, you can save each cost estimate as a separate file for comparison. A variety of reports in graph or table format that allow you to compare the material, setup, process, and tooling cost breakdowns for each analysis. Within each breakdown, you can also see how changes in such parameters as number of mould cavities affect cost. A special Cost Reduction Report identifies significant cost contributors that can serve as a focus for redesigning the part. You strive to create well-designed products. When you use DFM Concurrent Costing, what-if explorations in new design directions come with the assurance that your designs are also affordable to produce.

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On-site DFMA Workshops

The pace of today's design-to-product launch cycles makes fast and smooth implementation of new productivity technologies a critical requirement for manufacturing success. Engineering teams need to work at learning to use technology much in the same way they work on product development: simultaneously. Our workshops aim for the maximum exploitation of DFMA benefits in hands-on, on-site application workshops by helping the DFMA teams to quickly and effectively use the DFMA approach - with their own products. Immediate Results...Ongoing Support The goal of our implementation services is to help customers achieve the powerful results of DFMA programs quickly and permanently. We aim to accomplish this by combining over a decade of DFMA research with the experience of industry DFMA-champions and users. A proven tool for re-engineering the product development process, DFMA can help you make your next product your first DFMA success story. 1-3+ Day DFMA Training & Application Workshops DFMA Workshops are presented in a focussed hands-on format and help fulfil several functions including: training DFMA users, getting your company started on its first or next DFMA project and helping CE teams learn new strategies for success. The process begins with overview sessions to help build management support, then to coach participants through a baseline analyses, including the companys own products, using DFMA best-practice written and software approaches. The product analysis exercise focuses initially on the concept stage and continues by working with team members throughout the development process to ensure significant DFMA results. If you are just getting started with DFMA or looking to improve upon current DFMA programs, application workshops are an ideal way to make your project a case-study quality success story and improve profitability, quality and efficiency. Workshop Benefits: Trains teams in the principles and benefits of DFMA strategies. Provides a hands-on understanding and use of DFMA software on your own products. Gives a working knowledge of non-software DFA analysis. Encourages design creativity, teamwork and innovation.
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Participants gain a thorough understanding of the theories behind DFMA along with awareness of case-study successes. Gives team members a structured example of team use of DFMA. Helps users realise immediate design improvements on their own products.

Use DFMA to Improve: Overall product cost Assembly and manufacturing efficiency Customer satisfaction Product quality and reliability Time-to-market launch cycles Number of post-release design changes

What others have said after completing an on-site, hands-on workshop: "Provided the opportunity for manufacturing and development engineers to work together in a team effort." "Opened closed minds to new methods of design." "The workshop was beneficial. It addressed real problems and solutions." "Allows hands-on use of software, walks through step by step." "Real world experience from other companies, not just academies." "Practical use with (our) product was a valuable part of the program" "you can't make an argument not to use these workshops." Getting the Most from DFMA... The main objective of our workshops is to teach teams to apply DFMA as a catalyst for Concurrent Engineering and company-wide communication efforts. This is best achieved using the DFMA software. Teams exercise their knowledge by analysing either an existing product or a new design concept. All key developers, including management, should attend the workshop and, on the last day, review DFMA design changes. Additional days are often recommended to aid in the implementation of these changes. Workshop Duration The length of workshops is determined by the objective, complexity of any product(s) to be analysed, whether a DFM cost analysis is performed and the number of delegates. One and twoday DFA workshops are open to those who require only limited analysis of their products, small numbers of delegates and for refresher scenarios. Further day-long workshops, often without defined agendas or specific tuition, can be scheduled to complete analyses or provide expert project-based coaching and trouble-shooting.
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DFMA software users

Computer
Dell Compaq Seiko Epson StorageTek

Medical
LifeScan Novo Nordisk Respironics St. Jude Medical

Consumer
Char-Broil Four Square Kohler Mira Whirlpool

Manufacturing
Assa Abloy Domino Inkjet OI Superconductivity Teradyne

Defence
Bombardier-Shorts Israeli Aircraft Rolls Royce Marine Thales Missile

Telecommunications
Ericsson Motorola Nokia Sanmina

Energy

Automotive

ABB GEC Alsthom Honeywell Schlumberger

Daimler Chrysler Ford Motor Co JCB Thule

and many others...

September 2006

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