TOOL AND MANUFACTURING

ENGINEERS HANDBOOK
VOLUME VI
DESIGN FOR MANUFACTURABILITY

Copyright 1992 Society of Manufacturing Engineers. All rights reserved.

SOCIETY OF MANUFACTURING ENGINEERS

OFFICERS AND DIRECTORS, 1992
President
Douglas E. Booth, CMfgE, PE
Bond Robotics, Inc.
President-Elect
Frank H. McCarthy, CMfgE, PE
Raytheon Company (retired)
Second Vice President
Charles A. Templeton, CMfgE, PE
Charles A. Templeton Machine
Third Vice President
Gustav J. Oiling, PhD, CMfgE, PE
Chrysler Corporation
Secretary/Treasurer
Clinton 0. Larson, CMfgE, PE
Honeywell, Inc .

James F. Barcus, Jr.

Black & Decker Corp. (retired)
Russ G. Biekert, PhD, CMfgE
Allied-Signal Aerospace Co.
Joseph E. Brown
(Retired)
Gary L. Cline, CMfgE
Brunswick Corp.
Jack L. Ferrell
TRW Inc. (retired)
Leon W. Fortin, PE
L. W. Fortin Consultants
Donald G. Foster, CMfgE, PE
Consultant
Keith M. Gardiner, PhD, PE
Lehigh University
James M. Hardy
Hardy Associates

Ronald P. Harrelson, CMfgE

Caterpillar Institute
Rita M. Hiiyer, CMfgT
Veeder-Root Co .
Jim C. Hoover
Northrop Corporation
Elvin W. Keith, Jr., CMfgE, PE
E. W. Keith & Associates
Ken K. Koch, CMfgE, PE
Parker Hannifin Corp.
Homer P. Lane, CMfgE, PE
Engineering Consultant
James F. Lardner
Deere & Co. (retired)
James K. Long
AMP Inc.
Alan T. Male, PhD, PE
Consultant
Paul A. Misegades, CMfgE
General Electric Company
Louis M. Papp, CMfgE, PE
Windsor-Essex County Dev. Comm.
John T. Parsons
JuTohrr T. P m m s Company

Michael Reggia, CMfgE, PE

Thiokol
Gerald Reynolds
Perkin-Elmer Corporation
Vern L. Stumpenhorst
Ford New Holland Inc.
Ronald H. Vander Weerd, CMfgE
Pella-Rolscreen Company

Copyright 1992 Society of Manufacturing Engineers. All rights reserved.

TOOL AND MANUFACTURING

ENGINEERS HANDBOOK
FOURTH EDITION

VOLUME VI
DESIG N FO R MANUFACTURABILITY
A reference book for manufacturing engineers, managers, and technicians

Ramon Bakerjian, CMfgE

Handbook Editor
Philip Mitchell
Staff Editor

Produced under the supervision of

the SME Reference Publications
Committee in cooperation with the
SME Technical Divisions

Society of Manufacturing Engineers

One SME Drive
Dearborn, Michigan

Copyright 1992 Society of Manufacturing Engineers. All rights reserved.

ISBN NO. 0-87263-402-7

Library of Congress Catalog No. 91-060347
Society of Manufacturing Engineers (SME)
Copyright 01992, 1976, 1959, 1949 by Society of Manufacturing Engineers,
One SME Drive, P.O. Box 930, Dearborn, Michigan 48121
All rights reserved, including those of translation. This book, or parts thereof, may not be
reproduced in any form without written permission of the copyright owner. The Society
does not, by publication of data in this book, ensure to anyone the use of such data
against liability of any kind, including infringement of any patent. Publication of any data
in this book does not constitute a recommendation of any patent or proprietary right that
may be involved. The Society of Manufacturing Engineers, as well as all contributors and
reviewers of information in this volume, disclaim any and all responsibility for use of the
information contained herein by readers and users of this Handbook.
First edition published 1949 by McGraw-Hill Book Co. in cooperation with SME under
earlier Society name, American Society of Tool Engineers (ASTE), and under title Tool
Engineers Handbook. Second edition published 1959 by McGraw-Hill Book Co. in cooperation with SME under earlier society name, American Society of Tool and Manufacturing Engineers (ASTME), and under title Tool Engineers Handbook. Third edition published 1976 by McGraw-Hill Book Co. in cooperation with SME under current Society
name and under title Tool and Manufacturing Engineers Handbook.
Printed in the United States of America.

Copyright 1992 Society of Manufacturing Engineers. All rights reserved.

SME
The Society of Manufacturing Engineers is a professional society dedicated to
advancing manufacturing through the continuing education of manufacturing managers, engineers, technicians, and other manufacturing professionals. The specific goal of
the Society is to advance scientific knowledge in the field of manufacturing and to
apply its resources to research, writing, publishing, and disseminating information.
The purpose of SME is to serve the professional needs of the many types of
practitioners that make up the manufacturing community.. .The collective goal of the
membership is the sharing and advancement of knowledge in the field of manufacturing
for the good of humanity.
The Society was founded in 1932 as the American Society of Tool Engineers
(ASTE). From 1960 to 1969 it was known as the American Society of Tool and
Manufacturing Engineers (ASTME), and in January 1970 it became the Society of
Manufacturing Engineers. The changes in name reflect the evolution of the manufacturing engineering profession and the growth and increasing sophistication of a
technical society that has gained an international reputation for being the most
knowledgeable and progressive voice in the field.
Associations of SME- The Society provides complete technical services and
membership benefits through a number of associations. Each serves a special interest
area. Members may join these associations in addition to SME. The associations are:
Association for Finishing Processes of SME (AFP/SME)
Computer and Automated Systems Association of SME (CASA/SME)
Machine Vision Association of SME (MVA/SME)
North American Manufacturing Research Institute of SME
(NAMRUSME)
Robotics International of SME (RVSME)
Composites Manufacturing Association of SME (CMA/SME)
Association for Electronics Manufacturing of SME (EM/SME)
Machining Technology Association of SME (MTA/SME)
Networking and Communications in Manufacturing Group of SME
~

Members and Chapters-The Society and its associations have 80,000 member in 73
countries, most of whom are affiliated with SMEs 300-plus senior chapters. The
Society also has some 8000 student members and more than 150 student chapters at
colleges and universities.
Publications -The Society is involved in various publication activities encompassing handbooks, textbooks, videotapes, and magazines. Current periodicals include:
Manufacturing Engineering
Manufacturing Insights (a video magazine)
SME Technical Digest
SME News
Journal of Manufacturing Systems

Copyright 1992 Society of Manufacturing Engineers. All rights reserved.

vii

Certification -This SME program formally recognizes manufacturing managers,

engineers , and technologists based on experience and knowledge. The key certification
requirement is successful completion of a two-part written examination covering (1)
engineering fundamentals and (2) an area of manufacturing specialization.
Educational Programs -The Society sponsors a wide range of educational activities, including conferences, clinics, in-plant courses, expositions, publications and
other educationah-aining media, professional certification, and the SME Manufacturing Engineering Education Foundation.

viii

Copyright 1992 Society of Manufacturing Engineers. All rights reserved.

PREFACE
The first edition, published as the Tool Engineers Handbook in 1949, established a
useful and authoritative editorial format that was successfully expanded and improved
in the publication of highly acclaimed subsequent editions published in 1959 and 1976.
Now, with continuing dramatic advances in manufacturing technology, increasing
competitive pressure both in the United States and abroad, and a significant diversification of the information needs of the modern manufacturing engineer, comes the
need for further expansion of the Handbook. As succinctly stated by Editor Frank W.
Wilson in the preface to the second edition: ...no bible of the industry can
indefinitely survive the impact of new and changed technology.
Although greatly expanded and updated to reflect the latest in manufacturing
technology, the nature of coverage in this edition is deeply rooted in the heritage of
previous editions , constituting a unique compilation of practical data detailing the
specification and use of modern manufacturing equipment and processes. Other
volumes in this Handbook series include: Volume I, Machining, published in March
1983; Volume 11, Forming, in April 1984; Volume 111, Materials, Finishing and
Coating, in July 1985; Volume IV, Quality Control and Assembly, in January 1987;
and Volume V, Manufacturing Management, in April 1989.
The scope of this edition is multifaceted, offering a ready reference source of
authoritative manufacturing information for daily use by engineers, managers , and
technicians, yet providing significant coverage of the fundamentals of manufacturing
processes, equipment, and tooling for study by the novice engineer or student.
Uniquely, this blend of coverage has characterized the proven usefulness and reputation
of SME Handbooks in previous editions and continues in this edition to provide the
basis for acceptance across all segments of manufacturing. In this, and other TMEH
volumes, in-depth, coverage of all subjects is presented in an easy-to-read format. A
comprehensive index cross-references all subjects , facilitating quick access to information. The liberal use of drawings, graphs, and tables also speeds information
gathering and problem solving.
This volume of the Tool and Manufacturing Engineers Handbook (TMEH) series has
two audiences; the manufacturing engineer or manager and the product designer. Both
should find all of the chapters beneficial.
The first half of the book-chapters 1 through 8 -addresses background information
and topics of Design for Manufacturability (DFM): an introduction to DFM, how it
relates to Concurrent Engineering (CE) , management issues, getting started in DFM,
how to justify using DFM, applying quality tools to DFM, and how DFM is affecting
computer technology (and vice versa).
Chapters 9 and 10 cover topics starting with the creative thinking process to
combining DFM with geometrical dimensioning and tolerancing (GDT). Figure 9-2
(while rather lighthearted for Handbook-style material) sums up the situation found in
manufacturing that DFM will overcome, knocking down the walls between departments.
Chapters 11 through 16 cover product design information that TMEH contributors
felt was important for the designer to know when committing pen to paper or mouse to
pad. This is meant to be non-process related material. There are no detailed
descriptions of processes, drawings of typical machines, or tables of feeds and speeds,
that material can be found in the first four volumes of this edition. The designer should
Copyright 1992 Society of Manufacturing Engineers. All rights reserved.

know when the job begins what are allowable tolerances, surface finishes, geometries,
and so on, for a particular process or material that is being used.
Finally, two appendices are included to help the reader get further along in DFM.
Appendix A shows how large and small companies are applying DFM to their products
and organizations. Some of these case studies are familiar and others border on being
proprietary. Appendix B lists various DFM products and services. Neither appendix is
an exhaustive listing of successes or services.
The reference material contained in this volume is the product of incalculable hours
of unselfish contribution by hundreds of individuals and organizations, as listed at the
beginning of each chapter. No written words of appreciation can sufficiently express
the special thanks due these many forward-thinking professionals. Their work is deeply
appreciated by the Society; but more important, their contributions will undoubtedly
serve to advance the understanding of manufacturing management throughout industry
and will certainly help to spur major productivity gains in the years ahead. Industry as
a whole will be the beneficiary of their dedication.
Further recognition is due the members of the SME Reference Publication Committee for their expert guidance and support as well as the many members of the SME
Technical Activities Board.
The Editors

SME staff who participated in the editorial development and production of this volume
include:

EDITORIAL

TYPESETTING

GRAPHICS

Thomas J. Drozda
Director of Publications
Robert E. King
Publications Manager
Ramon Bakerjian
Handbook Editor
Philip Mitchell
Staff Editor
Suzanne Kosacheff
Technical Copy Editor
Frances Kania
Editorial Secretary
Dorothy Wylo
Editorial Secretary

Shari L. Smith
Supervisor
Kathy Allison
Typesetter
Marcia Theisen
Typesetter

Judy Munro
Art Director

Gregory J. Ross
Ross Services
Donna Hicks
Adcomp Services

vi
Copyright 1992 Society of Manufacturing Engineers. All rights reserved.

CONTENTS
VOLUME VI-DESIGN

FOR MANUFACTURABILITY

Symbols and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

xi

Design for Manufacturability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Concurrent Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Management Involvement in DFM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Team Building and Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Justification of DFM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Quality Tools in DFM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Computer-aided Technologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Design for Assembly : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary Design Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Product Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Forming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Finishing and Coating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastening and Joining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Design for Electronics Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1
2-1
3-1
4-1
5-1
6-1
7-1
8-1
9-1
10-1
11-1
12-1
13-1
14-1
15-1
16-1

Appendix A-DF'M Case Studies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix B-DFM Products and Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A-1
B-1

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

Copyright 1992 Society of Manufacturing Engineers. All rights reserved.

ix

To order call
1-800-733-4763
or visit
www.sme.org/store
and search on book title