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
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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
Business Challenge
Cust. Reqn’ts
Quality/
Reliability
Prod. Def.
Elect. Design
HR
Fulfillment/Rep
air
Ind./Mech. Design
Finance
Software Dev.
Proj. Mgmt.
Bus. Process
Mktg/Sales
Vol. Mfg.
Proto Mfg.
Packaging/
Logistics
Test Dev.
Lack of Technical Expertise: Internal
resources often lack sufficient or appropriate
technical expertise to support projects.
Resource Availability: Internal resources are
not always available in the timeframe
required to meet project needs.
Project Management and Integration: Internal
resources have limited bandwidth to manage
multiple outside partners effectively.
Engineering
Manufacturing
New Part Requests
Spreadsheets
Emails
Faxes
?
• 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
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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
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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
Cost of changes multiplies
By 10 with each step
C
O
S
T
Prototype
Launch
First
production
Design
10
100
1000
10,000
DEVELOPMENT STAGES
PRG/TBC
11
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Process Challenges
Guidelines for Assembly
Fundamental Considerations
PRG/TBC
12

American Airlines

Southwest
◦ Fleet of 737 aircraft =
streamlined cost
◦ Fleet of 12 different
aircraft = 11 x cost
REDESIGN FOR TITER PLATE ASSEMBLY
Existing Design:
33 piece part items
98 pieces of hardware (Includes 34 rivets)
Redesign:
19 piece part items
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
14
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
15
REDESIGN FOR TITER PLATE ASSEMBLY
Detail 4:
Qty 1 machined component. Replaced with qty 1 simplified fabricated component.
PRG/TBC
16
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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
What is Product Lifecycle Management
(PLM)?
Concept and
Planning
Design and
Engineering
CAD/CAE
Manufacturing
Planning
cPD
Visualization
Full
Production
Service and
Support
SCM/SRM
CRM
Web, Excel,
Visio, etc.
PDM
ERP/MRP
PLM provides a data platform for managing forward processing of
data, AND recycling it back for subsequent products.
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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
Q and A
PRG/TBC
24