INTRODUCTION TO DESIGN

FOR MANUFACTURE AND

ASSEMBLY (DFMA)
J.JAYARAMAN

CENTRE FOR AEROSPACE SYSTEMS DESIGN

ENGINEERING
INDIAN INSTITUTE OF TECHNOLOGY , BOMBAY

STRUCTURE OF THE
PRESENTATION
WHY AND WHEN:
EARLY MANUFACTURING KNOWLEDGE IMPROVES
PRODUCT SUCCESS
EXAMPLES OF BENEFITS
DFMA IN WORLD WAR II
WHAT:
WHAT IS INTEGRATED DESIGN AND
MANUFACTURE

STRUCTURE OF THE
PRESENTATION (CONTD.)
HOW:
HOW TO ACHIEVE INTEGRATED DESIGN AND
MANUFACTURE
-BDI SOFTWARE
-FMECA
EXAMPLES:
- ACCELERATION SENSING UNIT
-WORKED EXAMPLE
-POWER SUPPLY OF LASER Tx HIGH VOLTAGE
CONCLUSION

BEST PRACTICES TO
PRODUCT DEVELOPMENT
PRODUCT DEVELOPMENT
TECHNOLOGY
DEVELOPMENT

INTEGRATION

KNOWLEDGE
POINT 1

TECHNOLOGIES
AND RESOURCES
MATCH
REQUIREMENTS

PROGRAM
LAUNCH

DEMONSTRATION

KNOWLEDGE
POINT 2

DESIGN PERFORMS
AS EXPECTED

PRODUCTION

KNOWLEDGE
POINT3
PRODUCTION
CAN MEET
COST
SCHEDULE
AND
QUALITY
TARGETS

ATTAINMENT OD DESIGN AND

MANUFACTURING KNOWLEDGE
WEAPON SYSTEM % OF DWGS. COMPLETED % OF CRITICAL MFG.
PRIOR TO MFG.

PROGRAM

PROCESSES IN CONTROL EXPERIENCE

AT PRODUCTION

BEST PRACTICE

AIM-9X
(AIR-AIR MISSILE)

F-22 FIGHTER

AT LEAST 90% DWGS.

COMPLETED

95%

26%

ALL CRITICAL
PROCESSES
IN STATISTICAL
CONTROL

UNKNOWN

44%

MEET COST &

SCHEDULE
TARGETS

4% UNIT COST
INCREASE
1 MONTH
PRODUCTION
DELAY
23% UNIT COST
INCREASE
18 MONTH
PRODUCTION

ATTAINMENT OF DESIGN & MFG.

KNOWLEDGE (contd.)
WEAPON SYSTEM % OF DWGS. COMPLETED % OF CRITICAL PROCESSES PROGRAM
PRIOR TO MFG.
F18 E/F FIGHTER

PATRIOT
ADVANCED
CAPABILITY
(PAC-3)
MISSILE
ADVANCED
THREAT
INFRARED
COUNTERMEASURES/
COMMON MISSILE
WARNING SYSTEM

58% *

21 %

IN CONTROL AT PRODN.
78%

35 %

21%
0%

EXPERIENCE
NO UNIT COST
INCREASE
3 MONTH
PRODUCTION
DELAY
159 % UNIT
COST
INCREASE
39 MONTH
PRODUCTION
DELAY
182 % UNIT
COST
INCREASE
34 MONTH
PRODUCTION
DELAY

BENIFITS OF DFMA
THERE IS A MUCH BETTEER OPPORTUNITY TO MEET
PREDICTED COST SCHEDULE AND QUALITY
TARGETS WHEN THE MANUFACURING PROCESS
DATA IS CAPTURED EARLY

BENEFITS OF DFMA
(CONTD.)
F 18 E/F HAS 42% FEWER PARTS THAN C/D
EVEN THOUGH IT IS 25% LARGER
REDUCED
-PRODUCTION COSTS
-DEFECTS
-REWORK
BY APPLYING DFMA BDI SOFTWARE & SOURCES
OF VARIATION IN THE PROCESS

BENEFITS OF DFMA
( CONTD.)
TOMOHAWK CRUISE MISSILE
STRATEGIC

TACTICAL

PARTS

11500

7500

FASTENERS

2500

800

CIRCUIT CARDS

45

22

CONNECTORS

160

45

610

195

$1000,000

$500,000

ASSEMBLY/ TEST
HOURS
UNIT PRODUCTION
COST

ASSEMBLYTIME FOR
BALL CAGE DEVICE
REDUCED TO 15SEC
FROM 130 SEC.
8 SCREWS TO NO
SCREWS
DFMA METHOD
OF ELIMINATING
FASTENERS

ASSEMBLY
OPERATIONS
FROM 83 TO
54

TOTAL ASSY.
TIME 592SEC.
TO 277 SEC.

RIBBON BASEPLATE
DIABLO PRINTER
OLD DESIGN 77 PARTS

NEW DESIGN
36 PARTS

COMPARISON OF ORIGINAL
NEW DESIGNS OF RETICLE
ASSY.
ORIGINAL DESIGN REDESIGN

IMPROVEMENT%

ASSY. TIME HRS

2.15

0.33

84.7

NO. OF DIFF. PARTS

24

66.7

TOTAL NO. OF PARTS

47

12

74.5

METAL FABN. TIME HRS.

12.63

3.65

WEIGHT LBS.

0.48

.26

71.1
45.8

ORIGINAL

OPTION 1

PILOTS INSTRUMENT
PANEL
LONG BOW APACHE
AH-64D HELICOPTER
BOEING COMPANY

OPTION 2

PILOTS INSTRUMENT
PANEL
ORIGINAL PANEL

NEW PANEL
( OPTION 1 )

PARTS COUNT
FABRICATION TIME HRS.
ASSY./INSTALLATION TIME HRS.
TOTAL TIME

HRS.

74

305

20

149/153
697

WEIGHT KG.

3.0

COST $

56000

8/153
181
2.74
15000

Advantages of DFMA
Typical results of DFMA application
Results of 88 published case studies
Decreases
51% parts count reduction
37% parts cost
50% time to market
64% in assembly time
57% in manufacturing assembly time
58% in assembly operations
69% in separate fasteners
68% in assembly defects
57% in service calls
68% in improvement in quality and reliability

Benefits of DFMA
Shorter developmental schedules and reduced
cycle times.
Better first article quality
Development of robust product designs
Easier transition of designs to production
Better supplier product integration
More effective risk management

McDonnel Douglas experience

Reduce number of parts and fasteners used on aircraft
It means fewer opportunities for defects
For each fastener there is the chance that the hole will be
drilled in the wrong place or be the wrong size
By reducing the number of fasteners numbers of defects
reduced, therefore, produce a higher quality product
Weight is critical. Fuel costs approximately $50,000 per
pound of aircraft weight over 6000 hrs of the life of the
aircraft
There are 179000 on the FA-18 CD fasteners
In previous models several parts were made of sheet metal
because machined parts were unable to reach minimum
gage limits
With high speed machining thinner gauge limits have
become possible

ACCELERATION SENSING ASSEMBLY

OPTION-I

OPTION-II

COMARISON TABLE ASA OPTIONS

PARAMETER

OPTION - I

OPTION - II

NATURAL FREQUENCY

250 Hz

548 Hz

ESTIMATED ACCURACY

3.5 MINUTES

1.5 MINUTES

MEASURED ACCURACY

2.7 MINUTES

1.5 MINUTES

EMI GASKET PROVISION

NO

YES

254 x 117 x 86 mm

254 x 117 x 78 mm

ESTIMATED WEIGHT (W/O ELECTRONICS)

1.90 Kg

1.80 Kg

MEASURED WEIGHT (W/O ELECTRONICS)

1.92 Kg

1.72 Kg

25

15

MACHINING TIME

18.1 Hours

8.3 Hours

MACHINING COST

Rs 559.17

Rs 256.75

SIZE

NUMBER OF FABRICATED PARTS

DFMA IN WW II
WORLD WAR II EXPERIENCE:
US AVIATION INDUSTRY GREWW TEN FOLD
P-51 MUSTANG FIGHTER
- TO FACILITATE EASE OF MANUFACTURE
STABILISERS FINS WINGTIPS SQUARED OFF
- FUSELAGE THREE SECTIONS- COMPLETE
PLUMBINGS, CABLE DISCONNECTS TO
FACILITATE ASSEMBLY AND DISASSEMBLY
FOR PACKING AND SHIPPING

DFMA IN WW II (CONTD.)
DFMA INFLUENCE ON DESIGN OF GRUMMAN F-6F
HELLCAT
- USED FEWER COMPOUND CURVES IN
EXTERNAL DESIGN-UGLY- SEVERELY
CLIPPED WINGS
- PRODUCED IN LARGE QUANTITIES
- 32 KPH SLOWER THAN F4U HERITAGE 1980
DFMA INFLUENCE PERMITTED SHIPMENT BY
BOAT OR LAND. OUT WING PANELS AND EVEN TAIL
ASSEMBLIES REMOVED AND REPLACED AT THE
DESTINATION POINT.

SPITFIRE VS.
MESSERCHMIDST
IN 1940 Mes OUTNUMBERED SPITFIRES THREE TO
ONE. DESIGN ATTRIBUTABLE TO DFMA
PHILOSOPHY. Mes 4000 LABOUR HOURS TO
SPITFIRE 13000 HOURS
AIR WAR HISTORIANS DESIGNATE SPITFIRES AS
THE BETTER AIRCRAFT, THE LONG AND
SUCCESSFUL CAREER OF ME 109s DURING ARAB
ISRAELI WAR 1948 DEMONSTRATED THAT MAJOR
ATTENTION TO DFMA PRODUCES EFFECTIVE
AIRCRAFT DESIGN EVEN AS EARLY AS 40s

SPITFIRE VS.
MESSERCHMIDST.
SPITFIRE:
DESIGNED FOR AERODYANAMIC
PERFORMANCE AND STRUCTURAL
EFFICIENCY
BEAUTIFUL ELLIPTICAL WINGS CHOSEN FOR
AERODYNAMIC PERFORMANCE WAS A
NIGHTMARE TO MASS PRODUCE
DIFFICULT TO LEARN TO FLY, HIGHLY
MANOEUVERABLE
WAS PRODUCED IN LARGE NUMBERS
BECAME A MAJOR FORCE IN BATTLE OF
BRITAIN AIR CAMPAIGN 1940-41

SPITFIRE VS.
MESSERCHMIDST
MESSERCHMIDST
DESIGN WAS A DFMA CLASSIC
A MINIMUM OF COMPOUND CURVES USED IN THE
EXTERIOR
RUDDER AND HORIZONTAL STABILISERS WERE
SQUARED OFF FOR PRODUCTION EFFICIENCY
COCKPIT CANOPY WAS MADE ALMOST ENTIRELY
OF FLAT GLASS
20 MM CANNON FIRED THROUGH A HOLLOW
PROPELLER SHAFT TO OVERCOME
COMPLEXITIESOF WING INSTALLATION AND TO
ELIMINATE SIGHTING PARALLAX

INTEGRATED DESIGN AND

MANUFACTURE
SIMULTANEOUSLY ADDRESS DESIGN FOR
PERFORMANCE AND DESIGN FOR PRODUCTION
SYSTEMS ENGINEERING HAS ALIGNED DESIGN
ENGINEERS IN REQUIREMENTS ANALYSIS, THE
DEVELOPMENT OF FUNCTIONAL FLOWS etc.
INCLUDING THE ASPECTS OF MANUFACTURING
PROCESS DEVELOPMENT IN THE SYSTEM
ENGINEERING PROCESS HAS BEEN MORE DIFFICULT
TO ACHIEVE

DESIGN HAS DIFFERENT

MEANINGS
TO SOME IT IS AESTHETIC DESIGN
TO SOME IT MEANS ESTABLISHING THE BASIC
PARAMETERS OF A SYSTEM
TO SOME IT IS DETIALING OF THE MATERIALS,
SHAPES,AND TOLERANCE OF THE INDIVIDUAL PARTS
OF THE PRODUCT
DFMA ADDRESSES THE LAST ASPECT OF PRODUCT
DESIGNS

DFMA
THREE MAIN APPROACHES TO DESIGN FOR
ASSEMBLY HAVE BEEN DEVELOPED AND USED
Viz.:
DESIGN HEURISTICS
DESIGN RATINGS
DESIGN REVISION

DESIGN HEURISTICS
GENERAL SET OF RULES eg.:
MINIMIZE THE NUMBER OF PARTS &
ASSEMBLY DIRECTIONS
AVOID PARTS THAT SHINGLE TANGLE etc.
HEURISTICS CAN BE APPLIED TO A
DESIGNERS THINKING PRIOR TO ACTUAL
PRODUCT DEVELOPMENT OR ONCE AN
ASSEMBLY IS COMPLETE
USED TO SIMPLIFY PRODUCT

DESIGN RATING
PROVIDE RATINGS FOR COMPONENTS AS
WELL AS OVERALL DESIGN
ASSEMBLY RATINGS CAN BE CALCULATED
BDI HAS THEORETICAL HANDLING AND
MATING RATINGS
OTHER DFA RATING METHODS PROVIDE
DIFFERENT SCHEMES

DESIGN REVISION METHOD

COMBINATION OF HEURISTICS AND RATING
METHOD eg. BDI
BDI COMBINES A COMPONENT RATING SCHEME
WITH AN ASSEMBLY TIME AND COST ESTIMATION
METRIC AS WELL AS SPECIFIC RULES IN AN
ORDERED SEQUENCE FOR DECIDING HOW TO
REVISE A DESIGN. THIS HAS ENABLED PRODUCT
DESINERS IN MINIMISING ASSEMBLY SIMPLICITY

DFMA METHODOLOGY
WALKING THROUGH A CONCEPTUAL OR
EXISTING DESIGN IN A VERY SPECIFIC
PROCEDURE THROUGH OUT
THE PROCEDURE FOLLOWED AND THE DATA
BASE SYSTEM ALLOWS A DESIGN ENGINEER OR
CROSSFUNCTIONAL TEAM TO ANALYSE AND RATE
PRODUCT DESIGNS FOR EASE OF ASSEMBLY,
DESIGN EFFICIENCY AS WELL AS PREDICT
PRODUCT ASSEMBLY AND MANUFACTURING COST

DFMA
METHODOLOGY(CONTD.)
CAD RESULTED IN POWERFUL QUANTITATIVE
OR ANALYTICAL TOOLS, PROVIDED BASIS FOR
JUDGING A DESIGNERS PERFORMANCE. DFMA
HAS GIVEN MANUFACTURING ENGINEERS SUCH A
TOOL.
DFMA IS ATTEMPTING TO FORESEE AT THE
PRODUCT CONCEPTUAL DESIGN STAGE , WHAT
MANUFACTURING ASSEMBLY AND QUALITY
PROBLEMS WILL BE TO ARRIVE AT A BETTER
PRODUCT

DFMA tools

Are tools for DFM & DFA

DFM TOOLS

DFM ACTIVITY
OPTIMIZE SIMPLIFY

DFM TOOLS
DESIGN AXIOMS
DFM GUIDELINES
DESIGN FOR ASSY. METHOD
TAGUCHI METHOD
MFG. PROCESS DESIGN RULES
DESIGNERS TOOLKIT
COMPUTER AIDED DFM
GROUP TECHNOLOGY
FMEA
VALUE ANALYSIS

CONCEPT

ENSURE
PROCESS
CONFORMANCE

OPTIMIZE
PRODUCT
FUNCTION

DFM METHODOLOGY COMPARISON (CONTD)

KEY TO DISADVANTAGES
A. INTERPRETATION NOT ALWAYS SIMPLE
B.. REQUIRES BUY IN ON PART OF USER
C. EXCEPTIONS ARE NOT INDICATED
D. RATES ONLY EASE OF ASSY.DOES NOT
ADDRESS PART HANDLING OR OTHER
RELATED MFG. PARAMETERS
E. DEVELOPMENT REQUIRES INPUT FROM
EXPERIENCED EXPERTS FAMILIAR WITH
SPECIFIC PROCESS CAPABILITIES AND
NEEDS
F. TO BE USED ON A REGULAR BASIS
IMPLEMENTATION MUST BE USER
FRIENDLY
G. MUST BE DEVELOPED AND/OR
CUSTOMISED FOR EACH SPECIFIC
APPLICATION
H. OFTEN REQUIRES DIFFICULT TO OBTAIN
KEY TO APPLICATIONS
INFORMATION
A. MECHANICAL AND ELECTROMECHANICAL
DEVICES AND ASSEMBLIES
B. ELECTRONIC DEVICES AND SYSTEM
C. MANUFACTURING AND OTHER PROCESSES
D. SOFTWARE INSTRUMENTATION AND CONTROL SYSTEM INTEGRATION
E. MATERIAL TRANSFORMATION PROCESSES
F. SPECIFIED AND OR UNIQUE MANUFACTURING FACILITIES SUCH AS
FLEXIBLE ASSEMBLY SYSTEMS
KEY TO ADVANTAGES
A. NARROW RANGE OF POSSIBILITIES
B. RESULTS IN INHERENT ROBUSTNESS
C. READY REFERENCE TO BEST
PRACTICES
D. EMPHASISES EFFECTS OF
VARIATIONS
E. HELPS IDENTIFY AND PRIORITIZE
CORRECTIVE ACTION
F. PROVIDES BOTH GUIDANCE AND
EVALUATION
G. CAN SHORTEN DESIGN /TOOLING
CYCLE
H. CAN REDUCE TOOLING AND
FIXTURING COST

DFMA application areas

DFMA has been applied successfully to
Structural design
System design
Landing gear system
Flight controls
Electrical, electronic hydraulic systems
Environment controls

COST AND EASE OF MODIFICATIONS

BENIFITS OF IMPROVED ASSY.

MANUAL DESIGN ASSEMBLY EFFICIENCY (%)

( DFA INDEX )
IMPROVED ASSEMBLY DESIGN EFFICIENCY RESULTS IN INCREASED RELIABILITY

When to apply DFMA

WHEN CONCEPTUAL LAYOUTS ARE BEING
MADE. THEN DESIGNER ENVISIONS AN
ASSEMBLY EASY TO INSTALL THAT
REQUIRES MINIMUM NUMBER OF PARTS TO
PERFORM THE REQUIREMENTS PREVIOUSLY
ESTABLISHED
WHEN ASSEMBLY LAYOUTS ARE BEING MADE.
DESIGNER IMPLEMENTS OPTIMISATION TO
EASE OF MANUFACTURING ,
RELIABILITY
AND MAINTAINABILITY

Who are using DFMA

Over 400 companies and institutions
Aerospace companies
Allied signal
Hughes Aircraft
McDonnell Douglas Corpn.
Have implemented DFMA philosophy throughout
their product line
Automotive industries
Medical electronic equipment
PC industry and others

DFMA Team
Multidisciplinary teams
Design engineers
Manufacturing engineers
Shop floor mechanics
Suppliers reps
Specialist in product support
Maintainability
Reliability

DFMA
BDI software
Is used by manufacturing team members to estimate
and predict the savings that can be obtained.
Data are entered system does its analysis in
different areas.
A complete listing of all the activities required to
perform the assembly including
It provides complete overview of the tasks to be
performed

DFMA TECHNIQUE
DESIGN CONCEPT

DESIGN FOR ASSEMBLY

( DFA )
SELECCCTION OF
MATERIALS AND
PROCESSES AND EAZRLY
COST ESTIMATES

SUGGESTIONS FOR
SIMPLIFICATION FOR
PRODUCT STRUCTURE
SUGGESTIONS FOR
MORE ECONOMIC
MATERIALS AND
PROCESSES

BEST DESIGN CONCEPT

DESIGN FOR MANUFACTURE
( DFM )
PROTOTYPE

DETAIL DESIGN FOR

MINIMUM MANUFACTURING
COST

PRODUCTION

BDI
software
It does an assembly analysis profile on a standard format where it theorizes the
number of tasks to be performed, fasteners required, connectors to be installed,
candidates for elimination, acquisition of items not in reach or in stock, requisition
of tools not in hand, standard operations, library of operations and
recommendations.

All these activities are numbered and plotted. It automatically provides

suggestions for improvement.

System provides suggestions for design and indicating every task with its time
saving and its percentage reduction. It indicates specific instructions to perform
the related tasks in order to obtain the suggested savings.

It also lists design for assembly analysis totals all parameters used for analysis
such as total assembly time, totally assembly cost, total assembly weight, number
of parts, sub assemblies theoretical minimum numbers of parts or unanalysed sub
assemblies and the hourly labour rate.

All suggestions and comments included in the computer generated tables are
automatically provided to aid the designers and manufacturing engineers to obtain
a better view of the job

Questions asked in DFMA about

each part in a product design
Does the part move with respect to other parts
already assembled
Must the part be made from a different material or
isolated from all other parts already assembled
These questions lead the reviewers to re-evaluate
each part and process that has been specified
If a part does not meet any of these criteria it is a
candidate for elimination or consolidation with
another part

Results of Design for Assembly (DFA) Analysis for the Motor Drive
Assembly Redesign

TYPICAL FUNCTIONAL
FLOW
1.3.2.1.1
CHARGE STORAGE
CAPACITOR

1.3.2.1.6
TRANSMIT PULSE
THROUGH LENS

1.3.2.1.2
RECEIVE PULSE
INITIAE SIGNAL

1.3.2.1.5
CREATE LASER
PULSE SHAPE

1.3.2.1.3
DISCHARGE CAPACITOR
THROUGH LASER DIODE 1

1.3.2.1.4
CREATE LASER
PULSE ENERGY.

TYPICAL PROCESS FLOW

P 1.1
PRODUCE ACTIVE
TRANSMITTER
P 1.2
PRODUCE ACTIVE
RECIEVER

AND

P 1.3
PRODUCE PASSIVE
RECEIVER

AND

P 1.6
ASSEMBLE INTO
UPPER HOUSING
ASSEMBLY

P 1.7
PRODUCE LOWER
HOUSING ASSEMBLY

P 1.4
PRODUCE FLEX.
ASSEMBLIES
P 1.5
PRODUCE PWB
ASSEMBLIES

SEE NEXT SLIDE

TYPICAL PROCESS FLOW (CONTD)

P 1.3.1
CODER
ATTACH

P 1.3.2
CLEAN BOND
PADS

P 1.3.3
WIRE BOND
CODER

P 1.3.4
PICK AND PLACE
PbSe
INTERCONNECT
STANDOFF

P 1.3.2
CLEAN BOND PADS

P 1.3.6
INSPECT

P 1.3.5
WIRE BOND
PbSe

ACTIVITIES TO ACHIEVE
MFG. KNOWLEDGE

IDENTIFY KEY SYSTEM CHARECTERISTICS AND CRITICAL

MANUFACTURING PROCESSES

DETERMINE PROCESS IS IN CONTROL AND CAPABLE

CONDUCT FMEA

SET RELIABILITY GROWTH PLAN AND GOALS

CONDUCT RELIABILITY GROWTH TESTING

CONDUCT REVIEW TO BEGIN PRODUCTION

Contd..

BEST APPROACH TO
PRODUCT DEVELOPMENT
SYSTEM
TECHNOLOGY
DEVELOPMENT

INTEGRATION & DEMONSTRATION

KP1

KP2

TECHNOLOGY MATURITY
DESIGN MATURITY
PRODUCTION MATURITY

KP3

PRODUCTION

CONCLUSION
THE NEED FOR DFMA DURING EARLY STAGES OF PRODUCT
DEVELOPMENT IS SEEN
TWO METHODS Viz. BDI AND FMECA APPROACHES APPEAR TO
BE YIELDING EXCELLENT RESULTS.
A COMBINATION OF THE TWO IS LIKELY TO SERVE OUR
PURPOSE BOTH IN MECHANICAL AND ELECTRONIC PRODUCTS

ACTIVITIES TO ACHIEVE STABLE

DESIGN KNOWLEDGE
LIMIT DESIGN CHALLENGE
DEMONSTRATE DESIGN MEETS REQUIREMENTS
COMPLETE CRITICAL DESIGN REVIEWS
STAKE HOLDERS AGREE DRAWINGS COMPLETE
AND PRODUCIBLE
REVIEW TO BEGIN INITIAL MANUFACTURING

PROCESS CAPABILITY INDEX &

PROBABILITY OF A DEFECTIVE PART
MFG. PROCESS CAPABILITY (Cpk)

Cpk .67 ( NOT CAPABLE)

Cpk 1.0 ( MARGINALLY CAPABLE )
Cpk 1.33

( INDUSTRY STD.)

Cpk 2.0 ( INDUSTRY GROWTH

GOAL)

ASSOCIATED DEFECT RATE

1 IN 22 PARTS PRODUCED

1 IN 370 PARTS PRODUCED

1 IN 15152 PARTS PRODUCED

1 IN 500,000,000 PARTS PRODUCED

ACTIVITIES TO ACHIEVE MFG.

KNOWLEDGE
IDENTIFY KEY SYSTEM CHARECTERISTICS AND
CRITICAL MFG. PROCESSES
DETERMINE PROCESSES IN CONTROL AND CAPABLE
CONDUCT FAILURE MODE AND EFFECTS ANALYSIS
SET RELIABILTY GROWTH PLAN AND GOALS
CONDUCT RELIABILITY GROWTH TESTING
REVIEW TO BEGIN PRODUCTION

EXAMPLES OF
PROTOTYPES USED
PROTOTYPE

PURPOSE

BUILD
ENVIRONMENT

PRODUCT

PRODUCT

INTEGRATION

DEMONSTRATION

ENGG. PROTOS.
VIRTUAL OR
PHYSICAL

PRODUCTION

PRODUCTION
REPRESENTATIVE
PROTOTYPES

INITIAL PRODUCTS

DEMONSTRATE
DEMONSTRATE
PRODUCT IS
DEMONSTRATE
FORM FIT
CAPABLE RELIABLE
READY FOR FULL
FUNCTION AND
A STABLE DESIGN AND MFG. PROCESSES SCALE PRODUCTION
IN CONTROL

ENGINEERING

MFG. FIRST SET OF

PRODUCTION TOOLING

PRODUCTION ALL
RATE TOOLING

Advantages of DFMA
Ford $ 1.2 billion in 87 using DFA alone
GM 30-60% on certain projects in 89
MD-11 cargo liner savings per aircraft $ 86,000, a
bulkhead cost saving $4,000
McDonnel Douglas has ranged 36-96% parts count
reduction on several of its aircraft component
assemblies
FA-18 CD bay shelf design savings

84% in number of parts

73% in cost
11% in weight
89% in assembly time

WHAT IS DFMA (CONTD.)

DFMA ENCOURAGES CONCURRENT ENGINEERING
DURING PRODUCT DESIGN SO THAT PRODUCT
QUALITIES RESIDE WITH BOTH THE DESINERS AND
OTHER MEMBERS OF THE PRODUCTION TEAM
IT IS A COMMUNICATION TOOL FOR THE TEAM
IT IS A BENCH MARKING TOOL
IT DEFINES THE DESIGN AND MANUFACTURING
CAPABILITIES OF SELF AND COMPETITOR

WHAT IS DFMA (CONTD.)

IT PROVIDES A NON-THREATENING WAY TO GET
PEOPLE TALKING ABOUT A DESIGN WITHOUT
FEELING LIKE OTHERS ARE ENCROACHING ON
THEIR TERRITORY
EINSTEIN SAID THE BEST DESIGN IS THE
SIMPLEST ONE THAT WORKS . DFMA PROVIDES
THE CHEAPEST WAY TO THAT GOAL

WHAT IS DFMA
DFMA IS AN EXACTING DESIGN REVIEW
METHOD
IT IDENTIFIES:
-OPTIMAL PART DESIGN
-MATERIAL CHOICE
-ASSEMBLY AND FABRICATION OPERATIONS
TO PRODUCE AN EFFICIENT AND COST
EFFECTIVE PRODUCT
IT REVEALS THAT INITIAL IDEAS MAY NOT BE