Design For Manufacturing Techniques Research Articles

A multi-criteria model for evaluating design for manufacturability

The design for manufacturability (DFM) method is most effective when integrated with the new product development (NPD) process. Due to the focused nature of the associated product and process knowledge and the extensive effort required, there are many NPD situations where classical DFM techniques cannot be readily applied. In this paper, Pro-DFM a multi-criteria model for manufacturability analysis that identifies product realisation opportunities (PRO) for cost reduction is presented. The key assumption in Pro-DFM is that the NPD team has a baseline estimate of production costs, and the evaluation question is how DFM issues will affect the expected unit production cost. The Pro-DFM model analyses a new design in three different factors: part procurement and handling, product assembly fabrication processes, and inventory costs. Each of these is independently analysed using a hierarchy of multiple criteria and sub-criteria. This approach is found to be amenable to most NPD processes, and conducive to easy integration. Each evaluation sub-criterion is presented in the form of a simple query, which is associated with a set of responses that is flexibly anchored to a uni-dimensional scale. A case study example is used to demonstrate the DFM evaluation process and the derivation of the cost penalties.

An approach to integrate manufacturing process information in part design phases

Design for Manufacturing (DFM) is the integrated practice of designing components while considering their manufacture (O’Driscoll, M., 2002. Design for manufacture. Journal of Material Processing Technology, 122, 318–321). The benefits of this practice have been widely acknowledged in the industry. Several techniques fall under the umbrella of Design for Manufacturing, and their implementation depends heavily on the context in which they will be applied. How to enhance their use by designers is still an issue. The use of a formalized design process, in which a software application is used to bring manufacturing knowledge to the forefront, would improve DFM implementation. In such a context, a fundamental issue is to define the manufacturing information that should be presented to the designer. This work addresses the capture and documentation of essential DFM information to make design decisions. Essential manufacturing information is that which can affect the fulfilment of functional requirements and product constraints. The proposed approach combines DFM techniques and principles of Axiomatic Design (AD) theory. The manufacturing information is represented by the concepts of Process Property (PP) and process Execution Variable (EV). The ultimate aim of the approach is to define manufacturing knowledge structures and develop a knowledge-based application for DFM. The approach was applied to a case study in which a connecting rod was the part to de designed and manufactured. The manufacturing processes selected were forging and powder metallurgy. The DFM information about these manufacturing processes, related to the connecting rod, was identified and formalized in a table-based data structure.

A survey report on design for manufacture in the UK furniture manufacturing industry

This article reports on a questionnaire survey with the aim to determine the extent of familiarity with and use of design for manufacture (DFM) in the UK furniture manufacturing industry. It was revealed that only a small proportion had experimented or applied one or more DFM techniques. The majority of them did not understand what exactly DFM was and wished to know more about it, while a noticeable level of benefits had been achieved, perceived, or expected. Embedding DFM activities in day‐to‐day operations was perceived by industrialists as the most effective way of implementing DFM while training for a formal team was necessary for its introduction. A high level of management support was evident, so were worries about the high risk and cost. However, the special needs of the furniture industry require further investigation.

Evaluating customer support during new product development—An exploratory study

Anyone who has struggled with a balky computer understands the importance of product support. Useful support for a high-tech product may take various forms, including installation, documentation, field service, user training, and product upgrades. All these forms of support share a common goal: achieving customer satisfaction with the product. To increase the likelihood of customer satisfaction with a high-tech product, a firm must carefully consider the product's support requirements during the design stage of the new-product development (NPD) effort. As Keith Goffin points out, however, relatively little research has been published about the manner in which product design influences product support. He suggests that firms may benefit from considering product support requirements during the design stage, in much the same way as design for manufacturability (DFM) techniques enable firms to increase ease of manufacture. In a survey of high-tech firms, he explores the ways in which companies evaluate product support requirements during the design stage. The study also examines whether firms use quantitative goals to focus the design team's attention on a product's support needs. To provide deeper understanding of the interrelationship between support requirements and product design, he also presents a case study involving Hewlett-Packard's development of a complex medical device. With responses from 66 companies, the survey offers the first empirical data on how compaines plan for product support. Whereas DFM techniques involve consideration of manufacturability during the early stages of design, more than two-thirds of the companies in the study begin planning for support during the second half of the product development process. Only slightly more than one-half of the respondents report the use of a formal product support plan, although use of this type of document is more prevalent among the computer firms in the study. The companies in this study do not consider all aspects of support during product planning. The respondents also do not set quantitative goals for all aspects of support during the design stage. They typically set quantitative goals for service-related aspects of support—for example, product reliability targets such as annual failure rate—rather than for such support areas as user training. The survey responses identify a range of measures which could be used for performing a more comprehensive evaluation of support requirements during the design stage.

Evaluating Customer Support During New Product Development—An Exploratory Study

Anyone who has struggled with a balky computer understands the importance of product support. Useful support for a high‐tech product may take various forms, including installation, documentation, field service, user training, and product upgrades. All these forms of support share a common goal: achieving customer satisfaction with the product. To increase the likelihood of customer satisfaction with a high‐tech product, a firm must carefully consider the product's support requirements during the design stage of the new‐product development (NPD) effort.As Keith Goffin points out, however, relatively little research has been published about the manner in which product design influences product support. He suggests that firms may benefit from considering product support requirements during the design stage, in much the same way as design for manufacturability (DFM) techniques enable firms to increase ease of manufacture. In a survey of high‐tech firms, he explores the ways in which companies evaluate product support requirements during the design stage. The study also examines whether firms use quantitative goals to focus the design team's attention on a product's support needs. To provide deeper understanding of the interrelationship between support requirements and product design, he also presents a case study involving Hewlett‐Packard's development of a complex medical device.With responses from 66 companies, the survey offers the first empirical data on how companies plan for product support. Whereas DFM techniques involve consideration of manufacturability during the early stages of design, more than two‐thirds of the companies in the study begin planning for support during the second half of the product development process. Only slightly more than one‐half of the respondents report the use of a formal product support plan, although use of this type of document is more prevalent among the computer firms in the study.The companies in this study do not consider all aspects of support during product planning. The respondents also do not set quantitative goals for all aspects of support during the design stage. They typically set quantitative goals for service‐related aspects of support—for example, product reliability targets such as annual failure rate—rather than for such support areas as user training. The survey responses identify a range of measures which could be used for performing a more comprehensive evaluation of support requirements during the design stage.

A statistical methodology as applied to a 256 Mbit DRAM pass transistor design

We present a novel design for manufacturing (DFM) methodology that has been applied to the design of a pass transistor for 256 Mbit DRAM. The design inputs that include gate oxide thickness, which limits the booted wordline voltage, the threshold voltage adjust implant, and the substrate bias voltage, for different channel lengths, are optimized to meet the constraints on performance, reliability, and robustness against manufacturing variations. The problems associated with applying conventional DFM techniques are discussed and a new methodology based on margins is presented. The results pertaining to the optimized DRAM pass transistor design for a power supply voltage V/sub cc/=2.5 V are presented,.

Design for Manufacture Techniques Help the Team Make Early Decisions

SUMMARY This paper introduces the role and value of design for manufacture tools and techniques in a team-based simultaneous engineering design process. The Lucas design for assembly techniques is described and the benefits of its use in terms of parts count reduction, assembly cost reduction and product cost reduction are given. A second technique, quality function deployment, is outlined and its advantages listed. Finally, an implementation strategy for design for manufacture is recommended.

Design for Assembly—A Key Element within Design for Manufacture

This paper will consider design for assembly (DFA) and its role within a design for manufacture (DFM) programme, placing particular emphasis on those elements with which it has strong synergy, namely simultaneous engineering, product teams and other DFM techniques.