DFM/A Workshops for your New Product Development Process

This three-day, hands-on workshop includes over 240 examples (both good and bad) of design for manufacturability and assembly practices. The workshop includes exercises to reinforce understanding of principles and DFM/A analysis of company assemblies to introduce a practical analysis methodology and better understand how the DFM/A principles apply to your organization’s products. The workshop is preceded by one day on-site to customize it to your products and processes.

1. DESIGN FOR MANUFACTURABILITY/ ASSEMBLY (DFM/A)

DFM/A Introduction
Design Impact on Cost
DFM/A Fallacies vs. Reality

2. DESIGN FOR ASSEMBLY

Principles of Design for Assembly
Simplicity – Minimize Part Count and Consolidate Part Functions
Minimize Parts Exercise
Commonality and Standardization – Minimize Part Variety
Commonality and Standardization Approach and Method
Mistake-Proof Fabrication and Assembly – The Six Mistake-Proofing Principles and the Relative Benefit
Mistake-Proofing Approach and Methodology
Mistake-Proofing Exercise – Identify Mistake-Proofing Opportunities
Assembly Process Framework
Design for Parts Feeding and Handling
Design for Part Orientation
Design for Location and Insertion
Axes of Assembly, Reorientation & Blind Assembly
Top Down, Uni-Axis Assembly
Self-Fixturing vs. Production Fixtures
Joining & Fastening Guidelines
- Integral Attachment Guidelines
- Threaded Fastener Considerations & Guidelines
- Adhesive Joining Guidelines
- Welding Guidelines
Finishing, Adjustment & Calibration
Applying DFA to Packaging
Design for Assembly Analysis Exercise

3. DFM/A FOR ELECTRONICS

Use of DFM/A Guidelines for Boards
Simplify the Assembly Process – Mixing Technology and Board Sides
Reduce Thermal Cycles
Board Size and Panelization Guidelines
PCB Layout Guidelines
- Panel Considerations and Keep-Out Area
- Tooling Hools
- Fiducials
- Through-Holes and Vias
- Trace Width and Spacing
- Pad Layout and Component Spacing
- Test Point Access
Component Selection Guidelines
Avoid Manual Assembly
Other Component Considerations
DFM/A Assessment for Boards
Automated Design Rules Checking

4. DESIGN FOR MANUFACTURABILITY

DFM Framework
Material and Process Evaluation
Material and Process Evaluation Exercise
Raw Material Standardization
General DFM Guidelines
Machining Guidelines and Examples
Manufacturability Analysis Exercise
Sheet Metal and Stamping Guidelines and Examples
Injection Molding Guidelines and Examples
Casting Guidelines and Examples
Minimize Finishing Requirements
Design for the Supply Chain

5. PROCESS CAPABILITY AND TOLERANCES

What is Process Capability and the Effect on Manufacturability
Variation and Specifications
Parameter and Tolerance Objectives
Statistical Process Capability and Capabilities Indices – Cp and Cpk
Effect of Tolerances
Tolerance Optimization

6. DFM/A AND THE DEVELOPMENT PROCESS

Design for Manufacturability/Assembly Process Steps
Early Manufacturing Involvement
Early Supplier Involvement
DFM/A Collaboration Tools and Methods
Role of Solids and Assembly Models in DFM/A Evaluation
How to Effectively Consider Design Alternatives to Address DFM/A Issues
Product Cost Models to Estimate Costs & Evaluate Design Alternatives
Developing Design Guidelines
Formal DFM/A Analysis & Assessment
Conducting Design Reviews to Address DFM/A
Capturing Issues with Build Reports
Closing the Loop with a Final Production Review
DFM/A Performance Measurement & Metrics

7. SUMMARY

Summary
Questions and Discussion

8. DFM/A ANALYSIS OF COMPANY PRODUCT OR ASSEMBLY

Transitioning from the Workshop to Product Design – Exercise Objectives
Introduction of Analysis Methodology and DFM/A Worksheet
Team Analysis of Company Products or Assemblies
Team Consideration of DFM/A Improvements
Team Reporting Out and Exercise Discussion
Concluding Questions and Discussion