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Where applicable, it is recommended to use non-destructive testing methods since the test piece will still be fully operational and intact even after completing the testing process. Product design is probably one of the key factors that has significant implications on the feasibility of the operation. An efficient design can cut down costs and lead times remarkably, sometimes through seemingly minor modifications. This is why designers need DFM tools to analyse the effects of their design choices on production. Leveraging the digital enterprise streamlines these validation processes and puts more capability in the hands of designers for the product’s sustainability.
Happy's Essential Skills: Design for Manufacturing and Assembly, Part 2 - I-Connect007
Happy's Essential Skills: Design for Manufacturing and Assembly, Part 2.
Posted: Wed, 20 Sep 2023 05:21:12 GMT [source]
OUTCOMES OF AN EFFECTIVE DFM
Reliability principles require designers to identify the cause of each failure and work to minimize that risk so the failure doesn’t occur within the product’s lifecycle. DFM principles recommend compliance testing on a design before it enters mass production, as correcting these problems is far more expensive at the end of product development. This type of testing should also be non-destructive to ensure the test piece is fully functional afterward.
Streamlined product development process
While there may be a good reason for this, it may also identify a design flaw that, if corrected, could dramatically accelerate the manufacturing process and drive down cost accordingly. While the principles are a great start, digital manufacturing simulation is the key to unlocking the analytical problem at the heart of DFM. Your goal is to decide on the optimal manufacturing process based on factors like cost, production volume, and product factors.
What Are the Principles of Design for Manufacturing?
The quality of products and their ability to meet customer requests will be even better thanks to these innovations, which will allow for automated decision-making, real-time monitoring and predictive analytics. Adjustments guided by DFM also made ejection better by making sure the molded product came out of the mold more uniformly. Adding ejection surfaces to the rib connection points significantly improved the part's reliability and manufacturability. This case study shows how important design in manufacturing is for improving electronics manufacturing efficiency and component design.
What is Design for Manufacture and Assembly?
DFM is usually used to reduce these costs.[1] For example, if a process may be done automatically by machines (i.e. SMT component placement and soldering), such process is likely to be cheaper than doing so by hand. Leveraging product lifecycle management (PLM) software helps a business source and compare potential suppliers based on sustainability request-for-proposal (RFP) requirements. Doing so not only takes available information about suppliers into account, but also adds further information to your digital enterprise from supplier logistic network simulations. Did you know 80% of a product’s environmental impact is determined in the design phase? With so much dependence on design, it is critical to start thinking about the environmental impact of a product as early as possible, alongside the traditional drivers of cost, quality, and time. Surrogate parts are placeholder parts used to assess specific functional aspects of a design and tune in the final manufacturing process before mass production.
Both approaches should be considered and implemented to ensure that a product is designed and manufactured efficiently and effectively. Computational Fluid Dynamics (CFD) evaluates fluid flow and heat transport with the goal of developing better cooling systems and fluid-based manufacturing processes. With Moldflow Analysis, you can optimize your component design and mold setup for injection molding.
This form of optimization can be incredibly advanced when using computer-aided design (CAD) software that integrates DFM analysis capabilities. Naturally, the time taken for any process will depend on the product, parts, manufacturing process, and the complexity of operations required. However, on average, a DFM process will take around two weeks to complete. This number may increase to three or even four weeks for more complex products. On one hand, design and manufacturing teams need to communicate their requirements, constraints, and goals to the supplier clearly. On the other hand, suppliers should be proactive in sharing their expertise and offering constructive feedback on the proposed designs.
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Moreover, material selection is much more than about part functionality alone. Additionally, some materials have a negative environmental impact and can contribute to violations of carbon footprint goals. The job of design for manufacturability experts is to find ways to optimize these processes. At first, they look at the design and see if the design engineers have made the right process selection. With the key objectives of cost reduction, quality enhancement, and sustainable waste reduction in mind, engineers look to improve the following five areas of a manufacturing process during DFM analysis.
The Manufacturing Laminate Creation utility allows users to generate and organize manufacturing data early in the development process, concurrent to the design engineering phase. For example, engineering software from Siemens NX and CATIA from Dassault Systèmes enables the simulation of machining, casting and shaping, among other industrial processes. Engineers and product designers using a DFM approach by collaborating in a modern office. Corrosion-resistant composite materials, i.e. pultruded products, are replacing the old paradigm of what offshore oil rigs once looked like. In addition, it cuts costs by reducing the time and labor needed to make parts. Furthermore, DFM increases the possibilities for automation by reducing the need for manufacturing oversight.
In this video, you’ll hear how Spirit Aerosystems uses aPriori’s manufacturing insights to evaluate parts for cost drivers and to identify cost reduction opportunities. Discover how Spirit Aerosystems used aP Pro to support the development of internal fabrication discrete parts estimates. The right manufacturing cost modeling software makes it far easier to generate detailed insight into cost structure that can impactfully inform supplier negotiations.
Opting for a more straightforward manufacturing technique, such as injection molding, rather than CNC machining can lead to reduced production costs but less design flexibility. However, choosing a more specialized material with better qualities can raise material prices and lead times. To further aid in problem identification and parameter optimization for effective production, process simulation tools mimic machining, casting and forming operations. In the end, these tools help engineers optimize designs, anticipate performance and evaluate manufacturability.
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