Design For Manufacturability:
Design for Manufacturing & Design for Assembly
Design for Manufacturing and Design for Assembly are the integration of product design and process planning into one: Design for Manufacturability (DFM). Design for Assembly is concerned with reducing product assembly cost: minimizing number of assembly operations and individual parts tend to be more complex in design. Design for Manufacturing is concerned with reducing overall part production cost: minimizing the complexity of manufacturing operations. Together, the overall objective is to design a product that is as easily and economically manufactured as possible. The importance of DFM is emphasized by the fact that about 70% of manufacturing costs of a product (cost of materials, processing, and assembly) are determined by design decisions. Production decisions (such as process planning or machine tool selection) are responsible for only 20%, with the remaining 10% being other processes involved. In very simple terms applying a good DFM, integration should reduce the cost and difficulty of manufacturing.
Reduce Total Number of Parts. The reduction of the number of parts in a product is feasibly the best opportunity for reducing manufacturing costs. Fewer parts imply fewer purchases, handling, processing time, development time, engineering time, assembly difficulty, inventory, equipment, service inspection, testing, less chance of default or assembly issues, etc. Some approaches to part-count reduction are based on the use of one-piece structures and selection of manufacturing processes such as injection molding, precision casting, etc. that optimize the process.
Utilize Standard Components. There are quite a few benefits to using standard components versus custom ones. For starters, they are highly available which reduces product lead times. The manufacturer that needs a standard part has less worry they will get it on time from the supplier because of the fact it is readily available and can choose which supplier offers the best deal for the quantity needed in the time frame that is necessary to remain on the production schedule. More importantly, they are less expensive than custom.
Minimize Handling and Assembly Directions. All parts should be assembled from one direction if possible. In a vertical direction would be considered the best choice to add parts from above parallel to the downward direction, also known as Top-Down Assembly. Having to compensate any other way from various angle degrees would complicate production, slowing production time, and could lead to a higher chance of product defect. In regards to handling, symmetrical parts should be used. For all instances where the parts are not symmetrical, the asymmetry must be amplified to avoid product defects. The subsequent operations should be designed so the orientation of the parts is maintained. Minimizing the flow of material waste, parts, etc. in the manufacturing operations along with considering consolidated packaging options that are still safe and appropriate for the final product.
Design Parts to Be “Multi”. Multi-functional parts reduce the total number of parts in a design. Parts that can be classified as multi-use can be shared within multiple products that the manufacturer has, allowing one purchase order from the supplier to utilize in more than one product. All of which allows for versatility, less production time, and ultimately less cost. To proceed, one must identify the parts that are most suitable for multi-use. All parts used by the manufacturer (purchased or made) should be sorted for all parts that are used commonly all or most products and in part families, with subcategories of similar parts in each grouping. The goal is to minimize the number of categories. The outcome is a set of standard part families which multi-use parts are established. Once organized, the manufacturing process is standardized for each part family. Now allowing the ability to skip operations that are not required.
EASTEK IS YOUR GLOBAL CONTRACT MANUFACTURING SOLUTION.
Our mission is simple: to enable our customers to be their most successful. We do this by utilizing our U.S. and China manufacturing expertise and global resources to efficiently provide our customers with the highest quality, most cost-effective product, on time and on-budget.
We offer cutting-edge product engineering services that include:
- Product Engineering
- Failure Mode & Effects Analysis (FMEA)
- Design for Manufacturability & Assembly (DMA) (including 3D modeling)
- Product Validation Testing
Eastek’s product engineering services can help you take your business to the next level. As your single-source partner, we can help you to get to market faster and reduce costs. We maintain a highly trained staff of manufacturing engineers, process engineers and manufacturing professionals
- Lean, reliable manufacturing operation ensures products that consistently meet design and performance characteristics
- Statistical process control minimizes variation and ensures part conformance
- Examined components are marked to ensure full traceability so raw materials can be linked to products
- We use state-of-the-art inspection and metrology equipment
We are a total solutions provider for product life cycle and cost reductions:
- Re-engineer product design
- Design for Cost
- Design for Reliability
- Design for Maintainability
- Design for Manufacturability
- Re-engineer the manufacturing process
- Identify and qualify lower cost supply opportunities based at our Dongguan, China facility
Our manufacturing engineering personnel work directly with our suppliers to engage in a process of “Continuous Improvement” to improve quality and reduce part cost by leveraging enhanced technologies and improved processes of the suppliers.
EASTEK INTERNATIONAL provides complete Design for Manufacturability (DFM) support, ensuring your products can be produced at the lowest cost, with the highest efficiency, and the shortest time-to-market. Eastek’s engineering team places emphasis on defect prevention and non-value added process step elimination by analyzing the design data package for common errors relating to the BOM selection, PCB design, and manufacturing materials/processes used to assemble the customer’s product.
- Assembly Materials Selection
- Availability/Alternate Selection
- BOM Analysis
- Component Placement for SMT
- Component Review
- Fabrication Note Review
- Fiducials for Automated Assembly
- Form/Fit Requirements
- Test Point Access
- Land Pattern Review
- Manufacturing Process Parameters
- PWA Manufacturing Analysis
- PWB Depanelization Requirements
- PWB Drawing Review
- Silkscreen Identifiers
- Soldermask Clearance