Design for Manufacturing & Assembly     

On-site
Delivery

I.D.# 95032Printable Description
Duration: 1 Day

Design for Manufacturing and Assembly (DFM+A), pioneered by Boothroyd and Dewhurst, has been used by many companies around the world to develop creative product designs that use optimal manufacturing and assembly processes. Correctly applied, DFM+A analysis leads to significant reductions in production cost, without compromising product time-to-market goals, functionality, quality, serviceability, or other attributes. This seminar will include information on how DFM+A fits in with QFD, Concurrent Engineering, Robust Engineering, and other disciplines.

Each participant will receive and use the hard-bound authoritative reference textbook "Product Design for Manufacture and Assembly", written by Geoffrey Boothroyd, Peter Dewhurst and Winston Knight.

You are also asked to bring a calculator capable of making simple calculations.

Learning Objectives
Upon successful completion of this course, you will be able to:

  • Perform Design for Assembly (DFA) Analysis using the BDI Manual (Worksheet) Method
  • Perform DFM Analysis (manufacturing cost estimation)
  • Apply Design for Service (DFS) Principles
  • Reduce your company's production costs by analyzing and eliminating the factors that greatly affect the time, cost, and quality of manufacturing, assembly and service processes
  • Utilize effective analysis, brainstorming, and trade-off techniques for redesigning assemblies and subassemblies

Who Should Attend
You should attend if you are a product designer, product engineer, or manufacturing engineer. Individuals involved in a new or ongoing product development process will benefit by learning how to help synchronize and optimize fabrication and assembly activities. This course is most effective when attended by product development teams. However, this is not a requirement for attendance.

Topical Outline

  • Welcome and Introduction
  • What is DFM+A
    • The history of DFM+A
    • The various "Design fors"
    • Why companies are using DFM+A
    • DFM+A success stories
    • DFM+A benefits
    • Key factors in ensuring DFM+A success
  • DFA Good Design Principles
    • The Boothroyd Dewhurst Design for Manual Assembly Method
    • Using the manual handling and insertion tables
    • Determining theoretical minimum part count
    • Filling in the BDI DFA worksheet
    • Computing the DFA Index
  • DFA Baseline Analysis Exercise (Pneumatic Piston)
  • Redesign Project (Pneumatic Piston Assembly)
    • Developing design concepts
    • Identifying conservative and "stretch" designs
    • Selecting the best DFA concept
    • Analysis of redesign
    • Presentation of team results
  • General Approach to Manufacturing Cost Estimation
    • Manufacturing cost drivers
    • Estimating piece cost
    • Cost calculation exercise
  • BDI Design for Manufacture (DFM) Cost Estimation
    • Injection molding cost algorithms
    • Sample calculation
    • Exercise (analyzing part from pneumatic piston)
  • Brief Design for Service (DFS) Overview
  • DFM+A Workshop Checklist
  • Institutionalizing DFM+A in Your Organization
    • How DFM+A fits in with other strategies
    • Lessons learned from other companies
    • Ideal workplace implementation plan
  • Wrap Up
  • Course Evaluation

Instructor(s): Kevin Zielinski
Kevin Zielinski currently owns and operates Red Cedar Media LLC, a training and corporate communications consulting, design, development and delivery company based in Michigan. Previously, Kevin was Senior Applications Specialist for EDS (including General Motors/EDS and Hewlett Packard/EDS) specializing in technical training delivery, training consulting, courseware design and development, and e-Learning. He has designed, developed and delivered over 40 lecture- and web-based courses attended by General Motors and EDS employees worldwide. Mr. Zielinski has also served as Adjunct Professor for the Wayne State University College of Engineering and WSU/Focus:Hope for many years. His areas of expertise include: e-Learning design and development, Quality Tools and Methods (Design of Six Sigma, Robust Engineering, Design of Experiments (DOE), Statistical Tolerancing and GD&T); Design for Manufacturing and Assembly (DFMA); Engineering Economics; and Plant Floor Throughput Improvement. He has been an instructor for SAE Professional Development since 1990, and is a recipient of SAE's Forest R. McFarland Award (April 2005). He holds a bachelor's and master's degree in engineering from Wayne State University.

Fees: $895.00 ; SAE Members: $716.00 - $806.00

.7 CEUs
You must complete all course contact hours and successfully pass the learning assessment to obtain CEUs.

For additional information, contact SAE Customer Service at 1-877-606-7323 (724/776-4970 outside the U.S. and Canada) or at CustomerService@sae.org.

For a quote on bringing this course to your company site, fill out a Corporate Learning Solutions Request Form