Edward C.

Lai & Associates

Introduction to Design For Manufacturing and Assembly (DFMA)

ber o he num fasteners imize t f 1. Min ize the use o im 2. Min rdize s da ponent 3. Stan difficult com mblies id se 4. Avo odular subas arts m lp 5. Use ultifunctiona n's m tio 6. Use ize reorienta ures at im 7. Min lf-locating fe se ng 8. Use special tooli id ps ty 9. Avo e accessibili & process ste vid ations 10. Pro ze oper nimi 11. Mi

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2009, Edward C. Lai and Associates and the World Academy of Personal Development, Inc. OPTIMAL THINKING is a registered trademark of The World Academy of Personal Development Inc. All Rights Reserved.

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What is DFMA?

Edward C. Lai & Associates

A proactive product design process that focuses on meeting customer requirements while balancing among cost, quality and performance. It is a concurrent engineering team approach that involves engineering, manufacturing and suppliers early in the design cycle. The best results occur when DFMA is used in the product conceptual stage. The cross-functional team work towards minimizing the number of components, manufacturing steps and operations while designing to proven manufacturing capabilities. Optimal Thinking is the core of all activities.

2009, Edward C. Lai and Associates and the World Academy of Personal Development, Inc. OPTIMAL THINKING is a registered trademark of The World Academy of Personal Development Inc. All Rights Reserved.

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Edward C. Lai & Associates

Design Philosophy
The

best design is the simplest one that works. Albert Einstein

er o e numb asteners h imize t ff 1. Min ize the use o im 2. Min rdize s da ponent 3. Stan difficult com mblies id se 4. Avo odular subas arts m lp 5. Use ultifunctiona n's m tio 6. Use ize reorienta ures at im 7. Min lf-locating fe se ng 8. Use special tooli id ps ty 9. Avo e accessibili & process ste vid t io n s 10. Pro e opera nimiz 11. Mi

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es rincipl f parts MA P

2009, Edward C. Lai and Associates and the World Academy of Personal Development, Inc. OPTIMAL THINKING is a registered trademark of The World Academy of Personal Development Inc. All Rights Reserved.

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Design Complexity
(Components through Systems)

Edward C. Lai & Associates

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100% Test
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1 0 0%

ed F e a tu

2009, Edward C. Lai and Associates and the World Academy of Personal Development, Inc. OPTIMAL THINKING is a registered trademark of The World Academy of Personal Development Inc. All Rights Reserved.

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Repa

How to Attack Complexity ?

One Bite at a Time Apply Design Simplification Rules Challenge Old Beliefs Take a New look at Current Design Work as a Team Use a Facilitated Process

Edward C. Lai & Associates

2009, Edward C. Lai and Associates and the World Academy of Personal Development, Inc. OPTIMAL THINKING is a registered trademark of The World Academy of Personal Development Inc. All Rights Reserved.

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DFMA Methodology

Edward C. Lai & Associates

SELECTION OF BEST IDEAS / DESIGN OPTIONS

IMPLEMENTATION AND CONTINUOUS OPTIMIZATION

2009, Edward C. Lai and Associates and the World Academy of Personal Development, Inc. OPTIMAL THINKING is a registered trademark of The World Academy of Personal Development Inc. All Rights Reserved.

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DFMA Basic Principles

1. 2. 3. 4. 5. 6. 7.

Edward C. Lai & Associates

Minimize the number and types of parts used in the assembly Minimize the use of fasteners (number & types) Standardize (e.g. material, finishes, parts, processes, tooling, etc.) Avoid difficult components (e.g. open-ended springs, small/loose HW, etc.) Use modular subassemblies Use multifunctional parts Minimize reorientation & assembler awkward movements
(e.g. stooping, bending, reaching, tugging, balancing, etc.)

8. Use self-locating features (e.g. molded shapes, keying, chamfers, dimples) 9. Avoid special tooling/test equipment 10. Provide accessibility for assembly, test/inspection and rework 11. Minimize operations & process steps (including excess handling, etc.) Eliminate...Minimize...Standardize...Productionize
2009, Edward C. Lai and Associates and the World Academy of Personal Development, Inc. OPTIMAL THINKING is a registered trademark of The World Academy of Personal Development Inc. All Rights Reserved.

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Typical Participants
Systems Eng Electrical Eng Mechanical Eng Material & Process Eng Manufacturing Manufacturing Eng Supply Chain Management Key Suppliers Program Office Customer Quality Subject Matter Experts (Outside of the design team)

Edward C. Lai & Associates

2009, Edward C. Lai and Associates and the World Academy of Personal Development, Inc. OPTIMAL THINKING is a registered trademark of The World Academy of Personal Development Inc. All Rights Reserved.

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Typical Workshop Agenda

Introduction to DFMA Objectives, programmatics, commonality DFMA Overview Scope, deliverables, decision criteria, rules Baseline design overview Design ground rules and requirements Identify issues on cost, schedule and performance Brainstorm, evaluate and select best alternatives Define optimal assembly process Review assumptions, action items and parking lot Next steps

Edward C. Lai & Associates

2009, Edward C. Lai and Associates and the World Academy of Personal Development, Inc. OPTIMAL THINKING is a registered trademark of The World Academy of Personal Development Inc. All Rights Reserved.

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Decision Criteria
Cost (Implementation) Cost (Recurring) Schedule Risk (Technical, schedule, cost) Performance
: Same as baseline

Edward C. Lai & Associates

: Better than baseline

: Worse than baseline

2009, Edward C. Lai and Associates and the World Academy of Personal Development, Inc. OPTIMAL THINKING is a registered trademark of The World Academy of Personal Development Inc. All Rights Reserved.

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Edward C. Lai & Associates

For more information on DFMA, please contact : Ed Lai 310-365-0629 elai001@aol.com

2009, Edward C. Lai and Associates and the World Academy of Personal Development, Inc. OPTIMAL THINKING is a registered trademark of The World Academy of Personal Development Inc. All Rights Reserved.

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