Design for Manufacturability / Assembly Workshop

1. Design for Manufacturability / Assembly (DFM/A)

DFM/A Perspective
Competitive Gap - A Case for DFM/A
A Framework for DFM/A

2. Design for Assembly

Principles of Design for Assembly
Minimize Part Count
Minimize Parts Exercise
Standardization Approach and Method
Design for Ease of Fabrication
Design for Parts Handling and Orientation
Design for Ease of Assembly
Top Down, Uni-Axis Assembly
Mistake-Proof Assembly (Poke Yoke)
- Mistake-Proofing Principles
- Mistake-Proofing Examples
Design for Joining & Fastening
- Threaded Fastener Considerations & Guidelines
- Integral Attachment (Snap-Fit Assembly) Guidelines
- Other Fastening Methods and Guidelines
Minimize Flexible Parts
Simplify Interconnections
Design for Assembly Exercises
Case Studies and Benefits - Aerospace, Automotive, Electronics, Mechanical Machinery

2. Design for Automated Assembly (optional module)

Production Considerations for Manual, Flexible Automation and Hard Automation
Cost / Benefit Analysis of Automation
Design for Feeding Guidelines
Feeders & Orientation
Flexible Automation
- Robotic Assembly
- Design for Robotic Assembly Guidelines
- Design for Vision System Guidelines
- Gripper Design Guidelines
Hard Automation
Case Studies & Summary

3. Design for Manufacturability

DFM Framework
Material and Process Evaluation
Tolerances and DFMA Impact
Raw Material Standardization
General Guidelines
Machining Guidelines
Sheet Metal Guidelines
Injection Molding Guidelines
Guidelines for Other Fabrication Processes

4. DFM/A for Electronics

Simplify the Assembly Process
Reduce Thermal Cycles
Board Size and Panelization Guidelines
PCB Layout Guidelines
- Panel Considerations and Keep-Out Area
- Tooling Holes
- Fiducials
- Holes
- Trace Width and Spacing
- Test Point Access
Component Selection Guidelines
Component Orientation Guidelines
Examples & Results

5. Process Capability and Tolerances

Determining a Process Strategy
What is Process Capability
Variation and Specifications
Parameter and Tolerance Objectives
Statistical Process Capability
- Normal Distribution
- Capabilities Indices - Cp and Cpk
- Capability Index Exercises
- Six Sigma Capability and Defects per Million
Effect of Tolerances
Cost Impact of Tolerances
Tolerance Analysis
- Worst Case
- Root Sum of Squares (RSS)
Building a Tolerance Model
Tolerance Optimization

6. Design for "X"

Design for the Supply Chain
Design for Leadtime
Design for Safety
Design for Human Factors
Design for Reliability
Design for Disassembly
Design for Serviceability/Maintainability
Design for the Environment (DFE)
DFE Examples & Case Study

7. Analysis Tools and Techniques

Function Analysis
Function Analysis Exercise
Brainstorming and Creativity
Brainstorming Exercise
A List of DFM/A Software Tools
Illustration of DFA Tool in Use
Illustration of DFM Tools in Use (Machining)
Injection Molding and Casting Analysis
PD-Trak DFA Assessment Tool
Product Cost Models to Estimate Costs & Evaluate Design Alternatives

8. DFM/A Process and Metrics

DFM/A Process Steps
Early Manufacturing Involvement
Early Supplier Involvement
Determining Process Capabilities
Developing Design Guidelines
Conducting Design Reviews to Address DFM/A
Performance Measurement & Metrics

9. Summary

10 Steps to DFM/A
DFM/A Survey Results
Key Success Factors
Sources of Further Information
Questions and Discussion

10. Analysis Of Company Item(s) With PD-Trak

For further information, please contact us at: info@pd-trak.com or at 925-484-8436.

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