Eliminate over 40% of the components of an assembly or system.  Each component eliminated can save millions of dollars.

Design for assembly is performed before design for manufacturing.  Each part that is eliminated eliminates design functions, assembly functions, and manufacturing functions.  Eliminating functions is the only way to remove root causes.  All other solutions delay failure well past the warranty period.  

Removing components eliminates assembly causes.  Removing components eliminates component part handling, selection, location, orientation, and joining causes.  Eliminated components minimizes the BOM.  

Design for manufacturing creates components that have low energy densities at contact points and through all cross-sectional areas of the component.  It produces optimal performance and reliability using the most cost-effective materials.  Dimensions make a design work.  Materials make the design last.

Design for Assembly – Eliminate parts and optimize those that remain (DFM)

• DFA Overview
• Component functions – combining functions of many components into a single component.
• Simplifying the component design
• The new assembly process functional block diagram.
• The potential failure modes of all theoretical assembly functions
• The function fault state map
• Planning 7FM mistake-proofing (failure mode controls) and 7FM error-proofing (cause removal)
• Optimizing Insertion and Handling
• Eliminating Fasteners
• Self-location Strategies
• Self-hold strategies
• Single hand Z-Axis Assembly – freeing up both hands for assembly and reducing assembly time by over 50%
• Minimizing dependent/interrelated assembly, locate, orient, and hold functions
• Optimizing Assembly Flow

Design for Manufacturing

• DFM Overview
• Performed after DFA has been completed or on an individual component that requires optimization
• Component Architecture
• Designing the minimum material component that will survive without failure
• Energy enters material, is focused by dimensions, and exits through another dimension’s material
• Excessive energy density causes material change
• Material fatigues and fail –Energy density factor of 1.0, 2.0 (automotive safety), and 3.0 (automotive functional safety) strategies
• Component Configuration
• Energy, material, and dimension functions,
• Natural language function descriptions,
• Technical language function descriptions,
• Function performance specifications.
• Optimization
• Eliminate or minimizing costs
• Minimize movement
• Minimize material and manufacturing costs
• Cost reduction report