Design for Manufacturability/Assembly Workshop

Practical, hands-on workshop. Includes over 240 examples of good and bad design for manufacturability and assembly practices. Includes exercises to reinforce understanding of principles and analysis of company assemblies to transition learning back to your workplace. The three-day workshop includes one day on-site prior to the workshop to customized it to your products and processes.

1. DESIGN FOR MANUFACTURABILITY/ ASSEMBLY (DFM/A)

  • DFM/A Introduction
  • Design Impact on Cost
  • DFM/A Fallacies vs. Reality

2. DESIGN FOR ASSEMBLY

  • Principles of Design for Assembly
  • Simplify Product Architecture
    • Modularity and Structure with Architecture
    • Partitioning, Collocation, and Orientation Effect on Interconnections
    • Modular Design vs. Integral Design
  • Simplicity – Minimize Part Count
  • Minimize Parts Exercise
  • Standardization – Minimize Part Variety
  • Standardization Approach and Method
  • Mistake-Proof Assembly – The Six Mistake-Proofing Principles and the Relative Benefit
    • Elimination Principle and Examples
    • Replacement Principle and Examples
    • Prevention Principle and Examples
    • Facilitation Principle and Examples
    • Detection Principle and Examples
    • Mitigation Principle and Examples
  • Mistake-Proofing Approach and Methodology
  • Mistake-Proofing Exercise – Identify Mistake-Proofing Opportunities
  • Assembly Process Framework
  • Design for Parts Feeding & Handling
  • Design for Part Orientation
    • Considering and Applying Symmetry vs. Asymmetry
    • Measuring Symmetry – Alpha, Beta and Combined Symmetry
  • Design for Location and Insertion
  • Minimize Flexible Parts
  • DFA Considerations with Gaskets, Interconnections, & Connectors
  • Axes of Assembly, Reorientation & Blind Assembly
  • Top Down, Uni-Axis Assembly
  • Self-Fixturing vs. Production Fixtures
  • Joining & Fastening Guidelines
    • Integral Attachment (Self-Fastening & Snap-Fit Assembly) Guidelines
    • Threaded Fastener Considerations & Guidelines
    • Adhesive Joining Guidelines
    • Welding Guidelines
    • Other Fastening Methods and Guidelines
  • Finishing, Adjustment & Calibration
  • DFA Considerations to Facilitate Test and Inspection
  • Applying DFA to Packaging – The Final Assembly Step
  • Case Studies and Benefits – Aerospace, Automotive, Electronics, Mechanical Machinery
  • Design for Assembly Analysis Exercise

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
  • Feeding Systems & Orientation
  • Flexible Automation
    • Design for Robotic Assembly Guidelines
    • Design for Vision System Guidelines
    • Gripper Design Guidelines

3. DFM/A FOR ELECTRONICS

  • Use of DFM/A Guidelines for Boards
  • Simplify the Assembly Process – Mixing Technology and Board Sides
  • Reduce Thermal Cycles
  • Board Size and Panelization Guidelines
  • PCB Layout Guidelines
    • Panel Considerations and Keep-Out Area
    • Tooling Hools
    • Fiducials
    • Through-Holes and Vias
    • Trace Width and Spacing
    • Pad Layout and Component Spacing
    • Test Point Access
  • Component Selection Guidelines
  • Avoid Manual Assembly
  • Other Component Considerations
  • DFM/A Assessment for Boards
  • Automated Design Rules Checking

4. DESIGN FOR MANUFACTURABILITY

  • DFM Framework
  • Material and Process Evaluation
  • Material and Process Evaluation Exercise
  • Raw Material Standardization
  • General DFM Guidelines
  • Machining Guidelines and Examples
  • Manufacturability Analysis Exercise
  • Sheet Metal Guidelines and Examples
  • Injection Molding Guidelines and Examples
  • Casting Guidelines and Examples
  • Minimize Finishing Requirements

5. PROCESS CAPABILITY AND TOLERANCES

  • 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
  • Tolerance Analysis
    • Worst Case
    • Root Sum of Squares (RSS)
  • Tolerance Optimization

6. DESIGN FOR “X” (Optional topics covered on request)

  • 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. DFM/A AND THE DEVELOPMENT PROCESS

  • DFM/A Process Steps
    • During Concept Development Phase
    • During Design Phase
    • During Validation and Pilot Phase
    • During Production Launch Phase
  • Early Manufacturing Involvement
  • DFM/A Collaboration Tools and Methods
  • Role of Solids and Assembly Models in DFM/A Evaluation
  • How to Effectively Consider Design Alternatives to Address DFM/A Issues
  • Product Cost Models to Estimate Costs & Evaluate Design Alternatives
  • Early Supplier Involvement
  • Developing Design Guidelines
  • Formal DFM/A Analysis & Assessment
  • DFM/A Manual and Software Tools
  • Conducting Design Reviews to Address DFM/A
  • Capturing Issues with Build Reports
  • Closing the Loop with a Final Production Review
  • DFM/A Performance Measurement & Metrics

8. SUMMARY

  • 10 Steps to DFM/A
  • DFM/A Survey Results
  • Sources of Further Information
  • Questions and Discussion

9. DFM/A ANALYSIS OF COMPANY PRODUCT OR ASSEMBLY

  • Transitioning from the Workshop to Product Design – Exercise Objectives
  • Introduction of Analysis Methodology and DFM/A Worksheet
  • Team Analysis of Company Products or Assemblies
  • Team Consideration of DFM/A Improvements
  • Team Reporting Out and Exercise Discussion
  • Concluding Questions and Discussion

Seminar Leader



Kenneth-Crow Kenneth Crow is an internationally recognized expert in the field of integrated product development, a distinguished speaker, and creator of the NPD Body of Knowledge. Ken’s experience includes work in aerospace, automotive, capital equipment, consumer products, electronics and high technology, mechanical machinery, and medical equipment industries. He has conducted hundreds of workshops and trained over 2,500 professionals and managers on subjects related to new product development. (More)

More Details


Call for more information: 800-577-3528 U.S. toll free | 971-222-6234 main office