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Lean Six Sigma Basics
Published in James William Martin, Lean Six Sigma for the Office, 2021
The first strategy to reduce complexity is not producing products and services that do not add value, are unprofitable, or are not strategically aligned. Because NVA features and functions creep into products, services, and supporting processes at any time, some of them may not be in demand or direct labor, and materials costs are increased causing operational inefficiencies. An effective way to see this is to create an analysis that prioritizes them by their volume, profitability or gross margin, and strategic alignment. It is often a surprise to see which products and services have a negative margin. A major goal should be identification and removal of products and services that are not part of an organization’s core product and service portfolio, and improvement of the efficient production of those that are. This helps to focus on more impactful project areas. A second goal should be to apply simplification, consolidation, modularization, and standardization methods to remaining products and services. An example is the proven methodology of Design for Manufacturing (DFM) used to simplify product design, eliminating and aggregating features, functions, materials, components, and work tasks.
BASICS Model: Implementation (I)
Published in Protzman Charles, Protzman Dan, Keen William, The BASICS Lean™ Implementation Model, 2019
Protzman Charles, Protzman Dan, Keen William
Using DFM will guide us toward a product with fewer parts and a more efficient production line. DFM gathers all the attributes of manufacturability and quantifies them into data that can be calculated into usable metrics. We can utilize the metrics to compare different design scenarios and ensure intelligent choices and decisions will be made. The inventory turns of a company is rarely a concern of the designer during the product development, but it should be. R&D should own the product from concept to end of life. General guidelines to consider are as follows: Don’t tie operators or customers to machinesSemi-automate where possibleProvide easy-to-use fixturing for operatorsDesign-in mistake-proofingEliminate, simplify, and combine wherever possible
Miscellaneous Issues
Published in Paul H. King, Richard C. Fries, Arthur T. Johnson, Design of Biomedical Devices and Systems, 2018
Paul H. King, Richard C. Fries, Arthur T. Johnson
Design for manufacturability ensures that a design can be repeatedly manufactured while satisfying the requirements for quality, reliability, performance, availability, and price. One fundamental principle is reducing the number of parts in the device. Existing parts should be simple and add value to the product. All parts should be specified, designed, and manufactured to allow 100% usable parts to be produced. Design for manufacturability is desirable because it reduces cost, due to the following: A simpler design with fewer partsSimple production processesHigher quality and reliabilityEasier to service
Investigation of design for additive manufacturing in professional design practice
Published in Journal of Engineering Design, 2018
Patrick Pradel, Zicheng Zhu, Richard Bibb, James Moultrie
Design for manufacturing (DFM) is the practice of designing products to reduce or minimise manufacturing difficulties and costs, focusing at a component level, to optimise a component for the chosen process. Design for Additive Manufacturing (DfAM) aims to take advantage of the unique capabilities of AM to (i) design and optimise components according to the functions of the product/component and the requirements of the selected AM process for production; and (ii) rethink, redesign and refine an existing product/component, utilising the characteristics of AM to improve the functionality (Hietikko 2014). Guidance on DfAM has typically encouraged designers to tailor their designs to utilise the advantages of AM in enabling complex geometries and reducing weight, whilst being aware of AM process limitations, to ensure the manufacturability or ‘printability’ of the component or product.
Design for manufacture and assembly in construction: a review
Published in Building Research & Information, 2020
Shang Gao, Ruoyu Jin, Weisheng Lu
The typical DfMA process can be arranged into stages, as summarized in Figure 1. Boothroyd (1994) has noted that DfA should always be the first consideration, leading to a simplification of the product structure. This is followed by the economic selection of materials and processes and early cost estimates. In this process, cost estimates for original design and new (or improved) design will be compared, in order to make trade-off decision. Once the materials and processes have been finally selected, a more thorough analysis for DfM can be carried out for the detailed design of the parts. At this stage, DfM is assisted with guidelines for standardization, component design and component assembly to reduce total manufacturing cost.
Study on 3D printed auxetic structure-based non-pneumatic tyres (NPT’S)
Published in Materials and Manufacturing Processes, 2022
Narasimhulu Andriya, Varnali Dutta, Vemula Vijaya Vani
FDM technology (shown in Fig. 1) has one of the most widespread application levels in terms of functional prototypes/tools, solid imagining/concept tools, direct tooling, and direct manufacturing, as it employs Design for Manufacturing principles (DFM). DFM methodologies allow the designers to customize their design and simultaneously minimize the fabricating, assembly, and logistics costs to comply with manufacturing constraints.[8]