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Design for Manufacturing: Maximizing Efficiency and Quality

Learn how to optimize design for manufacturing flow, enhance product specifications, and follow engineering guidelines to improve reliability and cost competitiveness. Discover general design principles for simplicity, standard materials, and component usage, liberal tolerances, and more. Enhance collaboration with manufacturing personnel for valuable insights.

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Design for Manufacturing: Maximizing Efficiency and Quality

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  1. ME317 – Design For Manufacturing

  2. Flow of Design Knowledge Manuf. The Customer Prototype/Product Design Specifications Manufacturing Guidelines Engineering Designers Drawing Package

  3. Why Design for Manufacturing? • Mechanical engineering designs generally include off-the-shelf components and fabricated parts. • Knowing the strengths and limitations of the fabrication techniques makes for higher quality and more cost competitive designs.

  4. Ten General Design Principles(Chapter 1.3)

  5. Simplicity • Description: minimize the number of parts, intricate shapes, and manufacturing operations • Motivation: generally provides reduced cost, improved reliability, easier servicing, and improved robustness

  6. Part Count Reduction

  7. Standard Materials and Components • Description: Use standard off-the-shelf parts and widely available materials • Motivation: eases purchasing, simplifies inventory management, and avoids tooling investments • Example: Screws

  8. Standardized Design of the Product • Description: For similar products, specify the same materials, parts, and subassemblies as much as possible. • Motivation: provides economies of scale, simplifies operations, and simplifies inventory management • Example: automotive platforms, Black & Decker

  9. Liberal Tolerances • Description: make tolerances as forgiving as possible • Motivation: tight tolerances are expensive (in a non-linear fashion) • Example: Figure 1.3.1

  10. Use Easily Processed Materials • Description: take advantage of materials that have been developed for easy processibility • Motivation: while material may cost more, it will often provide lower overall cost • Example: “Free-Machining” Grades, Many polymer grades are tuned to a process

  11. Avoidance of Secondary Operations • Description: minimize the need for secondary operations • Motivation: secondary operations (e.g. deburring, inspection, painting, and heat treating) can be as expensive as the primary manufacturing operation • Example: Pre-painted steel, investment casting

  12. Design to Expected Level of Production

  13. Understand and Utilize Manufacturing Process Characteristics • Description: understand and take advantage of the special capabilities of various manufacturing processes • Motivation: can often eliminate manufacturing operations and reduce the number of parts • Example: injection molding snap fits and living hinges

  14. Avoid Process Restrictiveness • Description: on part drawings, specify only the final characteristics needed; do not specify the process to be used • Motivation: potential cost savings

  15. Teamwork with Manufacturing Personnel • Description: collaborate with the people who will be producing your product (the earlier the better) • Motivation: they provide a unique body of knowledge and useful insights

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