DFA

Design for Assembly (DFA) and Manufacturing Analysis ( MA )are key elements of Concurrent engineering. In TeamSET they are integrated with a full set of other tools to produce the most powerful suite of concurrent engineering software

DFA is a simple, structured analysis technique which gives design teams the information they need to reduce product costs by simplifying product structure and optimising manufacturing processes

Typical benefits

• reducing the number of parts
• optimising manufacturing processes
• simplifying parts handling
• improving product assembly

• Reduced inventory
• Fewer orders
• Fewer invoices from fewer suppliers
• Fewer quality problems

DFA used as part of an integrated approach encourages the design of products that can be produced at minimum cost and maximum quality and reliability. It gives the best results when used by multi-disciplined New Product Introduction ( NPI ) teams.

DFA gives optimum results when used with the other TeamSET tools: QFD, FMEA, MA, DTC. It is most effective when used by multi-disciplined New Product Introduction ( NPI ) teams.

FMEA is another key tool. It is a simple, structured analysis technique which gives design teams the information they need to improve product quality and reduce cost by:

• Increasing product reliability
• ensuring the design is robust
• reducing the number of engineering changes
• correcting design errors before production starts

Failure Modes and Effects Analysis is standard practice in the automotive industry. Its use is increasing rapidly in a wide range of other industries to produce more reliable products with less wasted cost.

QFD is a detailed planning technique used to translate the 'voice of the customer' into company specifications at each major stage of the Product Introduction Process.

Design to Target Cost (DTC) is the managed process of monitoring and controlling manufacturing cost to a fixed cost target set at the product specification stage. The responsibility for attaining the target cost resides with the project team.

Concept Convergence is a simple, structured technique for comparing and selecting solutions for a set of requirements. DFA software from TeamSET provides an integrated New Product Introduction toolkit for use by concurrent engineering teams. The toolkit consists of:

• DFA
• Manufacturing Analysis
• Design to Target Cost
• FMEA
• QFD
• Controlled Concept Convergence

These are all tools that contribute towards efficient New Product Introduction ( NPI ) and Lean Manufacture.

It is important that all the tools are applied as a team exercise, with input and involvement from all the major stakeholders. This ensures that all aspects of the product design are considered from different points of view.

The evaluation is carried out by the following method:

Functional analysis

By interrogation of component parts through the methodology, each can be classified as essential ‘A’ parts or non-essential ‘B’ parts. Given this awareness, re-designs can be evolved around the essential components.

Handling analysis

All component parts must have the correct orientation before the assembly can take place. The difficulty of achieving this can be assessed and components receiving high ratings can then be modified to give an acceptable rating. Poka-Yoke devices can be installed in the manufacturing process to ensure zero defects from this source.

Assembly analysis

To assist the analysis process an assembly flowchart is constructed and the difficulty of assembling each part in the sequence can be rated using the DFA databases. Difficult assembly tasks and non-value-added processes are revealed for correction by re-design. Simple concepts such as the ability to assemble in layers from above can result in major cost saving at the manufacturing stage.

Each of the above stages in the methodology have appropriate measures of performance which are accepted as an indication of good design.

Follow this link for more information on TeamSET's DFA software.