Engineering Project Management & Finance

(UESTC 3031 & UESTCHN 3012)

Design For Manufacturing

(Part 1)

Dr. Amir Parnianifard

Email: [email protected]
 Design For Manufacturing (DFM)-Part 1: Introduction & Design for Sustainability

▪ Part 1: Introduction & Design for Sustainability

▪ Part 2: Quality Control & Cost of Quality

▪ Part 3: Robust Manufacturing Design

▪ Part 4: 6-Sigma & Process Capability

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 Design For Manufacturing (DFM)-Part 1: Introduction & Design for Sustainability

Definition
• Design For Manufacturing (DFM) is the process of designing
components of high-quality products for ease of manufacturing at a
lower cost.

• This is done by lowering complexity,

optimizing performance, and redefining
the product.
• DFM has various advantages, including
lower production costs, higher product
quality, and a shorter time to market.

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 Design For Manufacturing (DFM)-Part 1: Introduction & Design for Sustainability

How do you design something for manufacturing?

As you develop your design, consider the following:
✓ The function of your product.
✓ How it will be used?
✓ What it will be made of?
✓ How long consumers will use your product?
✓ Will it require a warranty?
✓ How much it will cost to manufacture?
✓ Will you be able to make a profit from your product?
✓ etc.
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 Design For Manufacturing (DFM)-Part 1: Introduction & Design for Sustainability

History
• DFM has its roots in the post-World War II era
when companies were looking for ways to
improve their competitiveness in the global
market.
• While manufacturers were facing with strong competition by other
manufacturers (rivals), at the time, they were under pressure to
reduce costs, enhance the quality of products, and increase production
efficiency.
• In response, companies began to adopt a more systematic approach to
product design, incorporating consideration of production processes,
tooling, and other manufacturing factors into the design process. 5
 Design For Manufacturing (DFM)-Part 1: Introduction & Design for Sustainability

Flow of Design Knowledge

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 Design For Manufacturing (DFM)-Part 1: Introduction & Design for Sustainability

Product
Development
Lifecycle

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 Design For Manufacturing (DFM)-Part 1: Introduction & Design for Sustainability

Why is DFM Important?

• It is usually
accepted
(demonstrated)
that 70% to 80% of
production costs
are determined by
design decisions.

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DFM vs DFA
• DFM is a design method to
reduce the complexity of
manufacturing operations
and the overall cost of
production including the
cost of raw materials.

• Design for Assembly (DFA) is a design method to

facilitate or reduce the assembly operations of parts or
components of a product.
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 Design For Manufacturing (DFM)-Part 1: Introduction & Design for Sustainability

Principles of DFM (1/6)

• Simplicity: The design should be kept simple with as few parts as possible and
use straightforward shapes and structures to make production easier and
more cost-effective.

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 Design For Manufacturing (DFM)-Part 1: Introduction & Design for Sustainability

Principles of DFM (2/6)

• Standardization: Whenever possible, standard components and

manufacturing processes should be used in the design, as this can save time
and reduce production costs.

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 Design For Manufacturing (DFM)-Part 1: Introduction & Design for Sustainability

Principles of DFM (3/6)

• Tolerance: Proper tolerance design is critical in ensuring that the product fits
and functions as intended. Tolerances must be carefully considered to
balance the need for precision with the cost of manufacturing.

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 Design For Manufacturing (DFM)-Part 1: Introduction & Design for Sustainability

Principles of DFM (4/6)

• Material Selection: The choice of materials greatly impacts production costs

and the final product quality. We must consider the properties of the
materials, such as strength, durability, and manufacturability, when selecting
the materials for a product.

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 Design For Manufacturing (DFM)-Part 1: Introduction & Design for Sustainability

Principles of DFM (5/6)

• Automation: Automated processes

can significantly improve production
efficiency, reduce labor costs, and
improve product quality. The project
expert must carefully consider the
type and level of automation to be
implemented in the production
process.

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 Design For Manufacturing (DFM)-Part 1: Introduction & Design for Sustainability

Principles of DFM (6/6)

• Process Integration: Integrating product design, manufacturing processes,
and quality control are crucial in improving production efficiency and
reducing costs. A project expert has to work closely with other professionals,
such as industrial designers and process engineers, to ensure that the design,
manufacturing, and quality control processes are appropriately integrated.

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 Design For Manufacturing (DFM)-Part 1: Introduction & Design for Sustainability

Benefits of Product Development with DFM

• Lower Manufacturing Costs

• Improved Production Efficiency
• Improved Product Quality
• Streamlined Product Development
Process
• Better Supply Chain Management
• Enhanced Competitiveness
• Compliance with Regulations
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 Design For Manufacturing (DFM)-Part 1: Introduction & Design for Sustainability

Who is Responsible for DFM?

• Design Engineers
• Manufacturing
Engineers
• Quality Control
• Procurement
• Management

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 Design For Manufacturing (DFM)-Part 1: Introduction & Design for Sustainability

How Long Does DFM Take?

• The time required for design for
manufacturability is determined
by the product’s complexity, the
organization’s size, and the
resources available.
• As a general rule, DFM is a
continuous process that
continues through the entire
product lifecycle.

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 Design For Manufacturing (DFM)-Part 1: Introduction & Design for Sustainability

Other Methods Joint with DFM

Process
Capability

Quality
6-Sigma
Control

DFM

Cost of Design for

Quality Sustainability

Robust
Product
Design

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 Design For Manufacturing (DFM)-Part 1: Introduction & Design for Sustainability

Design for Sustainability (DFS)

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 Design For Manufacturing (DFM)-Part 1: Introduction & Design for Sustainability

What do you think regarding these photos?

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 Design For Manufacturing (DFM)-Part 1: Introduction & Design for Sustainability

Electronic Waste (E-Waste)

Projected electronic waste generation worldwide from 2019 to 2030 (in million metric tons)

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 Design For Manufacturing (DFM)-Part 1: Introduction & Design for Sustainability

Sustainability Definition
• Sustainability consists of fulfilling the needs of current generations without compromising
the needs of future generations, while ensuring a balance between economic growth
(Economic pillar), environmental care (environmental pillar),and social well-being (Social
pillar).

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What Is Design for Sustainability?

• DFS (also known D4S) is a subset methodology
under the DFX family (Design for Excellence)
with its main focus on developing sustainable
products.
• All of the sustainability strategies have either
one or both of the following objectives:
➢ Use fewer resources
➢ Prefer eco-friendly alternatives

• These resources could mean raw materials, processes, systems, distribution

methods and anything else that is necessary for a product to exist.
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Responsible for Sustainability

• It is not right to shift all the responsibility
to the end-user.
• Manufacturing companies and their
designers have to take the most
responsibility for the environmental
effects of their products and work actively
on designing more sustainable products.
• Consumers can make an environmental
impact when preferring socially
responsible products to minimize waste
and their carbon footprint.

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The Importance of Design Stage for Sustainability

• Almost all of the resource choices are
affected by its product design stage.
• In other words, the design stage is the most
influential in determining how a product will
affect the environment through its raw
materials, manufacture, distribution, usage,
maintenance and disposal.

• Sustainable Product Policy by the European Commission states that as much as

80% of a product’s negative impact on the environment is finalized at the
design stage.
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The Need for Sustainability

• Sustainability in production and in the
use of products has become
increasingly important in the past few
decades.
• Without sustainability, we will likely
➢ run out of natural resources,
➢ and damage environment that are
not recoverable.

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 Design For Manufacturing (DFM)-Part 1: Introduction & Design for Sustainability

Linear Economy
• Traditionally, the economy
has followed a straight-line
pattern.
• This kind of system is
highly unsustainable and
needs to change.
• A sustainable alternative to
this system is the circular
economy.

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Circular Economy
• The main focus of this type of
economic model is to reintroduce used
parts as raw materials for new
products.
• The intent is to move from a high-waste to a high-
value model.
• Such a system is highly resource-efficient and
reduces the effect of consumer demand on the
exploration, pollution, and wastage of natural
resources.

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Circular Economy
• The 4Rs in particular is a very effective tool in
building a circular economy. It includes four
principles that can be applied by almost every
individual and have an exponential effect. These
principles are:
✓ Reduce
✓ Reuse
✓ Repair
✓ Recycle

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Design for Sustainability Principles

• Using appropriate strategies can help us get closer to the concept of true
sustainability.
• Some actionable sustainable design principles that can be implemented to
create better designs are:
✓ Dematerialization
✓ Modular design
✓ Prefer renewable energy
✓ Migration to product-service systems
✓ Design for longevity
✓ Limit or eliminate long-distance outsourcing
✓ Invest in simulation

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Design for Sustainability Principles: Dematerialization

• The reduction of total material and energy throughput of any product and service,
and thus the limitation of its environmental impact.
• There are many ways to achieve this. One way is the miniaturization of the product.
A product with a smaller form also requires reduced packaging, storage area,
transportation and delivery costs and minimizes carbon emissions involved in each
of the product life stages.

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Design for Sustainability Principles: Modular design

• A modular design refers to
the use of components as
modules that can be used in
multiple products. Modules
are predesigned
components with a specific
function. The advantages
include cheaper and easier
manufacturing, assembly,
replacement, repair and
disposal.

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Design for Sustainability Principles: Prefer renewable energy

• Greater reliance on
renewable alternatives,
such as wind, solar power
and hydroelectricity
(instead of petrol, diesel,
gas and coal), propel us
towards sustainable
development while allowing
us to maintain similar
energy usage levels.

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Design for Sustainability Principles: Migration to product-

service systems
• Product service systems refer to a
business model where the
company provides services besides
the product to improve their
environmental performance and
sales. In such systems, a company
leases its products to the
consumer instead of selling them
for good.
• A great example of this practice is how IBM shifted to renting servers instead of
selling units directly to customers, or cloud services.
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Design for Sustainability Principles: Design for longevity

• Designers have the power to maximize how long a product can be used through its design.
• Durable products can considerably relieve the pressure on the environment by reducing
the amount of raw material and energy required to create new products.

Average lifespan (replacement cycle length) of Lifespan of Smartphones

smartphones worldwide from 2013 to 2020 (in months) 3636
 Design For Manufacturing (DFM)-Part 1: Introduction & Design for Sustainability

Design for Sustainability Principles: Limit or eliminate long-

distance outsourcing

• Increasing shipping capacities have made

freight more affordable. This has resulted
in outsourcing manufacturing operations
to countries with lower labor rates.

• The effect on the environment, however, is negative since the resources required to
manufacture the product are the same either way but now, we have added several
tones of extra emissions due to intercontinental transport (extra Greenhouse gases).

• It is important to prefer local suppliers when designing for sustainability. Besides

lowering the environmental impact, eliminating outsourcing would support local
industries.
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Design for Sustainability Principles: Invest in simulation

• Traditionally, many trial-and-error loops would

be required to arrive at the most optimal design.
• But with simulation, all these loops can
sometimes be completed in a matter of hours,
saving precious resources in terms of raw
materials, time and overhead energy costs
related to electricity, water etc.
• It also reduces wastage as only a small number of
products are out of spec when the part goes into
actual production. Such a production method is,
therefore, highly sustainable as well as
profitable.
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 Design For Manufacturing (DFM)-Part 1: Introduction & Design for Sustainability

Design for Manufacturing (DFM) is an important part of any product development cycle (e.g., initial design, final design,
fabrication, production, and product launch). Which item below is correct:

A – The DFM is more effective to be applied in the production stage because of the higher impact
and lower cost of changes due to the product being manufactured and can be changed promptly.

B – The DFM is more effective to be applied during product launch because of the highest impact
and lowest cost of changes.

C – The DFM is more effective to be applied to the initial design because of the highest impact and
lowest cost of changes.

D – The DFM is more effective to be applied after the initial design and before production when the
final design is being finalized and can effectively implement required changes according to
customer requirements.

E – The DFM is more effective to be applied in all stages after design because we are sure that the
customer requirements are recognized completely and any changes in the future do not impose
higher costs of changes.

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 Design For Manufacturing (DFM)-Part 1: Introduction & Design for Sustainability

There is a variety of actionable sustainable design principles that can be implemented to create better designs. Some of
them are below except:

A – Dematerialization.

B – Migration to product-service systems.

C – Limit or eliminate long-distance outsourcing.

D – Design for a shorter period of usage.

E – Invest in simulation.

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 Design For Manufacturing (DFM)-Part 1: Introduction & Design for Sustainability

Which of the following statements best describes the three pillars of sustainability?

A – Sustainability involves meeting the current generation's needs without consideration for future
generations, emphasizing economic growth, environmental care, and social well-being.

B – Sustainability entails achieving economic growth, environmental care, and social well-being
simultaneously, fulfilling the needs of current generations without compromising the needs of
future generations.

C – Sustainability primarily focuses on economic growth, with minimal consideration for

environmental and social aspects, to fulfill the needs of the current generation.

D – Sustainability prioritizes environmental care over economic growth and social well-being,
neglecting the importance of balancing all three pillars.

E – Sustainability emphasizes social well-being as the sole pillar, with economic growth and
environmental care being secondary considerations in fulfilling the needs of current and future
generations.

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 Design For Manufacturing (DFM)-Part 1: Introduction & Design for Sustainability

Design for Manufacturing (DFM) is an important part of any product development cycle. Which item below is not
correct regarding DFM:

A – The time required for design for manufacturability is determined by the product’s complexity, the
organization’s size, and the resources available.

B – As a general rule, DFM is a continuous process that begins at the initial stages of product design
and continues through the entire product lifecycle.

C – The DFM is more effective to be applied to the initial design because of the highest impact and
lowest cost of changes.

D – The DFM may impose higher manufacturing costs, instead can benefit from higher customer
satisfaction because of improved product quality.

E – The DFM consists of some main principles such as Simplicity, Standardization, Tolerance, Material
Selection, Automation, and Process Integration.

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 Design For Manufacturing (DFM)-Part 1: Introduction & Design for Sustainability

Describe briefly any two of these DFM principles.

Accept any two of the below:

- Simplicity: The design should be kept simple with as few parts as possible and use
straightforward shapes and structures to make production easier and more cost-effective.
- Standardization: Whenever possible, standard components and manufacturing processes should
be used in the design, as this can save time and reduce production costs.
- Tolerance: Proper tolerance design is critical in ensuring that the product fits and functions as
intended. Tolerance must be carefully considered to balance the need for precision with the cost
of manufacturing.
- Material Selection: The choice of materials greatly impacts production costs and the final
product quality. We must consider the properties of the materials, such as strength, durability,
and manufacturability when selecting the materials for a product.
- Automation: Automated processes can significantly improve production efficiency, reduce labor
costs, and improve product quality. The project expert must carefully consider the type and level
of automation to be implemented in the production process.
- Process Integration: Integrating product design, manufacturing processes, and quality control are
crucial in improving production efficiency and reducing costs. A project expert has to work
closely with other professionals, such as industrial designers and process engineers, to ensure
that the design, manufacturing, and quality control processes are appropriately integrated.

44
 Design For Manufacturing (DFM)-Part 1: Introduction & Design for Sustainability

The 4Rs in particular are very effective tools in building a circular economy for sustainable products. It includes four
principles that can be applied by almost every individual and have an exponential effect. List any two of these principles

Accept any 2 of the below:

- Reduce

- Reuse

- Repair

- Recycle

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 Design For Manufacturing (DFM)-Part 1: Introduction & Design for Sustainability

The product development cycle in general consists of the initial design, final design, fabrication, production, and
product launch. Which stage is more effective in DFM regarding the impact and cost of changes?

The DFM is more effective to be applied to the initial design, because of the highest impact and
lowest cost of changes.

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 Design For Manufacturing (DFM)-Part 1: Introduction & Design for Sustainability

Sustainability can make a balance between three main pillars. List any two of these pillars.

Accept any two of the below:

- Economic pillar
- Environmental pillar
- Social pillar

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 Design For Manufacturing (DFM)-Part 1: Introduction & Design for Sustainability

In the Next Lesson:

Part 2: Quality Control & Cost of Quality

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Design For Manufacturing (DFM)-Part 1: Introduction & Design for Sustainability