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MANUFACTURING ENGINEERING

Major changes in product design practices are occurring in all phases of the new product development process. These changes will have a significant impact on how all products are designed and the development of the related manufacturing processes over the next decade. The high rate of technology changes has created a dynamic situation that has been difficult to control for most organizations. | PART 3 MANUFACTURING ENGINEERING CHAPTER 30_ PRODUCT DESIGN FOR MANUFACTURING AND ASSEMBLY DFM A Gordon Lewis Digital Equipment Corporation Maynard Massachusetts 30.1 INTRODUCTION 935 30.2 DESIGN FOR MANUFACTURING AND ASSEMBLY 936 30.2.1 What is DFM A 937 30.2.2 Getting the DFM A Process Started 942 30.2.3 The DFM A Road Map 946 30.3 WHY IS DFM A IMPORTANT 950 30.1 INTRODUCTION Major changes in product design practices are occurring in all phases of the new product development process. These changes will have a significant impact on how all products are designed and the development of the related manufacturing processes over the next decade. The high rate of technology changes has created a dynamic situation that has been difficult to control for most organizations. There are some experts who openly say that if we have no new technology for the next five years corporate America might just start to catch up. The key to achieving benchmark time to market cost and quality is in up-front technology engineering and design practices that encourage and support a wide latitude of new product development processes. These processes must capture modem manufacturing technologies piece parts that are designed for ease of assembly and parts that can be fabricated using low-cost manufacturing processes. Optimal new product design occurs when the designs of machines and of the manufacturing processes that produce those machines are congruent. The obvious goal of any new product development process is to turn a profit by converting raw material into finished products. This sounds simple but it has to be done efficiently and economically. Many companies do not know how much it costs to manufacture a new product until well after the production introduction. Rule 1 the product development team must be given a cost target at the start of the project. We will call this cost the unit manufacturing cost UMC target. Rule 3 the product development team must be held .