Integrated Product Design
also known as
Design for Manufacture
Design for Manufacturability
or abbreviated: DFM
Quality is performance with respect to:
• Product Specifications
• Cost Specifications
• Time to Manufacture Specifications
Then Integrated Product Design asks questions:
...for Design for Manufacture
• Can your manufacturing technology build the product?
• Does the product design create processing difficulties?
• Can the design be manufactured so that the tolerances perform well statistically?
...for Design for Measurability
• Can you measure the product? Can you measure it in-process?
• Are the measurements meaningful?
• Is the product designed to survive shipping? Is it easily packaged?
...for Design for Assembly
• Can the product be inadvertently assembled incorrectly?
• Does the
force required to assemble it mask defects? Produce them?
Here's an example, where a plastic injection molded part needed to be replaced due to the change in an adjacent component.
A very basic Design for
Manufacture approach would be to draft the parts, and use the most inexpensive
plastic resin which will meet the manufacturing specifications.
The Integrated Product Design approach was a little more involved, and much more constructive:
• In the redesign, integrated 2 plastic parts into another part.
• In the redesign, created features which
replaced 3 instances of time-consuming plastic insulating tape
• The reduced parts simplified the installation of the plastic part which had to be replaced.
• Since the replaced part required a new
injection mold tool, Integrated Product Design used that opportunity
• All of this simplification shortened
the assembly time and labor, and actually remove an entire page of
Time. I had to ask management for a couple of additional weeks to do all of this. I told management that, if they could give me the time, I could save the company money.
Doing all of the above bullet points, I reduced $38,000/yr in part cost reductions, even though I had to use a more expensive plastic resin, plus another $21,000/yr in assembly labor. And that was on an implantable pacemaker-like assembly, and a low-volume production part at that. The summary is on my site here.
Similar Integrated Product Design terms: