Design for Manufacturing and Assembly (DFMA)

Design for Manufacturing and Assembly (DFMA) is a set of overlapping methodologies focused on designs that consider all requirements beyond the functional. DFA ensures a good design early in the design process by focusing on the number of parts, part handling, and ease of assembly. DFM It is the method of creating good product designs that simplify manufacturing techniques and use standardized parts and materials. Together DFMA helps organizations achieve the goal of developing a quality product at the lowest cost while saving time. This workshop will provide you with fundamental knowledge and hands-on practice with Design for Manufacturing and Assembly (DFMA) principles and key tools.

Learning Objectives
  • Understand how DFMA impacts product cost and quality
  • Identify ways to simplify your product and dramatically reduce part count
  • Understand the six principles of mistake-proofing (poka-yoke) and how to proactively apply them
  • Learn the principles of design for assembly for mechanical products
  • Obtain detailed guidelines of DFM covering fabrication processes and see examples of good and bad design for manufacturability
  • Learn how to optimize tolerances to enhance manufacturability
  • Learn a practical methodology for analyzing & improving the manufacturability of your company’s products
Course Outline
  • Design for Manufacturing and Assembly (DFMA)
    • Introduction, design impact on cost, fallacies vs. reality
  • Design for Assembly
    • Framework for DFA: The manual assembly process
    • DFA principles of simplicity and mistake-proofing
    • Methodology of part count reduction, fastener reduction, and consolidation
    • Exercise: Manual assembly analysis
    • Exercise: Minimize part count
    • Design for part orientation, location, insertion and securing
    • Self-fixturing, production fixtures; joining & fastening guidelines
  • Design for Automated Assembly
    • Component design & quality considerations for flexible automation and hard automation
    • Exercise: Automated assembly process analysis
    • Design guidelines & examples for automated handling and feeding, picking & placing, insertion, transformation
  • Design for Manufacturability
    • Framework for DFM: material section, cost estimation, process selection, and detailed feature design
    • DFM principles of standardization and process capability
    • Methods to estimate the cost of manufactured components
    • Exercise: Cost estimating of machined component
  • Design for Machining
    • Process-specific design guidelines & examples
  • Design for Metal Forming
    • Process-specific design guidelines & examples
  • Design for Injection Molding
    • Process-specific design guidelines & examples
  • Design for Casting
    • Process-specific design guidelines & examples
  • Design for Welding
    • Process-specific design guidelines & examples
  • Design for Surface Treatment
    • Process-specific design guidelines & examples
  • Design for Additive Manufacturing
    • Process-specific design guidelines & examples
  • Process Capability and Tolerances
    • Variation and specifications, effect of tolerances, design objectives
    • Process capability, tolerance analysis, allocation, and optimization
    • Exercise: Tolerance allocation & optimization
  • GD&T for DFMA
    • GD&T principles of variation, datum reference frames, tolerance zones, bonus tolerance, and drawing ambiguity without GD&T
    • How complete component specifications ensure assembly and economic manufacture
    • Methods to increase tolerances, reduce costs, increase yields, and achieve higher quality while ensuring parts assemble and function
  • DFMA And the Development Process
    • DFMA process steps: early manufacturing involvement & early supplier involvement
    • Conducting design reviews to address DFMA
    • Cost models to estimate costs & evaluate design alternatives
    • Developing design standards & guidelines
    • Implementation guidelines
Modes of Teaching and Learning
  • Classroom lecture / discussion, team exercises

Who Should Attend
The program is designed for all levels of design, engineering, and manufacturing personnel, as well as engineering management.  Anyone involved in design or manufacturing – including design engineers, product engineers, manufacturing engineers, process engineers, and quality engineers – will take away valuable knowledge.

Course Format
3-Day (24-Hour), Instructor-Led

Course instructors:
Angelo Scangas – President and CEO
James F. Leonard – Senior Consultant, Process Improvement and Statistical Methods
Laura Halleck – Senior Consultant, Quality Systems Auditing (Automotive, Aerospace)
Ed McFayden – Consultant, Quality Systems, Lean Six Sigma, Auditing
Saleha Yusof-Mullenix – Consultant, Lean Six Sigma

Payment Type
Date Attending
Name of Attendee(s)
Name of Company

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