Design for Manufacturing and Assembly (DFM&A)

Course Description
Design for Manufacturing and Assembly (DFM&A) 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 is the method of creating good product designs that simplify manufacturing techniques and use standardized parts and materials. Together DFM&A helps organizations achieve the goal of developing a quality product at the lowest cost while saving time.This course provides students with fundamental knowledge and hands-on practice with Design for Manufacturing and Assembly (DFM&A) principles and key tools. During training, students will obtain detailed guidelines of DFM covering fabrication processes and see examples of good and bad design for manufacturability. They will also learn a practical methodology for analyzing and improving the manufacturability of their companies’ products.

Who Should Attend
This course 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.

Learning Objectives
Upon completion of the course, students will:

  • Understand how DFM&A impacts product cost and quality
  • Be able to identify ways to simplify products and dramatically reduce part count
  • Understand the six principles of mistake-proofing (poka-yoke) and how to proactively apply them
  • Understand the principles of design for assembly for mechanical products
  • Be able to optimize tolerances to enhance manufacturability

Course Outline

  1. Design for Manufacturing and Assembly (DFM&A)
    • Introduction, design impact on cost, fallacies vs. reality
  2. 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
  3. 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
  4. 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
  5. Design for Machining
    • Process-specific design guidelines & examples
  6. Design for Metal Forming
    • Process-specific design guidelines & examples
  7. Design for Injection Molding
    • Process-specific design guidelines & examples
  8. Design for Casting
    • Process-specific design guidelines & examples
  9. Design for Welding
    • Process-specific design guidelines & examples
  10. Design for Surface Treatment
    • Process-specific design guidelines & examples
  11. Design for Additive Manufacturing
    • Process-specific design guidelines & examples
  12. Process Capability and Tolerances
    • Variation and specifications, effect of tolerances, design objectives
    • Process capability, tolerance analysis, allocation, and optimization
    • Exercise: Tolerance allocation & optimization
  13. GD&T for DFM&A
    • 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
  14. DFMA And the Development Process

Course Format
24 hours
Combination instructor-led lecture/discussion and team exercises
Available at QSG’s training facilities and on-site at your organization

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