Design for Manufacturing and Assembly (DFM&A)

Course Summary

This 3-day workshop will provide you with fundamental knowledge and hands-on practice with Design for Manufacturing and Assembly (DFMA) principles and key tools.

Event Details

24 hours
Instructor-led classroom training, in-person and in-groups, with lots of discussion and working sessions to practice learned skills.
Available at QSG’s training facilities or on-site at your organization

Participants will need to purchase Design for Manufacturability and Assembly Workbook, by Charles Gillis


Design for Manufacturing and Assembly (DFMA) is a set of overlapping principles applied to engineering design that consider 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 achieves good product designs using simple manufacturing techniques and using standardized parts and materials. Together DFMA helps organizations reach the goal of developing quality products at the lowest cost while saving time. This 3-day workshop will provide you with fundamental knowledge and hands-on practice with Design for Manufacturing and Assembly (DFMA) principles and key tools.

Who Should Attend

This course is designed for all levels of engineering and manufacturing personnel, as well as their managers. Anyone involved in design or manufacturing – including design engineers, product engineers, manufacturing engineers, process engineers, and quality engineers – will take away valuable skills and knowledge.

Learning Objectives

Through training, participants will learn the following:

  • Understand how DFMA impacts product cost and quality.
  • Learn the principles of design for assembly for mechanical products.
  • Identify ways to simplify your product and dramatically reduce part count.
  • Use step-by-step procedures for analyzing and improving DFA including design for handling, presentation, orientation, insertion, fastening, and mistake-proofing for design and process elements.
  • Obtain detailed guidelines of DFM covering fabrication processes and see examples of good and bad design for manufacturability.
  • Apply DFM principles and general tolerancing recommendations on the most pervasive manufacturing processes, including machining, metal forming, injection molding, casting, additive manufacturing, etc.
  • Conduct process capability studies to optimize design and manufacturing targets.
  • Analyze and assign appropriate tolerances for new designs.
  • Review drawings for proper use of Geometric Dimensioning and Tolerancing to increase tolerances and reduce cost without compromising product function.
  • Apply a practical methodology for analyzing & improving the manufacturability of your company’s products.

Course Outline

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
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
Design guidelines & examples for automated handling and feeding, picking & placing, insertion, transformation

Design for Manufacturing
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

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

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




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