DESIGN FOR MANUFACTURIBITY: GETTING MORE WITH LESS

The conceptualization of every product plays an integral role in its manufacturing. Before its eminence dawned on the industry, manufacturing was fundamentally driven by ‘if it’s designed, then it’s machined’. What followed next was often dreaded by both designers and manufacturers-a difficult (often failed) attempt to manufacture a product to meet unrealistic design expectations which in turn often resulted in an unpleasant match between the two (designer and manufacturer)….the end result of it all would be a final product at the expense of resources- time and money!

Bad old days no more

This was well before DFM, Design for Manufacturability reformed the industry for good. DFM promised greater returns with lesser inputs. With basic prerequisites such as a loose understanding of product manufacturing and producing designs pertaining to processes using which the product would be manufactured, DFM brought semblance of sorts into an industry where recursive and delay were permanent members.

Faster time-to-market due to accurate designs and faster expansion of production units, DFM is a win-win for all-manufacturers, marketers, designers, vendors and above all customers! Today, at the time of designing a product, multi-dimensional activities are possible. DFM guarantees proactive and premature feedbacks and actions.

Good days are here to stay

Sustained use of Design for Manufacturability (along with CAM) makes production automated and simplified. Therefore, integrating DFM instrument in design structures is a winning move in today’s competitive market. Any required (design) change at any given point in time does not always have to result in prolonged cycles and delayed time-to-market. DFM runs the necessary checks to ensure coordination between CAD and CAM. Depending on frequently used processes and tools- drilling, punching, milling or, multi-tip tool/single-tip tool, et al. DFM offers the benefit of customization.

Only machining?

The benefits of Design for Manufacturability is not limited to manufacturing alone. DFM can also be implemented in an environment with molding, casting, forging, assembly and other forming processes. From detecting costly undercuts to wholesome extraction of part from mold or, ways to improve performance of open die power forging hammers or, ways to improve fabrication process, optimization is the crux of it all!

Machining or forming, one which ensures synchronization in part design intended for manufacturing, always considers effective ways to use resources-cost and time. Well-versed with yesteryear dilemmas, Design for Manufacturability in the course of being useful impacts integral resources in the following manner-

Cost conscious

• With accurate design and sure manufacturability, DFM contributes to the quality of the product. Superior quality spells better performance with a decline in customer reported issues (and, return/ replacement request or other such claims). All in all, company saves cost involved in return/replacement of product.

• Undercuts are expensive features used in a part design. Inaccurate or unneeded at times, these features are often deemed complex and time-consuming. DFM identifies these features and validates the requirement of each, consecutively proposing optimized ways of manufacturing.

Similarly, parts with fasteners are closely analyzed and having weighed efficiency and cost effectiveness of each, DFM proposes an alternate fastening methodology (for improved manufacturability).

Time conscious

• As mentioned earlier, DFM guarantees shorter time-to-market. Being able to deliver as per commitment is a bonus for organization’s image (which results in increased business). Long waiting hours, delayed delivery and many such problems are eliminated due to early recognition of an (manufacturability) issue.

• Parts which undergo complex operations such as assembly are time consuming (both, to design and manufacture). A reliable DFM software would let designer visualize the impact of (changed) assembly part design on its manufacturability right to the end. Such integration handles last-minute design changes with ease. Thereby, being able to deliver the product on time.

One step solution

The benefits of DFM software is just like its number in the market-many. But DFMPro is for one and all. Intuitive, smart and tailored as per requirement, have you looked at DFMPro yet?