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Optimizing Design for Manufacturing: Principles and Practices

Explore the key principles of good design for manufacturing and industrial engineering, focusing on cost-effective strategies and efficient production techniques to enhance product quality and competitiveness. Learn how simplicity, standardization, teamwork with manufacturing personnel, and process optimization contribute to successful designs.

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Optimizing Design for Manufacturing: Principles and Practices

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  1. ME 317Design for Manufacturing

  2. What Constitutes a “Good” Design?

  3. SMIU Rules for Good Design Good Design Should –

  4. SMIU Rules for Excellent Design Excellent Design Should -

  5. Why Design for Manufacturing? • Mechanical engineering designs generally include off-the-shelf components and fabricated parts. • Knowing the strengths and limitations of the fabrication techniques makes for higher quality and more cost competitive designs.

  6. Ten General Design Principles(Chapter 1.3) • Simplicity • Standard Materials and Components • Standardized Design of the Product • Liberal Tolerances • Use Materials that are Easy to Process

  7. Ten General Design Principles(Chapter 1.3) • Teamwork with Manufacturing Personnel • Avoidance of Secondary Operations • Design to Expected Level of Production • Utilize Special Process Characteristics • Avoid Process Restrictiveness

  8. Simplicity • Description: minimize the number of parts, intricate shapes, and manufacturing operations • Motivation: generally provides reduced cost, improved reliability, easier servicing, and improved robustness • Example: Braun Lift

  9. Part Count Reduction

  10. Standard Materials and Components • Description: Use standard off-the-shelf parts and widely available materials • Motivation: eases purchasing, simplifies inventory management, and avoids tooling investments • Example: Screws

  11. Standardized Design of the Product • Description: For similar products, specify the same materials, parts, and subassemblies as much as possible. • Motivation: provides economies of scale, simplifies operations, and simplifies inventory management • Example: Braun Lift

  12. Liberal Tolerances • Description: make tolerances as forgiving as possible • Motivation: tight tolerances are expensive (in a non-linear fashion) • Example: Figure 1.3.1

  13. Use Easily Processed Materials • Description: take advantage of materials that have been developed for easy processibility • Motivation: while material may cost more, it will often provide lower overall cost • Example: “Free-Machining” Grades, Many polymer grades are tuned to a process

  14. Teamwork with Manufacturing Personnel • Description: collaborate with the people who will be producing your product (the earlier the better) • Motivation: they provide a unique body of knowledge and useful insights • Example:

  15. Avoidance of Secondary Operations • Description: minimize the need for secondary operations • Motivation: secondary operations (e.g. deburring, inspection, painting, and heat treating) can be as expensive as the primary manufacturing operation • Example: Pre-painted steel, investment casting, MIM in firearms

  16. Design to Expected Level of Production

  17. Understand and Utilize Manufacturing Process Characteristics • Description: understand and take advantage of the special capabilities of various manufacturing processes • Motivation: can often eliminate manufacturing operations and reduce the number of parts • Example: injection molding snap fits and living hinges

  18. Avoid Process Restrictiveness • Description: on part drawings, specify only the final characteristics needed; do not specify the process to be used • Motivation: potential cost savings

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