Design for Manufacturing 201

additive manufacturing

The process of successively layering materials to make a part based on a three-dimensional computer model. Additive manufacturing allows for rapid prototyping, mass customization, and increased part complexity.

assembly

The process of joining components together into a larger or completed part. Assembly methods include mechanical fastening, adhesive bonding, and welding.

asymmetrical

Having features on either side of a point, line, or plane that differ in size, shape, or position. Asymmetrical parts and products have clearly distinguished sides and components, which can reduce assembly errors.

automation

The use of self-regulated equipment, processes, or systems that meet manufacturing requirements with limited human intervention. Automation is an efficient means of performing manufacturing processes.

Business Process Reengineering

BPR. Streamlining decision-making in product design, processes, and resources. Business Process Reengineering is a large-scope tool that uses DFX and concurrent engineering to implement lasting changes to business processes.

concurrent engineering

Cooperative design among multiple departments, disciplines, backgrounds, and skill sets within a company. Concurrent engineering, also known as Integrated Product and Process Development (IPPD), is fundamental to Design for X.

contingency plans

A strategy for anticipating unforeseen threats and opportunities and preparing a response. Contingency plans should be created in the initial stages of product development.

cost

Typically expressed as a dollar amount, the amount of time, money, and labor spent to create a product or perform a service. Placing primary emphasis on developing culture and quality, as well as ensuring flexible responsiveness, helps to reduce overall cost.

cycle times

The amount of time required to complete one manufacturing process from its beginning to its end. Cycle times are reduced by DFX methodologies.

Design for Assembly

DFA. A form of Integrated Product and Process Development that focuses on simplifying and streamlining assembly processes. Design for Assembly minimizes the total product cost by targeting assembly time, part cost, and the assembly process at the design stage of the product development cycle.

Design for Manufacturing

DFM. A form of Integrated Product and Process Development that focuses on designing, manufacturing, testing, and creating a part that functions correctly and is easy to manufacture. Design for Manufacturing involves considering part functionality and the limits of the manufacturing process.

Design for Quality Control

DFQC. A quality-driven form of Integrated Product and Process Development. Design for Quality Control focuses on developing the product, improving the product, and improving the system to make and sustain the product.

Design for X

DFX. A methodology that requires all decisions related to products, processes, costs, and constraints be made early on in the development process. Design for X encompasses many areas and processes of design, including Design for Manufacturing.

design freeze

The end point of the design phase when technical product descriptions are sent to production. Design freezes help lock in product requirements and reduce the chance of engineering changes.

DFA

Design for Assembly. A form of Integrated Product and Process Development that focuses on simplifying and streamlining assembly processes. DFA minimizes the total product cost by targeting assembly time, part cost, and the assembly process at the design stage of the product development cycle.

DFM

Design for Manufacturing. A form of Integrated Product and Process Development that focuses on designing, manufacturing, testing, and creating a part that functions correctly and is easy to manufacture. DFM involves considering part functionality and the limits of the manufacturing process.

DFQC

Design for Quality Control. A quality-driven form of Integrated Product and Process Development. Design for Quality Control focuses on developing the product, improving the product, and improving the system to make and sustain the product.

DFX

Design for X. A methodology that requires all decisions related to products, processes, costs, and constraints be made early on in the development process. DFX encompasses many areas and processes of design, including Design for Manufacturing.

dimensions

The desired measurement of a feature on a part. A dimension is listed as a number given in the appropriate units.

distribution

The movement of parts from manufacturers at the point of production to end-use customers. Distribution expenses are considered part of manufacturing system costs.

function

The ability of a product to optimally perform a set purpose. Function is a key design consideration.

geometric dimensioning and tolerancing

GD&T. An international standard for communicating instructions about the design and manufacturing of parts. Geometric dimensioning and tolerancing uses universal symbols and emphasizes the function of the part.

Integrated Product and Process Development

IPPD. Cooperative design among multiple departments, disciplines, backgrounds, and skill sets within a company. Integrated Product and Process Development, also known as concurrent engineering, is fundamental to Design for X.

Integrated Product and Process Team

IPPT. A multi-disciplinary group of employees focused on concurrent engineering and product design. The Integrated Product and Process Team is a term used by government institutions.

inventory

Manufactured products that are stored prior to being shipped to customers for end-use. Inventory allows manufacturers to have parts available to sell, but it also requires additional storage costs.

IPPD

Integrated Product and Process Development. Cooperative design among multiple departments, disciplines, backgrounds, and skill sets within a company. Integrated Product and Process Development, also known as concurrent engineering, is fundamental to Design for X.

IPPT

Integrated Product and Process Team. A multi-disciplinary group of employees focused on concurrent engineering and product design. The IPPT is a term used by government institutions.

iteration

Repeating actions and steps in processes. Iteration is an important aspect of Design for X because it allows for constant and quick re-designs during initial stages.

lean manufacturing

An approach to manufacturing that seeks to reduce the cycle time of processes, increase flexibility, and improve quality. Lean manufacturing seeks to eliminate waste in all its forms.

models

A representation of a specific part or product. Models are usually three-dimensional and can be physical or digital.

modular designs

Independent parts with standardized interfaces that allow for interchangeability and use across many projects. Modular designs provide greater efficiency.

overhead costs

Expenses associated with operating buildings and equipment, including rent, insurance, utilities, and repairs. Traditional manufacturing companies try to reduce overhead costs as much as possible.

poka-yoke

A Japanese term meaning mistake proofing. Poka-yoke is an error-prevention method that eliminates operator errors in production or assembly.

procurement

The process of acquiring a product or service, which includes defining needs, seeking bids, awarding contracts, taking delivery, and paying suppliers. Procurement is made easier by standardization.

product lifecycle

The series of stages a product goes through from conception to the end of its useful life. The product lifecycle includes design, production, distribution, and end-use by the customer.

prototypes

A preliminary model of a part used to evaluate the look and performance of a design. Prototypes are used to determine the specifications for the final part.

quality

Conformance to a set of standards or specifications that results in customer satisfaction in a product or service. Quality products are free of defects and meet the requirements of their anticipated use.

Quality Control Plan

QCP. A document that lists the checkpoints to be passed during or after a production run. The Quality Control Plan can include process, product, or regulatory considerations.

simulations

A computerized re-creation of a physical space and activity. Simulations are used to duplicate real-world situations and products in order to evaluate how a part will be manufactured and function.

SPC

Statistical process control. The use of statistics and control charts to measure key quality characteristics and to control the related processes. SPC separates special causes of variation from common causes.

specifications

A description of the essential physical and technical properties of a part. Specifications include information on the shape and tolerance of a part as well as required mechanical and physical properties.

statistical process control

SPC. The use of statistics and control charts to measure key quality characteristics and to control the related processes. Statistical process control separates special causes of variation from common causes.

statistical tolerancing

The process of using statistics to assign tolerances for mating parts of an assembly. Statistical tolerancing uses statistical process control (SPC) to measure and track variation.

supply chain

A network of companies that exchange resources such as materials and information to deliver products to customers. Supply chains consist of a company, its suppliers, its distributors, and its customers.

symmetrical

Having features on either side of a point, line, or plane that are identical in size, shape, and position. Both sides of a symmetrical part have the same dimensions, which can reduce assembly errors.

time-to-market

The length of time it takes from a product being conceived until it is available for sale. Quick time-to-market is a benefit of Design for X.

tolerance stacks

Accumulated variation that occurs when successive acceptable tolerances build on one another to form an unacceptable tolerance. Tolerance stacks can render a product unusable.

tolerances

An acceptable deviation from a desired dimension that still meets part specifications. Tolerances indicate the allowable difference between a physical feature and its intended design.

total cost

Combined expenses for all parts, labor, and overhead. Calculating total cost is the best way to account for the entire cost of a product and helps guide goals for DFM.

variable data

Data that can be measured on a scale and compared with other data. Variable data can be added to or subtracted from other variable data sets.