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Potential Conflicts between DFA and DFM

Application of DFA and DFM guidelines can reduce manufacturing costs and increase quality. However, the guidelines do not necessarily always do this. For example, one can increase part functionality to the point where the parts become so complex they cannot be easily produced. For example, in Figure 14.13, the part shown was used in the Kodak single-use camera and was very complex, supplying three separate lens functions for aiming light, also a switch actuator, and also snap fits for attachment functions. This part was sufficiently complex that in the next generation of Kodak single-use camera, the part was separated into two parts: one providing the lens function and a separate part providing the switch actuation function. This violates the DFA guideline of minimizing parts but was nonetheless a more cost-effective design, since the original part was sufficiently complex that it was excessively difficult to produce reliably.

Typically, this situation does not occur; it is almost always better to simplify a design by eliminating parts. To address such trade-off decisions, we must explore actual concept costing methods. Then, numerical comparisons can be made between designs with more complex assembly versus designs with more complex piece parts.

 

 

 

 

 

 

IV. ADVANCED METHOD: MANUFACTURING COST ANALYSIS

https://www.youtube.com/watch?v=3ngggrqr8q4

http://www.apriori.com/about-what-we-provide.htm

Understanding the cost structure designed into a product is important for deciding what portion of a design is more appropriate for detailed cost-reducing design activity and for comparing different design concepts. To do this, basic product cost accounting will be covered, followed by cost models for the various portions of the cost model, including part costs and assembly costs.

The design for manufacture and assembly philosophy underneath cost analysis is to determine how the product delivery major costs compare with the competition. Major cost drains can arise from material procurement, part production, assembly, or finished product delivery.

The design for manufacture and assembly cost-based redesign activity itself should be thought of in terms of an 80-20 rule: 80% of the cost reduction can occur in the top 20% of the relative high cost drains within a product. One can attain 80% of the possible cost reductions through the design-for-assembly simplification of a few key systems, design- for-manufacture redesign of a few expensive components, and adequate bidding on expensive purchased original equipment manufacturer (OEM) components.


Date: 2016-03-03; view: 1164


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