DESIGN FOR MANUFACTURE (DFM)

 One of the aspects of the concurrent engineering is integrating the design and
manufacturing in the product design stage. This is called Design For Manufacture (DFM).
 The major objective of DFM is to ensure that the product and the manufacturing processes
are designed together.
 This optimizes the manufacturing phase of the product life cycle, which results in
improving product quality as well as reducing the product cost.

Guidelines To Be Followed In Design For Manufacture (DFM) :

The general guidelines to be followed in design for manufacture are discussed below:

1. Minimize total number of parts in a product,

2. Minimize variety of parts,
3. Use standard parts,
4. Use modular design,
5. Design parts to be multifunctional,
6. Design parts for multiple use,
7. Select least costly material,
8. Design parts for ease of manufacture,
9. Shape the parts for minimizing the operations,
10. Design for general purpose tooling.

i. Minimize total number of parts in a product:

 A product cost is related to the number of parts in a product. Reducing the number of
parts in a product normally reduces the cost of the product.
 In addition, it also increases the reliability of the product.
 A part can be eliminated if, there is no need for relative motion between parts, no need
for adjustment between the parts, and no need for materials to be different.
 The number of parts can be reduced by :
(i) Combining two or more parts into an integral design;
(ii) Use of snap fits to replace fasteners;
(iii) Use of press fits to reduce the number of fasteners; and
(iv) Including labels in the mold and/or combining information from the labels
into one label.
 It is important to note that, sometimes the reduction of too many parts may increase the
cost of the product because the remaining parts may become too heavy or complex.
Sometimes, it may make the disassembly also difficult.

ii. Minimize variety of parts

Minimizing the variety of parts reduces the manufacturing cost, improves the quality of the
parts and minimizes the inventory requirement.

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 iii. Use standard parts
The standard (off the shelf) parts are always less expensive than the custom-made parts.
Therefore, as far as possible, standard parts should be used in a product.

iv. Use modular design

 A module is a self-contained component with a standard interface with other
components in the product.
 Product consisting of 4 to 8 modules with 4 to 10 parts per module are preferred for
automatic assembly.
Advantages of modular design :
The advantages of the modular design are as follows :
a. It customizes the product by using different combinations of standard modules.
b. It is relatively resistant to obsolescence, since a new generation product can utilize
most of the old modules.
c. It results in easier service and repair because the defective module can be replaced by
a new one.
d. It simplifies final assembly because there are fewer parts to assemble.
Disadvantage of modular design
The major disadvantage of the modular design may be cost, because extra fittings are
required.
v. Design parts to be multifunctional
In order to minimize the number of parts, the parts should be designed to fulfill more than
one function. For example, a part can be designed to serve as a structural member as well as
a spring.
vi. Design parts for multiple use
The parts should be designed such that they can be used in more than one product. For
example, the same shaft and gear can be used in different products. The multiple use parts
ultimately reduce the product cost.
vii. Select least costly material
In many products, 50 to 60 percent of the total product cost is attributed to the materials.
The least costly material which satisfies the functional requirements should be selected.
viii. Design parts for ease of manufacture:
The manufacturing process should be selected such that the minimum number of
economical operations are required to give the part a final shape. Finishing operations such
as grinding, lapping, honing, etc. should be avoided wherever possible.
ix. Shape the parts for minimizing the operations:
The parts should be shaped such that, they can produced with minimum number of
operations. For example, holes should be spaced in the parts such that they can be made in
one operation.
x. Design for general purpose tooling :
Whenever possible, parts should be designed to use general purpose tooling rather than
special purpose tooling.

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 An exception to this is a high volume production, where special purpose tooling may be
cost effective.

DESIGN CONSIDERATIONS FOR MACHINING

 Machining processes are the most versatile and most common manufacturing processes.
Almost all parts are subjected to some kind of machining process.
 The machining processes can either be Metal-cutting processes or Surface-finishing
processes

Metal-cutting processes: The metal-cutting processes are : shaping, milling, turning, boring,
drilling, reaming, broaching, slotting, hobbing, etc.
Surface finishing processes: The surface-finishing processes are : grinding, honing, lapping,
buffing, polishing, etc. The machining cost forms the significant portion of the total cost of the
part. The total cost of the part can be reduced by optimizing the machining processes.

Guidelines to be Followed in Design for Machining

1. Machine only functional surface,
2. Select widest tolerances and roughest surface finish that fulfills functional requirement,
3. Use minimum number of machines,
4. As far as possible design for existing machining facilities,
5. Machining should be completed in minimum machining positions,
6. Part should be rigid,
7. Use holes parallel or perpendicular to the axis of the part,
8. Use standard size tooling,
9. Use ends of blind holes conical,
10. Avoid continuation of threading up to the bottom of the hole,
11. Avoid intersection of finished surfaces to form internal corners,
For Parts with Rotational Symmetry:
12. Use concentric cylindrical surfaces,
13. Avoid internal features in long parts,
14. Avoid parts with very large or very small L/D ratios,
15. For internal corners on part specify the radii equal to the radius of the tool tip,
For Parts with Non-Rotational Symmetry:
16. Wherever possible, all machined surfaces should be perpendicular or parallel to each
other as well as to the base,
17. Avoid cylindrical bores in long parts,
18. Avoid extremely long and thin parts,
19. Wherever possible restrict plain surface machining processes like : slotting, grooving, etc.,
to one surface of the part.

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1. Machine only functional surface:
In a part, as far as possible, the surface should be machined only when it is needed for
functioning of the part. The machining area should be kept as minimum as possible, as
illustrated in Fig. 1.29.

(a) Poor (b) Good

Fig. 1.29

2. Select widest tolerances and roughest surface finish that fulfills functional requirement :

Select the widest tolerances and the roughest surface that will give the acceptable performance
for operating surfaces. This will reduce the machining cost. Fig. 1.30 shows the relative increase
in cost associated with closer tolerances and better surface finish.

Fig. 1.30: Effect of Tolerances and Surface Finish on Relative Cost Increase
3. Use minimum number of machines: The part should be designed such that it can be
machined using minimum number of machines.
4. As far as possible, design for existing machining facilities: Whenever possible, avoid the
machine processes that the company shop is not equipped to carry out. In an era of
increasing automation with high capital cost, the product should be designed to fit the
existing factory.
5. Machining should be completed in minimum machining positions: Whenever possible,
the part should be designed such that all the machining can be done in one position. If the
position needs to be changed, one of the already machined surface should be used as
reference surface.

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6. Part should be rigid: The part should be designed such that it is sufficiently rigid to
withstand the machining forces.
7. Use holes parallel or perpendicular to the axis of the part: As far as possible, the auxiliary
holes should be parallel or perpendicular to the axis of the part as illustrated in Fig. 1.31.

(a) Poor (b) Good

Fig. 1.31
8. Use standard size tooling: In a part, as far as possible, the hole dimensions (i.e. diameter
and length) should be selected such that they can be machined with standard drills or
boring bars.
9. Use ends of blind holes conical: Wherever possible, the ends of the blind holes should be
conical as illustrated in Fig. 1.32.

(a) Poor (b) Good

Fig. 1.32
10. Avoid continuation of threading up to the bottom of the hole: In a threaded blind holes,
the threads should not continue up to the bottom of the hole [Fig. 1.32].

11. Avoid intersection of finished surfaces to from internal corners:

Ensure that the surfaces to be finished are raised and never intersect to form internal corners.
[Fig. 1.33].

(a) Poor (b) Good

Fig. 1.33
For Parts With Rotational Symmetry:

12. Use concentric cylindrical surfaces:

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As far as possible, the cylindrical surfaces should be concentric and plane surfaces should be
normal to the axis of the part [Fig. 1.34].

(a) Poor (b) Good

Fig. 1.34

13. Avoid internal features in long parts :

14. Avoid parts with very large or very small L/D ratios :
15. For internal corners on part, specify the radii equal to the radius of the tool tip :
For Parts With Non-Rotational Symmetry:
16. Wherever possible, all machined surfaces should be perpendicular or parallel to each
other as well as to the base
17. Avoid cylindrical bores in long parts
18. Avoid extremely long and thin parts
19. Wherever possible, restrict plain surface machining processes like: slotting, grooving, etc.
to one surface of the part

DESIGN FOR ASSEMBLY

Another important aspect of the concurrent engineering is integrating the design and assembly
in the product design stage. This is called Design For Assembly (DFA). Minimizing the cost of
the assembly is one of the main design functions.

Guidelines to be Followed in Design for Assembly :

The general guidelines to be followed in design for assembly are discussed below :

1. Minimize total number of parts in product,

2. Use symmetrical parts in product,
3. Exaggerate asymmetry, if functional requirement demands,
4. Use slotted holes to accommodate variations in parts,
5. Minimize assembly direction,
6. Maximize assembly compliance features in parts,
7. Design the parts for the method of assembly.

1. Minimize total number of parts in product

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Reducing the number of parts in a product simplifies the assembly. Therefore it reduces the
assembly time as well as the cost of the assembly.
2. Use symmetrical parts in product

(a) Asymmetry Part (b) Symmetrical Part

Fig. 1.35
 Symmetrical parts require less handling and hence also reduce the assembly time,
especially in manual assembly.
 Symmetry is advantageous particularly when the product is to be assembled in the field.
 Fig. 1.35(a) shows an asymmetrical cover plate with only one correct assembly
orientation. The redesigned symmetrical cover plate, shown in Fig. 1.35(b), has four
correct assembly orientations.
3. Exaggerate asymmetry, if functional requirement demands :
Some parts will function only if assembled with a particular orientation. In such cases, it is
necessary to design the parts with asymmetry. If the asymmetry is difficult to distinguish as
shown in Fig. 1.36(a), the assembler may try to force the parts together with the wrong
orientation. Exaggerated asymmetry, as shown in Fig. 1.36(b), ensures the correct
orientation for assembly.

(a) Asymmetry (b) Exaggerated Asymmetry

Fig. 1.36

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 When incorrect assembly would result in a safely hazard, the asymmetry should be
exaggerated such that incorrect assembly should be virtually impossible.

4. Use slotted holes to accommodate variations in parts :

Slotted holes and similar features can be used to accommodate variations in parts. For
example, a motor base plate or cover plates may have slotted holes to allow adjustments.
5. Minimize assembly direction :
All parts should be designed so that they can be assembled from one direction. The need to
rotate parts in assembly requires extra time and motion, and hence requires additional
fixtures and transfer stations. This will increase the assembly time as well as the cost of the
assembly. The best way of assembly is to assemble in Z-direction.
6. Maximise assembly compliance features in parts :
Excessive assembly force may be required if the parts are not perfect. The addition of the
compliance features, like tapers, chamfers, radii, etc. to the parts reduce the assembly force
and hence simplify the assembly.
7. Design the parts for the method of assembly :
The parts can be assembled into products by one of the following methods :
i. Manual assembly,
ii. Mechanically aided manual assembly,
iii. Special purpose automatic assembly,
iv. Programmable automatic assembly with robots and parts magazines.
The method of assembly depends upon the volume of production, the number of parts in
product, the variety of parts in product and the likelyhood of design changes. The
following guidelines are to be followed in the automatic assembly.
a) In automatic assembly, small parts are fed and oriented by belts, tracks, rotary disks,
reciprocating arms and magnetic devices. Therefore, the parts must have sufficient
strength and rigidity to withstand feeding forces. Thin, weak and brittle parts should
be avoided.
b) Minimize the number of finished surfaces that must be protected from damage due to
scratching.
c) Use flanges or projections to protect finished surfaces from damage due to scratching.
d) If possible, design the largest and most rigid part of the assembly to serve as a base or
fixture. This eliminates the need for assembly fixture.

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