Practical, hands-on workshop. Includes over 240 examples of good and bad design for manufacturability and assembly practices. Includes exercises to reinforce understanding of principles and analysis of company assemblies to transition learning back to your workplace. The three-day workshop includes one day on-site prior to the workshop to customized it to your products and processes.

1. DESIGN FOR MANUFACTURABILITY/ ASSEMBLY (DFM/A)

• DFM/A Perspective
• Competitive Gap - A Case for DFM/A
• A Framework for DFM/A

2. DESIGN FOR ASSEMBLY

• Principles of Design for Assembly
• Simplify Product Architecture
• Simplify Interconnections
• Simplicity - Minimize Part Count
• Minimize Parts Exercise
• Standardization - Minimize Part Variety
• Standardization Approach and Method
• Assembly Process Framework
• Design for Parts Feeding & Handling
• Design for Part Orientation
• Design for Location and Insertion 
• Minimize Flexible Parts
• Design for Ease of Assembly
• Top Down, Uni-Axis Assembly
• Design for Joining & Fastening
  • Design Self-Fastening and Self-Jigging Features
  • Threaded Fastener Considerations & Guidelines
  • Integral Attachment (Snap-Fit Assembly) Guidelines
  • Welding Guidelines
  • Other Fastening Methods and Guidelines
• Avoid Adjustments
• Mistake-Proof Assembly (Poke Yoke)
  • The Six Mistake-Proofing Principles
  • Examples of the Six Mistake-Proofing Principles
  • Mistake-Proofing Exercise - Identify Mistake-Proofing Opportunities
• Case Studies and Benefits - Aerospace, Automotive, Electronics, Mechanical Machinery
• Design for Assembly Exercises

2. DESIGN FOR AUTOMATED ASSEMBLY(optional module)

• Production Considerations for Manual, Flexible Automation and Hard Automation
• Cost / Benefit Analysis of Automation
• Design for Feeding Guidelines
• Feeders & Orientation
• Flexible Automation
  • Robotic Assembly
  • Design for Robotic Assembly Guidelines
  • Design for Vision System Guidelines
  • Gripper Design Guidelines
• Hard Automation
• Case Studies & Summary

3. DESIGN FOR MANUFACTURABILITY

• DFM Framework
• Material and Process Evaluation
• Tolerances and DFMA Impact
• Raw Material Standardization
• General Guidelines
• Machining Guidelines and Examples
• Manufacturability Analysis Exercise
• Sheet Metal Guidelines and Examples
• Injection Molding Guidelines and Examples
• Casting Guidelines and Examples
• Minimize Finishing Requirements

4. DFM/A FOR ELECTRONICS

• Simplify the Assembly Process
• Reduce Thermal Cycles
• Board Size and Panelization Guidelines
• PCB Layout Guidelines
  • Panel Considerations and Keep-Out Area
  • Tooling Hools
  • Fiducials
  • Holes
  • Trace Width and Spacing
  • Test Point Access
• Component Selection Guidelines
• Component Orientation Guidelines
• Examples & Results

5. PROCESS CAPABILITY AND TOLERANCES

• Determining a Process Strategy
• What is Process Capability
• Variation and Specifications
• Parameter and Tolerance Objectives
• Statistical Process Capability
  • Normal Distribution
  • Capabilities Indices - Cp and Cpk
  • Capability Index Exercises
  • Six Sigma Capability and Defects per Million
• Effect of Tolerances
• Cost Impact of Tolerances
• Tolerance Analysis
  • Worst Case
  • Root Sum of Squares (RSS)
• Building a Tolerance Model
• Tolerance Optimization

6. DESIGN FOR "X"

• Design for the Supply Chain
• Design for Leadtime
• Design for Safety
• Design for Human Factors
• Design for Reliability
• Design for Disassembly
• Design for Serviceability/Maintainability
• Design for the Environment (DFE)
• DFE Examples & Case Study

7. ANALYSIS TOOLS AND TECHNIQUES

• Identifying Opportunities for Improvement
• Function Analysis
• Function Analysis Exercise
• Brainstorming and Creativity
• Brainstorming Exercise
• A List of DFM/A Software Tools
• Illustration of DFA Tool in Use
• Illustration of DFM Tools in Use (Machining)
• Injection Molding and Casting Analysis
• Product Cost Models to Estimate Costs & Evaluate Design Alternatives

8. DFM/A PROCESS AND METRICS

• DFM/A Process Steps
• Early Manufacturing Involvement
• Early Supplier Involvement
• Determining Process Capabilities
• Developing Design Guidelines
• Conducting Design Reviews to Address DFM/A
• Performance Measurement & Metrics

9. SUMMARY

• 10 Steps to DFM/A
• DFM/A Survey Results
• Key Success Factors
• Sources of Further Information
• Questions and Discussion

10. OPTIONAL ANALYSIS OF COMPANY ITEM