It is easy to get so lost in solving a problem that even the original prototype can be nearly impossible to make. On the flip side, one can get so focused on design for manufacturing that new products never make it out of the prototyping stage. In the early stages of new product development, the key is to simply keep it in mind. Your future self will thank you.
Let us start with the basics, this first one will help you even in early prototyping stages.
Design for manufacturing causes us to think about reaching each bolt with a wrench
This seems obvious, but it is a classic mistake made by designers sitting behind a desk. It is very easy to design a complete assembly in 3-D CAD software such as SolidWorks™ and overlook how you might get a physical tool onto a bolt!
This can occur a few different ways. Without design for manufacturing, designs may cause it to be physically impossible to access a piece of hardware. Or, sometimes we forget that a hex driver such as a socket fits around the outside of the hardware. This tool needs clearance space to fit. Other times, the hardware is accessible, but can only be turned a sixteenth of a rotation at a time.
The challenge goes beyond turning bolts. Without considering design for manufacturing, we can accidentally design sheet metal parts that cannot be bent, or machined parts with impossible features. It could be a plastic part which would be impossible to remove from its mold.
Some basic consideration of design for manufacturing can help avoid these challenges. Our recommendation is quite simple. Whenever designing an assembly, take some time to imagine yourself putting it together.
Really.
Close your eyes, slow down your mind and walk through each step of making every part. Imagine how you will reach that one screw, and with what tool. The same can be said for individual components. Imagine how each bend will be made in what order for sheet metal parts. Think about what tool will be used for each step of a machined part. If you are not sure what the limitations are of making a component, ask the people who will be making them.
Design for Manufacturing considers who will be making your product and what their capabilities are
The very people who will eventually produce your design are the most valuable resource you have when it comes to design for manufacturing. If you are working with a contract manufacturer show them your design while you are developing it. If manufacturing is internal to your business, keep the men and women on the production floor involved in the process.
Part of design for manufacturing is asking if your design makes sense, or if they can do it. You will be amazed at what you might learn.
To Design an Assembly for Manufacturing, Ask these questions:
Can this be made?
What challenges will you run into making this or these components and assembling them?
Does anything seem like it will be frustrating or unnecessarily challenging?
Everyone loves to be heard. You will be amazed at how much you will learn from asking these questions related to design for manufacturing. Experienced teams on the production floor have usually made something reminiscent of your design. Using this knowledge, they can recommend changes that will save immeasurable dollars and headaches down the road.
When working with contract manufacturers, two different businesses may recommend two different ways of making the same thing. It is not always that one is better than the other. Design for manufacturing may be based on their tools and experience. The ideal design could be made regardless of tooling constraints. This gives the flexibility to contract work out of your factory when in a scheduling bind, or to change contractors if needed.
Source parts that are easily available when thinking about Design for Manufacturing
Part of design for manufacturing is considering how you buy individual elements. When it comes to sourcing commercial off the shelf (COTS) components, try to choose ones which are reasonably priced and regularly stocked. Sometimes, your specific requirements call for something unusual. Often however there is a mass-produced component which will meet your needs.
In design for manufacturing run a web search for your chosen component. If it shows up on 10 different well-known websites each offering next day shipping, you know you have chosen wisely. If, however, the part shows up only a few times, shipping times are at least two weeks, and the pricing often shows up in other currencies, you may want to find another version of the part. By choosing your sub-components wisely, you will reduce schedule disruptions from long lead times.
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When it comes to new product development, design for manufacturing is really a mindset. Periodically, review your design against the items discussed in this article and you will find yourself in much better shape to keep costs and lead times down when it becomes time to manufacture your product.
