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可製造性設計(DFM)的關鍵要素
可製造性設計(DFM)不僅對於確保產品與設計的實際生產，而且對於保證其可靠性、可測試性、可重工性及耐用性至關重要。如果能夠正確實施DFM，就可以避免與現有製造技術不一致的設計，避免需要多餘步驟或手工技能的設計。
DFM文件是最優化設計(DFX)概念的核心，而DFX涉及從產品創意到產品發布的所有過程。如果能夠恰當實施DFX，就可以保證組裝的便利進行，減少產品需要後繼設計調整的發生機率。這一過程的關鍵部分是強有力的設計評估，能夠在設計階段之初發現問題，並確保其與DFM標準的一致性。缺乏強有力的DFX能力和DFX文化，常常導致設計失敗。
DFX成功的關鍵是為公司文化所接受，並與公司文化融為一體。因此首先要從管理層開始，逐漸滲透到所有的工程人員，最終傳遞到實際參與組裝產品的所有人員。
應該讓應用DFM或受DFM影響的所有部門都感覺到自己是整個過程的一部分，有責任為其內容構建做出貢獻。“團隊法”是實現這一目標的最佳方法，它允許團隊中的任何成員對DFM文件提出調整請求。團隊採取的第一個步驟應該是發現或研究出DFM文件中包含哪些訊息的概要。而補充細節則需要對設計和製造工藝的充分了解。研究中常常既需要獲得特定的明確訊息，又需要得到最專業的專家意見。從最基礎的東西開始，團隊漸漸能夠抽提並擴展DFM的範圍。在實施DFM之後，最好評估一下新設計符合DFM指南的程度。透過工廠及產品的可靠性數據，可以開發出符合量度表，並與工廠產量、循環週期時間相互聯繫 DFX的推展
一般而言，一家公司起初總是只有幾個員工從事產品的設計和製造。這一階段的設計標準可能不是書面的，所以必須倚賴涉及到的幾個員工的個人技能和知識。隨著公司的發展，更多人加入進來，將其設計產品的標準文檔化就非常必要了。一旦公司達到員工不能彼此直接面對面工作的規模，建立書面的DFM就至關重要了。書面的DFM建立得越早，DFM文化建立得越早，工作就越容易。
建立和維護DFM計畫並不簡單。不過儘管這一過程費時費力，其結果還是讓人感覺付出努力是值得的。在開始一項DFM計畫之前，目標必須明確。我們極力推薦以下策略性指導原則︰
‧ 成為公司文化的組成部分，也就是說，管理層必須提供支持和激勵。
‧ 客戶需求驅使。
Design For Manufacturability(DFM) Workshop
2-day workshop, 6.5 teaching hours per day, 1 hour lunch, two 30 min breaks
Practical, hands-on workshop. Includes many examples of good and bad design for manufacturability and assembly practices.
Includes exercises to reinforce understanding of principles.
 
1. DESIGN FOR MANUFACTURABILITY
- DFM Introduction
- Why DFM
- DFM considerations at product concept stage and during development process
- Problem Solving in Manufacturing
- Design Impact on Cost
2. DESIGN FOR MANUFACTURABILITY/ FRAMEWORK
- DFM Framework
- Material and Process Evaluation
- Material and Process Evaluation Exercise
- Raw Material Standardization
- Manufacturing Process Framework
- Design for Parts Feeding & Handling
- Design for Part Orientation
- Considering and Applying Symmetry vs. Asymmetry
- Measuring Symmetry - Alpha, Beta and Combined Symmetry
- Design for Location and Insertion
- Minimize Flexible Parts
- DFA Considerations with Gaskets, Interconnections, & Connectors
- Axes of Assembly, Reorientation & Blind Assembly
- Top Down, Uni-Axis Assembly
- Self-Fixturing vs. Production Fixtures
3. DESIGN FOR MANUFACTURABILITY PROCESSES DETAIL GUIDELINES
- General DFM Guidelines
- Manufacturability Analysis Exercise
- Production processes Guides
- Sheet Metal Guidelines
- Injection Molding Guidelines
- Casting Guidelines
- Joining & Fastening Methods and Guidelines: Ultrasonic Welding, Snap Fits, Living Hinges
- Adhesive Joining Methods and Guidelines
- Threaded Fastener Considerations & Guidelines
- Other Fastening Methods and Guidelines
- Painting Methods and Guidelines
- Plating Methods and Guidelines
- Rapid Prototyping
- Minimize Finishing Requirements
4. DESIGN FOR AUTOMATED ASSEMBLY
- Manual, Flexible Automation and Hard Automation: Production Considerations
- Cost / Benefit Analysis
- Design for Feeding Guidelines
- Feeding Systems & Orientation
- Robotic Automation
- Design for Robotic Assembly Guidelines
- Design for Vision System Guidelines
- Gripper Design Guidelines
5. DFM FOR PCB Assemblies (does not include PCB design guidelines)
- Use of DFM/A Guidelines for Boards
- Simplify the Assembly Process - Mixing Technology and Board Sides
- Reduce Thermal Cycles
- Board Size and Panelization Guidelines
- Component Selection Guidelines
- Other Component Considerations
- DFM/A Assessment for Boards
6. PROCESS CAPABILITY AND TOLERANCES Cp, Cpk, dpu
- Process Capability
- Variation and Specifications
- Statistical Process Capability
- Normal Distribution
- Capabilities Indices - Cp and Cpk
- Capability Index Exercises
- Six Sigma Capability and Defects per Million
- Process Yield, dpu analysis
- Tolerance Analysis
- Worst Case
- Root Sum of Squares (RSS)
- Monte Carlo Simulation
7. DFM and the Product Development Process
- DFM/A Process Steps
- During Concept Development Phase
- During Design Phase
- During Validation and Pilot Phase
- During Production Launch Phase
- Early Manufacturing Involvement
- DFM/A Collaboration Tools and Methods
- Role of Solids and Assembly Models in DFM/A Evaluation
- How to Effectively Consider Design Alternatives to Address DFM/A Issues
- Product Cost Models to Estimate Costs & Evaluate Design Alternatives
- Early Supplier Involvement
- Formal DFM/A Analysis & Assessment
- DFM/A Manual and Software Tools
- DFM/A Performance Measurement & Metrics
8. SUMMARY
- Putting it all together
- DFM/A Steps and Worksheet
- Sources of Further Information
- Questions and Discussion
9. DFM/A ANALYSIS OF COMPANY PRODUCT OR ASSEMBLY
- Team exercise: Company product evaluation for DFM/A
- Analysis Methodology and Worksheet
- Team presentations
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