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Dr. David M. Anderson is one of the world’s leading expert on Design for Manufacturability, Concurrent Engineering, Build-to-Order and Mass Customization. Based on these books, 25 years experience providing seminars to leading clients, and his book-length web site http://www.halfcostproducts.com/,  he can claim to be the leading expert on cost reduction up to and beyond half-the-cost.
 

BOOKS WRITTEN BY DR. ANDERSON

Just published in February 2014: Design for Manufacturability

Design for Manufacturability: How to Use Concurrent Engineering to Rapidly Develop Low-Cost, High-Quality Products for Lean Production

Available now at Amazon.com
 

DFM Book Features
  • Explains how to develop manufactured products right the first time
  • Describes how to significantly reduce total costs, raise quality, and achieve the quickest time to stable production
  • Illustrates how to make the most from lessons learned from previous/similar projects
  • Details how to design parts for optimal manufacturability and concurrently engineer factory processes
  • Spells out how to work with purchasing people early on to select parts and materials that maximize quality and availability while assuring desired functionality

DFM Book Summary

Design for Manufacturability: How to Use Concurrent Engineering to Rapidly Develop Low-Cost, High-Quality Products for Lean Production shows how to use concurrent engineering teams to design products for all aspects of manufacturing with the lowest cost, the highest quality, and the quickest time to stable production. Extending the concepts of design for manufacturability into to an advanced product development model, the book explains how to simultaneously make major improvements in all these product development goals, while enabling effective implementation of Lean Production and quality programs.

Illustrating how to make the most of lessons learned from previous projects, the book proposes numerous improvements to current product development practices, education, and management. It outlines effective procedures to standardize parts and materials, save time and money with off-the-shelf parts, and implement a standardization program. It also spells out how to work with the purchasing department early on to select parts and materials that maximize quality and availability while minimizing part lead-times and ensuring desired functionality.

  • Describes how to design families of products for Lean Production, build-to-order, and mass customization
  • Emphasizes the importance of quantifying all product and overhead costs and then provides easy ways to quantify total cost
  • Details dozens of design guidelines for product design, including assembly, fastening, test, repair, and maintenance
  • Presents numerous design guidelines for designing parts for manufacturability
  • Shows how to design in quality and reliability with many quality guidelines and sections on mistake-proofing (poka-yoke)

Describing how to design parts for optimal manufacturability and compatibility with factory processes, the book provides a big picture perspective that emphasizes designing for the lowest total cost and time to stable production. After reading this book you will understand how to reduce total costs, ramp up quickly to volume production without delays or extra cost, and be able to scale up production rapidly so as not to limit growth.

BUILD-TO-ORDER & MASS CUSTOMIZATION

He also wrote "Build-to-Order & Mass Customization; the Ultimate Supply Chain Management and Lean Manufacturing Strategy for Low-Cost On-Demand Production without Forecasts or Inventory," by Dr. David M. Anderson, (2008, CIM Press, 805-924-0200), Hardbound, 520 pages, ISBN 1-878072-30-7; $49.95.

See the complete Table of Contents at: http://www.build-to-order-consulting.com/books.htm

The book description and order form is at: www.amazon.com

Description:  This new book challenges many conventional practices and shows how to implement a revolutionary business model with evolutionary self-supporting steps. Instead of managing complex supply chains, the book has five chapters to show how to simplify supply chains to the point where parts can be spontaneously resupplied without forecasts or purchase orders. Instead of wrestling with all the problems of inventory, "on-demand lean production" can build products spontaneously without any finished-goods inventory. This and several other cost reduction strategies allow significant reductions in total cost. The same production facilities can build-to-order a wide variety of standard products and mass-customize products for niche markets or individual customers.
    The book is written for both managers and implementers with a 64 page executive overview of the whole book followed by 400 pages of detailed methodologies and implementation strategies. There are 300 sidebars throughout the book that emphasize key points.

 

DESIGN FOR MANUFACTURABILITY & CONCURRENT ENGINEERING (out of print)

Dr. Anderson “wrote the book on DFM,” literally and figuratively. Design for Manufacturability & Concurrent Engineering How to Design for Low Cost, Design in High Quality, Design for Lean Manufacturing, and Design Quickly for Fast Production (2010, 456 pages) is the definitive work on DFM, This book has the latest from the author's 25 years experience of providing in-house DFM seminars. 
 

 

 

AGILE PRODUCT DEVELOPMENT FOR MASS CUSTOMIZATION (out of print)

Dr. Anderson also wrote the first "how to" book on Mass Customization: "Agile Product Development for Mass Customization; How to Develop and Deliver Products for Mass Customization, Niche Markets, JIT, Build-to-Order, and Flexible Manufacturing," by David M. Anderson, with an introduction by B. Joseph Pine II, published by McGraw-Hill in 1996 is now out of print.  The book has been printed in a Chinese translation (simplified character Mandarin) from McGraw-Hill's Singapore office: www.asia-mcgraw-hill.com.sg

Link to book description and used book order links at http://www.amazon.com .

 

DESIGN FOR MANUFACTURABILITY; OPTIMIZING COST, QUALITY, AND TIME-TO-MARKET

Dr. Anderson wrote the first general book on DFM, Design for Manufacturability; Optimizing Cost, Quality, and Time-to-Market, 224 pages CIM Press, 1990).  This was the first book to publish the graph the is the basis of common quote that "80% of cost is determined by the design."   It was also the first book to publish a practical standardization procedure, based on the authors successful standardization program at Intel's System Group.

 

BOOK CHAPTERS WRITTEN BY DR. ANDERSON


ADVANCES IN PRODUCT FAMILY AND PRODUCT PLATFORM DESIGN

Dr. Anderson wrote the “how-to” chapter: “Supplying, and Designing Product Families" to be published by Springer soon. This chapter is available now to download at Springer site at: http://link.springer.com/chapter/10.1007/978-1-4614-7937-6_23

THE QFD HANDBOOK

Dr. Anderson was asked to write a Chapter 6, "QFD and Designing for Manufacturability and Customization," in the QFD Handbook, by Jack B ReVelle, John W. Moran, and Charles A. Cox (1998, John Wile, 410 pages)

SME TOOL AND MANUFACTURING ENGINEERS HANDBOOK

The Society of Manufacturing Engineers asked Dr. Anderson to write the opening chapter, "Design for Manufacturability," for its Tool and Manufacturing Engineers Handbook, Volume VI, on Design for Manufacturability, (1992. Fourth Edition, SME)

INDUSTRIAL ROBOTICS HANDBOOK

In 1983 Dr. Anderson wrote an essay on “The Future of Robotics” in the Industrial Robotics Handbook, by V. Daniel Hunt (1983, Industrial Press, 432 pages)
 

JOURNAL ARTICLES WRITTEN BY DR. ANDERSON

MECHANICAL ENGINEERING, Published by ASME

Dr. Anderson was asked to write the feature article, "Mass Customization's Missing Link," for the March 2011 issue of the journal, of the American Society of Mechanical Engineers, Mechanical Engineering, on how to build mass-customized products.

JOURNAL OF ORTHO WORLD

 Dr. Anderson was asked to write an article about total cost implications of offshoring, "Why Offshoring Manufacturing 'To Save Cost' Won’t, but Trying Compromises Product Development, Delivery, and Quality," which was published in the Spring 2010 issue of Otho World's journal: BoneZone.
 

FABRICATING & METALWORKING Magazine

Dr. Anderson was asked to write an article on Vendor/Partnerships for the January 2008 issue of Fabricating & Metalworking magazine. The title was “Tearing Down the Walls with Vendor/Partnerships.” The subhead: Design for Manufacturability and Concurrent Engineering require vendor/partnerships to reap the lowest total cost and the fastest time-to-market.
 

FLOW MANUFACTURING REPORT

Dr. Anderson wrote the article, "Mass Customization: The Payoff for Flow Manufacturing," for Flow Manufacturing Report, a Penton Publication, October 1999.

JOURNAL OF THE AGILITY FORM

Dr. Anderson was asked to be guest editor for the Mass Customization issue of the Agility Forum's Journal, Agility & Global Competition, in which he wrote the "From the Editor" introduction and his own article, "Implementing Mass Customization" in the Sprint 1998 edition, Vol. 2, No. 2.   He also arranged for articles to be written by B. Joseph Pine II (author Mass Customization), Steven W, Demster (President and CEO, Ross Controls), Henry F. Duignan (Project Manager for Ross's ROSS/FLEX flexible plant), Michael W. Pessina (VP Ops, Lutron Electronics), and Chris L. Conway (VP Technology and Design, Hoffman Engineering, who build a $30,000,000 flexible plant based on Dr. Anderson's principles).

 

WEB ARTICLES WRITTEN BY DR. ANDERSON

http://www.design4manufacturability.com/articles.htm has articles on:

  • Designing Low-Cost Products
  • Design for Manufacturability
  • Designing in Quality
  • Saving Cost and Time with Vendor/Partnerships
  • Reducing Cost and Material Usage for Large Parts
  • Half the Time to Stable Production
  • Standardization
  • Mass Customization
  • Build-to-Order & Mass Customization
  • Rationalizing Product Lines
  • DFM Training; how to arrange
  • How Seminars & Workshops Are Customized for Practicality and Relevance
     

http://www.halfcostproducts.com/articles.htm  has the following articles and 700 hyperlinks:

  • Build-to-Order
  • Commercialization
  • Counterproductive Policies that need to be corrected to design Half-Cost Products
  • Designing for Build-to-Order
  • Build-to-Order Future link to The Next Twenty Years site
  • Business Model for BTO&MC
  • How Not to Lower Cost
  • Design for Manufacturability link to DFM site
  • Low-Bidding
  • Mass Customization
  • Design for Mass Customization
  • Mass Production; the End of the Line for Mass Production
  • Mergers & Acquisitions
  • Lean Production
  • Designing for Lean Production
  • Off-Shore Manufacture
  • Cost of Quality
  • How to Design for Quality
  • Product Line Rationalization
  • Recession Strategies
  • Standardization
  • Supply Chain Cost Reduction
  • Total Cost
  • Saving Cost and Time with Vendor/Partnerships
     

http://www.build-to-order-consulting.com/articles.htm has the following articles:

  • Build-to-Order
  • Mass Customization
  • Training for Build-to-Order & Mass Customization
  • Achieving Growth through BTO & Mass Customization
  • On-Demand Lean Production
  • Spontaneous Supply Chain to pull parts and materials on-demand
  • Product Line Rationalization
  • Standardization
  • Automatic Resupply Techniques: steady flow, kanban, min/max, and breadtruck
  • End of the Line for Mass Production; No Time for Batches and Queues
  • Hoffman Enclosures case study, who used based a flexible plant on these BTO techniques to build a wide variety of standard and mass customized products on-demand.
     

    PUBLIC SPEECHES BY DR. ANDERSON

    Most of these speeches had written handouts either published in proceedings or handed out at the event.

    “Cost Strategy for Medical Devices; How to Reduce Cost and How Not To,” presented at the Orthopedic Design & Technology Forum, May 3 2012, in Memphis, TN

    “Designing Products Right-the-First-Time for the Best Cost, Quality, Compliance, and Time to Stable Production,” presented at the Medical Design and Manufacturing (MD&M) conference, March 14, 2012, in Fort Worth, Texas

    "Design for Manufacturability & Concurrent Engineering," presented to faculty and students at Cal Poly, February 4, 2010

    "Design for Manufacturability."  Presented to students and faculty of San Jose State University; September 12, 2007; September 6, 2006, September 7, 2005.

    "Integrated Product Development; Developing Half-Cost Products in Half the Time," Sept. 25, 2002 in Indianapolis, Indiana.

    "Design for Manufacturability; Optimizing Cost, Quality, and Time-to-Market by Design,"  Sept. 26, 2002, in Indianapolis, Indiana. 

    "Build-to-Order & Mass Customization," Sept. 23 - 24. 2002, in Indianapolis, Indiana.  

    "Profiting from Lean Production, sponsored by APICS (American Production and Inventory Control Society), one-day seminar, December 2, 1998, Rochester, New York

    "Spontaneous Build-to-Order," sponsored by AME (Association for Manufacturing Excellence), one-day seminar, October 15-16 and November 12-13, 1998, in Lexington, Kentucky

    "Agile Product Development for Mass Customization and Build-to-Order," presented at a convention of SAE (Society of Automotive Engineers), August 3, 1998, San Francisco, CA

    "Design for Mass Customization, Meeting Customer Demands," presented at the MegaSociety conference, July 16,1997, Anaheim, California

    "Agile Product Development for Mass Customization," presented at the Knowledge-Based Organization conference, May 15, 1997, Phoenix, Arizona

    "How Mass Customization Can Proactively Manage Change," presented at the Sixth Annual Agility Conference, March 4, 1997 in San Diego, California

    "Meeting Super-Urgent Demands for Product Customization," presented at the Project World Conference, December 12, 1996, Santa Clara, California

    "Agile Product Development for Mass Customization, Niche Markets, and Ultra-Fast Time-to-Market," presented at the Project World Conference, August 7, 1996, Washington, D.C.

    "Agile Product Development for Mass Customization," second day keynote speech presented at the IMC Conference on Mass Customization, June 19, 1996, Chicago, Illinois [voted best]

    "Agile Product Development for Mass Customization, Niche Markets, JIT, Build-to-Order, and Flexible Manufacturing," two-day short course, taught for University of California at Berkeley Extension, June 17-18, 1996 in Boston, Massachusetts

    "Design for Manufacturability," presented at the PCI Spring ‘96 Conference, May 3, 1996, San Jose, California.

    "Design for Manufacturability," University of California at Berkeley Extension, one-day class, October 27, 1995, San Francisco, California

    "Low-Cost Product Development," University of California at Berkeley Extension one-day class, October 26, 1995, San Francisco, California

    "Agile Product Development for Mass Customization, JIT, BTO, and Flexible Manufacturing," University of California at Berkeley Extension one-day class, October 25, 1995, San Francisco, California

    "Advanced Product Development," University of California at Berkeley Extension one-day class, October 23, 1995, San Francisco, California

    "Developing Agile Products for Mass Customization, Niche Markets, Build-to-Order, JIT, and Flexible Manufacturing," 19th Annual International Conference of the Product Development and Management Association, October 12, 1995, Minneapolis, Minnesota.

    "Designing for Manufacturing Success," presented at the PCI Spring ‘95 conference, March 27, 1995, San Jose, California

    "Agile Product Development for Flexible Manufacturing and Mass Customization," presented at the Silicon Valley Chapter of the Society of Concurrent Engineering meeting, July 14, 1994, Santa Clara, California

    "Designing Products for Mass Customization," presented at the IIR Conference on Mass Customization, February 17, 1994, New Orleans, Louisiana

    CORPORATE SPEAKER/PANELIST EXPERIENCE

    Dr. Anderson was an internal speaker/panelist for:

    • EDS Consulting (now AT Kearney),
    • Price Waterhouse R&D Effectiveness Practice,
    • Hewlett-Packard Engineering Conference,
    • Emerson Electric (two speeches),
    • Johnson Controls,
    • Caterpillar,
    • Freightliner,
    • BAE Systems,
    • Watkins-Johnson,
    • National Semiconductor,
    • Applied Materials,
    • Lam Research,
    • Beckman-Coulter,
    • Generic CADD (now Autodesk),
    • Octel,
    • Stanford Telecom,
    • Wiltron/Anritsu,
    • QSC Audio,
    • Rainbird,
    • Enodis,
    •  Schlumberger (for a speech on the future of manufacturing)
       

    PUBLIC SEMINARS AND COLLEGE COURSES

    Most of these seminars and courses were accompanies by written handouts.

     "New Product Development, the Management and Design of Manufacturable Products,"  3-unit graduate course at the Haas Graduate School of Business at the University of California at Berkeley " as part of the Management of Technology Program.  

    "Design for Manufacturability," 3-unit senior/graduate course, taught as Adjunct Professor at the University of Portland, Multnomah School of Engineering, Summer semesters, 1988 and 1989.

    "Computer Integrated Manufacture," 3-unit course senior/graduate, taught as Adjunct Professor at the University of Portland, Multnomah School of Engineering, Fall semester 1988

    "Techniques for Continuous Improvement," one-day short course, sponsored by PGE’s Energy Research Center, Portland, Oregon; June 27, 1989; October 26, 1989; April 27, 1990; October 3, 1991; May 28, 1992; and November 30, 1993.

    "Design for Manufacturability," 2-day short course, taught for University of California at Berkeley Extension, two to three times a year, 1990 to 1993.

    "Design for Manufacturability," 2-day short course, taught in Singapore for the Centre for Management Technology, July 15-16, 1991.

    "Techniques for Continuous Improvement," one-day short course at NORTHCON ‘91, Portland, Oregon, October 3, 1991.

    "New Product Development, the Management and Design of Manufacturable Products," 3-unit graduate course, taught at the Haas Graduate School of Business, University of California at Berkeley, Spring and Fall semesters, 1993.

    "Design for Manufacturability," one-day tutorial, NEPCON convention, Anaheim, California, February 10, 1993 and March 1, 1994.

    "Competitive Product Development," half-day tutorial presented at WESCON ‘93, September 30, 1993.

    "Advanced Product Development," taught 4 of 5 one-day courses for one week series, for University of California at Berkeley Extension, October 23-27, 1995. Individual course titles were: "Advanced Product Development Management," "Agile Product Development," "Low-Cost Product Development," and "Design for Manufacturability."

    "Agile Product Development for Mass Customization, Niche Markets, JIT, Build-to-Order, and Flexible Manufacturing," 2-day short course, taught for University of California at Berkeley Extension, June 17-19, 1996 in Boston, MA.

     "Design for Manufacturability," July 5-6, 1993, in  Singapore

     

    CLIENT ENGAGEMENTS, presented/facilitated by Dr. Anderson

Electronics Clients

  • eight seminar/workshop engagements at Hewlett-Packard,
  • five seminars at Plantronics (phone head sets),
  • four trips to Korea for LG Electronics,
  • two seminars at NCR (ATM machines and Point-of-Sale terminals),
  • two seminars and a workshop at Glenayre Electronics (pager transmitters),
  • seminar and two workshops for Advanced Energy Industries (workshops were on power-plant scale inverters and RF power supplies,
  • two seminars and a workshop at Winegard (tracking TV antennas for RVs),
  • Capetronic, Taiwan (seminar and workshop for computer CRT monitors)
  • SeaTel (seminar for tracking TV marine antennas),
  • Storage Tek (seminar for high capacity tape and disk drives)
  • Magnetic Analysis Corporation (seminar for non-destructive testers),
  • Industrial Scientific (seminar for gas detectors)
  • Lightwave (seminar for Lasers),
  • Silicon Light Machines (seminar for Laser projection systems)
  • ILC Technology (seminar for lamps and light sources)
  • AOptix Technologies (seminar for adaptive optics biometric scanners),
  • JDSU (seminar for coax cable diagnostic tools),
  • Anritsu (seminar for cable diagnostic tools),
  • Qualcomm (seminar cell-phone development prototypes and evaluation platforms),
  • Northern Telecom (seminar for telephones),
  • Network Equipment Technologies (seminar for network hardware).


Industrial Equipment Clients:

  • two seminars at  United Technologies Corp. (air conditioners and fire/security systems)
  • two engagements at GE Energy (seminar for fuel cells; consulting for Nuclear);
  • two engagements at Emerson Electric (seminars and consulting for electric motors; rationalization for gas regulators)
  • two seminars at FMC (food processing machinery)
  • Idatech (seminar and workshop for fuel-cell generators)
  • Hoffman/Schroff (seminars/workshops on large electrical enclosures)
  • Cooper Industries (seminar electrical cabinets and cable trays)
  • Badger Meter (seminar for water meters)
  • KI Furnature (seminar for office furniture)
  • Exemplis (seminar for office chairs)
  • Midmark Corporation (rationalization Dental/Medical tools and furniture)
  • Siemens (cost reduction consulting on postal automation equipment)


Medical Products Companies:

  • three seminars at Invivo, which has been acquired by Philips (MRI image processing);
  • two seminars and an implementation meeting at St. Jude Medical (pacemakers, defibrillators);
  • two seminars at Beckman-Coulter (hematology lab equipment);
  • a seminar, workshop, and executive overview at Salient Surgical Technology (transcollation surgical tools), ;
  • a seminar and two workshops at Varian Medical Systems (Oncology radiation treatment machines);
  • a seminar for four divisions of HP’s Medical Products Group, which have been acquired by Philips;
  • a seminar for Abiomed (seminar for catheter-based blood pumps);
  • a tooling workshop for Spectranetics (seminar for cather-based lasers)
  • a seminar for Biolase (seminar for laser-based dental surgical tools),
  • Advanced Bionics (seminar for Cochlear hearing implants),
  • Becton-Dickinson (seminar for laser-based immunocytrometry lab equipment);
  • Medrad (seminar for tracer injectors);
  • Origin Medsystems (seminar for surgical tools);
  • Natus (seminar for infant care products);
  • Bausch & Lomb (Mass Customization seminar for Ray-Ban glasses);
  • Allergan-Humphreys (seminar for medical products);
  • Hollister (seminar and plant evaluation for ostomy products);
  • plus management overviews for Baxter Healthcare, Guidant, Salient Surgical Technology, and Spectranetics.
     

Aerospace/Defense Clients

  • four seminars at BAE Systems (airplane controls and infrared vision/targeting systems),
  • four senubars at Smiths Aerospace, now GE Aviation (aircraft control panels and power supplies),
  • four seminars at Boeing (commercial aircraft),
  • three seminars at L-3 Communications (GPS systems);
  • three seminars at Laser Communications Inc., consortium of Ball Aerospace and Comdev (laser-connected communication satellites)
  • three engagements at Loral Western Development Labs, now L-3 (military radios)
  • seminar and implementation meeting at CPI Beverly Microwave Division, the radar spin-off of Varian (microwave assemblies, receiver/protectors, transmitters, magnetrons, amplifiers);
  • Randtron, now L-3 (radar antennas for AWACS),
  • Moog Aircraft, (seminar for hydraulic actuators),
  • Honeybee Robotics Space Mechanisms (seminar for space probe robots and mechanisms),
  • Kaiser Electronics (seminar for heads-up displays for fighter jets);
  • Driessen, (seminar for aircraft galleys),
  • Oceaneering Space Systems (seminar for astronaut tools),
  • B. E. Meyers (seminar for locating lasers),
  • Rix Industries (consulting for armored door egress mechanisms)

 

Processing Equipment Clients

  • PRI Automation (seminar and 6 years consulting on clean room robots)
  • Asyst Technologies (seminar for clean room environments)
  • Electro Scientific Industries (seminar and consulting for semiconductor processing equipment)
  • Prometrix (seminar semiconductor processing equipment)
  • Airco Coating Technology (seminar and months of consulting for deposition coating equipment)
  • Measurex (seminar for paper processing equipment)
  • Rader Companies (seminar forpaper pulp processing equipment)
  • Raco Manufacturing (consulting remote controls and alarms)

 

Commercial Vehicle Clients

  • six seminars/workshops for Emergency-One (mass customization seminar for firetruck manufacturer, implementation workshop, DFM seminar, standardization workshop, and two flexible tooling workshops for sheetmetal and tubing);
  • GE Transportation (seminar and workshop for Diesel Locomotive Engines);
  • Bucyrus , div of Caterpillar (seminar and steel/cost reduction workshop for underground mining vehicles)
  • Kinze Manufacturing (BTO/Cellular Manufacturing seminar, followed by workshops on Rationalization and Standardization for farm machinery),
  • Freightliner (DFM seminar and BTO strategy session for semi-tractors),
  • John Deere (yard tractors with an upcoming engagement for farm tractors);
  • Case Tractor (executive education at the Haas Graduate School of Business at UC Berkeley)

 

CREDENTIALS of Dr. Anderson

  • Dr. Anderson is a Fellow of ASME (American Society of Mechanical Engineers)
  • He has been certified for 12 years as a Certified Management Consultant (CMC) by the Institute of Management Consultants.
  • He is a Life Member of the Society of Manufacturing Engineers (SME).
  • His credentials include professional engineering (P.E.) registrations in Mechanical, Industrial, and Manufacturing Engineering
  • He holds a Doctorate in Mechanical Engineering from the University of California, Berkeley with minors in Business Administration and Industrial Engineering and a thesis on mechanisms
     

Dr. David M. Anderson, P.E.; CMC; Fellow, ASME
www.design4manufacturability.com
www.HalfCostProducts.com
www.build-to-order-consulting.com
1-805-924-0100 (Pacific Time Zone); anderson@build-to-order-consulting.com

 

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