Index for "Design for Manufacturability, Optimizing Cost, Quality, and Time-to-Market," Second Edition, 2001
[back]
Ability, as word suffix
Assembleability, 15, 164, 173
Customizability, 19, 65
Manufacturability, 1, 6, 13, 163,
179, 271
Recycleability, 21
Reliability, 206
Serviceability, 13, 215, 224
Testability, 13, 175, 267
Access
for parts and tools, 165
for test instruments, 176
sub-assemblies, 219
Accounting, cost, traditional approach
deficiencies, 142
distortions in product costing, 143
irrelevance for decision making, 144
Activity Based Costing (ABC), 141
cost drivers, 149
existing cost systems, 154
implementation effort, 155
implementation, easy
method, 157
implementing ABC, 154
implementing approaches, 147
low-hanging-fruit-approach, 149
resistance to, 154
results of implementation, 158
tracking R&D expenses, 156
Adding options, 165
Adding upgrades, 166
Adjustments
elimination of, 174
making in product, 218
protection of, 218
Agile product development, 61
Agility, 59
Analysis, statistically significant, 9, 10
Anderson's law, 104
Approval, 281
Arbitrary decisions, 5, 25, 26
and part proliferation, 77
examples in NPD, 26
Architecture
importance of, 51
optimizing, 54
Architecture optimization, 7
ASICs, 53
Assembly
ease of, 15
Assembly motion
screw fastening, 170
Assembly motion guidelines, 173
adjustment easy, 174
adjustment independent, 174
adjustments, avoid, 174
alignment, design for, 173
cables, minimize, 174
cables, minimize types, 175
calibration, avoid, 174
certifications, independent, 174
tests, independent, 174
tweaking, avoid, 174
Assembly motions guidelines, 173
Assembly order, 165
minimizing errors, 232
Assembly strategy guidelines, 164
Asymmetry guideline, 183
Auto-feed screwdrivers
as a standard process, 94
choosing fasteners for, 169
guideline, 169
Automatic handling, tolerances, 191
Automatic soldering, 257
Automation
for PC boards, 252
gripping guidelines, 193
handling by, 190
load capacity, 193
parts presentation, 192
use greater with DFM, 11
Automation guidelines, PC boards, 261
Availability, 223
of factory, 11
of spare parts, 217
Average quality level, 203
Awards, 286
Batch-size-of-one, 61
in mass customization, 66
Benefits
DFM program, 272
modular design, 70
of DFM, 10
Block tolerances, 189
Boeing, customers on design team, 39
Brainstorming, 30
rules of, 30
Bread-truck deliveries, 168
Breadth of product line, 18
Breadtruck automatic resupply, 102
Breadtruck resupply, cost savings, 132
BTO (build-to-order), 61
Build-to-order, 61
cost reduction from, 128
supported by standardization, 102
Building block modules, 69
Building parts on demand, 61
Bulk parts tangling, 191
Cables, minimizing types, 175
Capacity
shifting to/from flexible lines, 131
Capacity, production
doubling by doubling utilization, 130
Capital, working, 128
Captivated lockwashers, 171
Captivated washers, 170
Captive fasteners, 170
Catalog
information in, 110
organization, 109
Catalog hardware interfaces, 69
Catalog parts, 104
availability, 111
cost savings, 105
finding, 108
specials, 107
standardization effect, 104
time savings, 106
Catalogs
awareness, 108
design guidelines in, 110
information in, 110
sources, 108
Cell manufacturing, 60
Champion, 273
Change orders, 27
cost over time, 28, 124
minimizing cost, 124
total cost basis, 146
Changes
cost of, 27
forced by other changes, 8
Checklist
numbering, 281
Checklist formats, 279
Checklists, 278
Chrysler, suppliers like partners, 127
CNC, designing for, 64
CNC milling, designing for, 93
Co-location, 28
Combining parts
criteria, 181
for fastener elimination, 172
guideline, 181
Commonality, 82
fastener guidelines, 167
guidelines, 179
PC boards, 259
tools for repair, 216
Compaq, expanded space thru inventory reduction, 130
Competitive advantage,
of time-to-market, 19
Complementarity
optimizing workloads, 131
Compliance, 287
Computer Aided Design
in modular design, 69
Computer simulation, 9
Concept decisions, 54
Concept optimization, 7
Concept simplicity
key to reliability, 206
Concepts, DFM, 1
Concurrent engineering, 37
for build-to-order, 64
for flexibility, 64
Configuration, cost, when reactive, 128
Connections to sub-assemblies, 220
Consolidation of parts, 64
Constraints
and time, 27
misconceptions about, 4
realities about, 5
Continuous improvement, 126, 199
for complex products, 206
standardization's role, 101
Cooper, Robin, 142
Cost
capital equipment, 11
design consideration, 14
designed in, 117
minimizing overhead, 120
myths about, 5
of part proliferation, 76
per part number, 76
product introduction, 73
traditional measures, 118
when committed, 7
Cost distortion, 142, 143
Cost distortions, estimating degree, 146
Cost drivers, 149
Cost management, 145
Cost of changes, 27
Cost of quality
defects by the batch, 125
minimizing, 125
more than assembly, 125
Cost of variety
for parts, 75
minimizing, 129
Cost reduction, 115
avoiding diagnostic tests, 123
avoiding reinventing the wheel, 122
batches, eliminating cost of, 125
bills of materials, 136
breadtruck resupply, 132
build-to-order contribution, 128
build-to-order savings, 134
change orders, 124
configuration costs, 128
cost accounting difficulties, 145
cost of changes, 116
customization costs, 128
debug cost, 123
difficulty with poor costing, 145
distribution costs, 133
easy implementation, 157
ECOs, 124
engineering change orders, 124
expediting costs, 157
expensive inventory, 136
false perceptions, 94
field service, 132
finished goods inventory, 134
flexibility contribution, 128
floor space, 130
from catalog parts, 122
from faster NPD, 123
from flexibility, 73
from more efficient NPD, 123
from product extensions, 123
from teamwork, 121
hard to after design, 116
how not to achieve, 116
how not to ala Lopez, 126
inventory carrying cost, 135
inventory elimination, 129
inventory write-offs, 136
kitting elimination, 131
lean production contribution, 128
life cycle costs, 134
marketing, 133
mass customization, 128
materials management, 132
myths about, 116
non-value-added costs, 125
not from low-bidding, 117
not from off-shore production, 117
part overhead, 132
phasing in better products, 126
product development, 120
purchasing costs, 132
quality costs, 125
resources better applied, 117
sales costs, 133
setup labor, 130
spare parts logistics, 132
supplier cost, 132
supply chain costs, 134
thru design, 117
thru standardization, 95
transportation, internal, 130
utilization improvements, 130
variety costs, minimizing, 129
WIP inventory elimination, 129
with DFM, 10
with purchased parts, 105
Cost, inventory carrying, 135
Costs, overhead
allocations, 143
distribution, simplistic, 143
quantifying, 142
Counters, 224
Creative product development, 28
Creativity, 28
Crosby, Philip
cost of quality %, 125
"Quality is Free," 127
Cumulative effects
on product quality, 202
Custom parts from vendors, 110
Customer preferences in QFD, 48
Customers on design team, 39
Customers' needs, 18
Customization, 19
cost of when reactive, 128
Cutting tools, minimize variety, 185
Deadlines
how to set, 43
often set arbitrarily, 26
Decision making
enhanced by relevant numbers, 144
relevance: good costing, 144
Decisions
based on total cost, 122
Defects "by the batch", 125
Defects per million, 202
Definition, DFM, 1
Delivery, design consideration, 14
Dell Computer's build-to-order
transitioning first to new, 36
Deming, Edward
4th point, part quality, 197
9th point, teamwork, 197
Design
for maintenance, 224
to minimize errors, 228
Design considerations, 13
balance, 22
consequences of ignoring, 22
environmental, 20
factory, 14
marketing, 18
responsibility, 22
social, 17
traditional, 14
Design for Assembly, 15
software, 15
Design for fixturing, 184
Design for Manufacturability
benefits, 10
definition, 1
summary, 1
Design for repair, 215
Design freedom, 25
Design guidelines
in catalogs, 110
Design of experiments, 189
and robust design, 198
Design of Experiments, 10
Design philosophy, 13
Design review deadlines, 43
Design reviews, an alternative, 43
Design team leader, 41
Design teams, 37
Design time, resistance to DFM, 27
Designing flexible products, 66
Designing for manufacturability, 6
Designing in quality, 196
Designs, implementing, 31
DFM
benefits, 10
definition, 1
resistance, 4
DFM capabilities, 31
DFM concepts, 1
DFM products
appropriate overhead charges, 144
Diagnose
ability to, 215
Diagnostic tests
how to avoid, 39
how to avoid need, 123
when needed, 16
Dimensioning
optimizing with GD&T, 201
Disconnect features, 216
Discounted overhead, 286
Disposable parts, 217
Distribution
build-to-order cost savings, 133
design consideration, 16
minimizing costs, 133
revolutionized by build-to-order, 16
Do it right the first time, 8
strategy, 8
tools, 9
Dock-to-stock delivery, 60
Downtime, 223
Downward spirals
caused by poor costing, 145
Drucker, Peter
minimizing interstitial costs, 127
on supply chain costs, 134
Duplicate parts
eliminating, 80
problems for lean production, 80
E-commerce
problems with mass production, 65
Early effects of design, 7
Ease of assembly, consideration, 15
ECOs
cost over time, 124
minimizing cost, 124
total cost basis, 146
Elastic pins, 173
Empowerment, 43
compensation for poor costing, 149
Engineering change orders, 27
cost of, 27
cost over time, 28, 124
minimizing cost, 124
total cost basis, 146
Environmental design considerations, 20
Equipment cost, lower with DFM, 11
Ergonomics, design consideration, 17
Error avoidance
PC boards, 266
Error prevention
alternatives, 233
Error reduction, 228
Errors
commission, 229
omission, 231
sequence, 232
timing, 233
Errors of commission, 229
Errors of omission, 231
Expansion, design consideration, 19
Expediting costs
one-third in JIT, 157
Experience in factory, 32
Factory availability, 11
Factory experience, 32
Factory improvements, 2
Factory works on team, 40
Fastener commonality
guidelines, 167
PC boards, 260
Fasteners
captive, 170
geometry of, 169
reduction of, 167
snap-on, 172
use of fewer but larger, 167
use of minimum, 167
Fastening guidelines, 167
auto-feed screwdrivers, 169
captive fasteners, 170
combining parts, 172
lock-washers, captivate, 171
nuts, minimize, 170
press fits, 173
self-tapping, 171
snap together, 172
standardization, 167
tool standardization, 168
torque setting standardization, 168
washers, captivate, 170
Fastening strategy, 168
Feature standardization, 92
Federal Express
inventory-less deliveries, 135
Feedback, 275
Field data, 276
Field service
problems from part proliferation, 76
Finance role on team, 40
Finished goods inventory
cost minimization, 134
Fits, tolerances for, 173
Fixtures, versatile, 64
Fixturing, designing for, 184
for flexible operations, 184
Flexibility, 59
value of, 71
Flexible manufacture, for PCB, 255
Flexible manufacturing, 102
and group technology, 72
Flexible parts, 192
Flexible product development, 61
Flexible products, how to design, 66
Floor space
cost of, 130
minimizing, 130
Floor space reduction, 72
Flow manufacturing, 60
Focus, 24
Follow-up, 287
Ford, Mustang development
empowerment, role of, 43
Ford, Taurus
designers talking to customer, 31
Forecasts, eliminating the need for, 61
Freedom of design, 25
Function, design consideration, 14
Fuses, 219
Future designs, design consideration, 20
Future projects, 44
GD&T, 201
General Dynamics
cost variation of similar parts, 69
General Electric
supplier's view of standardization, 95
General Motors
results of Lopez "cost cutting", 126
Geometric Dimensioning & Tolerancing, 201
Goal, The; Goldratt, Eli, 128
Goals
DFM program, 271
optimizing real goals, 128
what achieves, 24
Goldratt, Eli; The Goal, 128
Gripping parts, 193
Group technology
for PC boards, 255
PC boards, 263
Grouping rules & guidelines, 280
Growth, Surviving, 3
Guideline, definition, 277
Guideline numbering, 163
Guidelines
assembly strategy, 164
parts, 179
past problems, understanding, 164
PC board components, 258
PC boards, 258
product design, 164
specific processes, 182
standardization, 179
Guidelines for part design, 179
Handling by automation, guidelines, 190
parts within gripper span, 193
Hewlett-Packard
automated screwdrivers, 95
cost driver implementations, 152
fastener display boards, 98
software debug strategy, 123
supplier standardization, 93
supply chain initiatives, 134
tracking R&D expenses, 156
Hoffman Engineering
build-to-order plant, 65
House of quality, QFD, 49
Human factors, 227
design consideration, 17
IBM
FPA threshold: no diagnostics, 123
threshold for diagnostics, 39
threshold for no diagnostics, 177
Idea generation, 30
Implementation, DFM program, 283
Implementing designs, 31
Incentives that reward quality, 201
Industrial Design, consideration, 18
Industrial designer role, 39
Industry Week best plant survey, 38
Infant mortality phase, 211
Institutes of Management Accountants
studies on cost distortions, 143
Integration of silicon, 53
Intel
standardization results, 88
variable material overhead, 151
varying mat'l overhead rates, 97
Interfaces between parts
elimination of, 181
Interference fits, tolerance, 173
Inventory
asset of liability?, 128
eliminating, effect on cost, 129
reducing WIP, 72
write-offs, eliminating, 136
Inventory carrying cost, 135
Inventory dilemma
of mass production, 66
Inventory elimination, 61
Inventory reduction, 60
at dealers, 135
finished goods, 70, 102, 135
from build-to-order, 135
from modular design, 70
from parts standardization, 100
supply chain, 135
work in process (WIP), 129
Inventory, finished goods
cost minimization, 134
Issues
resolution of, 45
to be resolved early, 46
Job rotation, 32
Johnson, H. Thomas, 142
Jones, Daniel T., 59
Judgement, 280
Just-in-time
and flexibility, 72
and group technology, 72
and standardization, 75
benefitting from standardization, 100
delivery of fasteners, 168
for PC boards, 255
Justification
based on total cost, 147
compensate, missing numbers, 148
in spite of usual numbers, 148
qualitative, 148
Kaizen, 126
Kanban for linear materials, 91
Kaplan, Robert, 142
justification approach, 148
Keiretsu and cost, 127
Kitting
eliminating costs of, 131
how to eliminate, 66
Leader of design team, 41
Lean production, 59
benefits, 60
cost reduction from, 128
Lean retailing, 17
Lean Thinking book, 59
Learning relationships, 133
Learning trades, 33
Levi's custom jeans
inventory savings, 133
Lexmark model
linear vs. concurrent, 51
Life cycle costs, minimizing, 134
Linear materials standardization, 180
Lockwashers, use of, 171
Lopez, J. Ignacio
real results of "cost cutting", 126
Lot size
reduction, 72
Lot size reduction, 102
Low cost, myths about, 116
Low cost product development, 115
Low cost, how not to achieve, 116
Low-bidding
encouraged by poor costing, 141
problems with at GM, 127
Low-hanging-fruit for ABC, 149
Machining, same setup, 201
Machining in the same setup, 185
Maintenance, 222
designing for, 224
measurements, 223
minimizing need for, 224
preventative, 222
unscheduled, 222
using modules, 225
Make of buy decisions, 107
Make or buy decision, 107
Make/buy decisions
biased by accounting, 126
Management support, 273, 285
Managing "by the numbers"
irrelevance of, 144
Manufacturability
Problems without, 2
Manufacturing, understanding, 32
Manufacturing on design team, 38
Market changes, quickly adapting, 131
Marketing
cost, acquiring new customers, 133
minimizing costs, 133
Marketing role on team, 38
Markets, expanding scope of, 65
Markets, export, customizing for, 65
Mass customization, 65
cost reduction from, 128
design consideration, 19
spectrum of, 65
Material overhead rates
varying for standard parts, 97
Materials standardization, 89
Matrix management, 42
Mazda, shifting production, 131
Mean response time, 223
Mean time to repair, 223
Measurements, maintenance, 223
Memory, eliminating dependence, 231
Minimizing cost, 115
thru design, 117
ways to, 117
Minimizing risk, 22
Mistake-proofing, 228
MKS instruments, kanban example, 91
Modular design, 69
and flexibility, 67
benefits of, 70
in engineering, 69
in manufacturing, 69
in repair, 218
strategy, 69
Modules, 69
Motivation, 284
Motivation for DFM, 3
MRP systems, 83
Multiple project coordination, 40
Murphy's Law about NPD, 4
Myths about product development, 5
National Semiconductor
FedEx inventory-less deliveries, 135
Niche market customization, 65
Not-invented-here
causing part proliferation, 77
Not-invented-here syndrome, 68
Nuts, use of, 170
Off-shore manufacture
encouraged by poor costing, 141
Omission errors, 231
One-piece flow, 60
Options, making easy to add, 165
Order of assembly, 165
Organizational structures, 42
Organizing DFM program, 272
Orientation
avoiding wrong, 230
maintaining, 191
of parts, 190
Outsourcing, and cell manufacture, 61
Over the wall, 42
Over the wall syndrome, 2
Overhead, on parts, 105
Overhead allocation
arbitrary nature of, 26
Overhead cost, allocations, 143
Overhead costs
effect on part cost, 104
minimizing , 120
quantifying, 142
Overhead rate
proportional to real overhead, 141
Overhead, material
varying for standard parts, 97
Overload protection, 219
Ownership, 273
Packaging, design consideration, 17
Parallel projects, 44
Part availability
at points of use in plant, 75
Part consolidation, 64
Parts, make differences obvious, 229
Part guidelines, 179
asymmetry exaggerated, 183
combining parts, 181
cutting tools minimized, 185
differences obvious, 184
fixturing, design for, 184
linear materials, standardize, 180
machined in same setup, 185
optimal tolerances, 184
part types, minimize, 179
parts, total, minimize, 180
pre-finished materials, 180
process guidelines, parts, 182
right/left parts, avoiding, 182
rule of ten, 185
sources reliable, 185
standardize design features, 179
standardize parts, use, 179
symmetry, 183
tooling complexity, minimize, 184
Part listing, 81
Part procurement, without forecasts, 62
Part proliferation, 75
and contract manufacturing, 78
and mergers/acquisitions, 78
and part minimum weight fallacy, 78
cost of, 76
duplicate parts, 79
eliminating duplicates, 80
examples, 75
qualifying part families, 78
results of, 79
understanding the need, 77
why it happens, 77
Part reuse studies, 68
Part type reduction, 81
Part types, minimizing number of, 179
Parts
designed by suppliers, 111
disposable, 217
floor stock, 98
independently replaceable, 165
pre-qualification, 98
Parts orientation, 190
Parts presentation to automation, 192
Parts standardization
guideline, 179
Preferred part lists, 82
better-than substitutions, 83
how to generate, 83
new generation parts, 84
Pareto sorts, 83
Philosophy, tolerances, 188
Philosophy of design, 13
Pilot design team, 287
Pins, elastic, 173
Plant layout, 72
Platforms, product, 64
Plug-in modules
in maintenance, 225
Poka-yoke, 228
Pollution, design consideration, 20
Pre-finished materials, 180
Preferred part lists
consolidate duplicate parts, 84
consolidate tolerances, 85
education, 86
issuing the lists, 86
ordering the list, 85
results, 88
small % of old lists, 88
strictness of enforcement, 87
Preferred parts, 82
Press fits, tolerances, 173
Preventative maintenance, 222
Pricing
distorted by cost distortions, 143
overpricing, 143
underpricing, 143
Principles, PC board DFM, 252
Printed circuit boards, 251
automation guidelines, 261
manufacture, 251
quality guidelines, 265
standard equipment, 256
Process guidelines, 182
Process order, minimizing errors, 232
Process standardization, 94
Process yield, PC boards, 254
Processes, understanding, 32
Processing, of sub-assemblies, 166
Processing pollution, consideration, 20
Procurement, without forecasts, 62
Product cost distortion, 142
Product appearance, consideration, 18
Product architecture
importance of, 51
optimizing, 54
Product customization, 19
Product definition, 47
to minimize cost, 122
Product design, strategy, 163
Product development
hindered by cost systems, 141
less risk if faster, 124
myths, 5
realities, 6
undermined by poor costing, 144
Product Development Teams, 6
Product failures, 11
causes, 2
without DFM, 11
Product families, 66
Product flow improvements, 72
Product guidelines
assembly direction, 164
assembly order, 165
assembly, designed for, 164
fabrication, designed for, 164
options, added easily, 165
parts independently replaceable, 165
past problems, understanding, 164
processing, designed for, 164
subassemblies, 166
tool access, 165
upgrading, 166
Product introduction, 106
quicker, 72
Product line breadth, 18
from group technology, 70
Product line rationalization, 16
Product platforms, 64
Product pollution, consideration, 20
Product portfolio planning, 64, 120
balanced criteria, 121
based on real profitability, 120
product families, 120
rational decisions, 121
Product recycling, consideration, 21
Product style, design consideration, 18
Production capacity
doubling by doubling utilization, 130
Production transition, quicker, 11
Productivity
how to double, 60
lowered by part proliferation, 76
Profitability
distorted by cost distortions, 143
high for customization, 65
identifying money losers, 147
relative, 26
understanding current, 120
Profitability, relative, 146
as product planning tool, 146
Profits
enhancing with early release, 19
enhancing with life extensions, 20
Proliferation of parts, 75
Protection of parts, 219
Prototyping parts, 106
Publication, 282
Pull signals, 61
Purchased parts, 104
cost savings, 105
finding, 108
specials, 107
standardization effect, 104
time savings, 106
Purchasing
leverage, 100
sub-assemblies, 167
Purchasing delays, how to eliminate, 61
Purchasing leverage, 100
Purchasing on design team, 38
QFD, 47
how it works, 49
Quality, 195
average level of, 203
better for standard parts, 95
continuous improvement, 199
cost of, minimizing, 125
cumulative effects, 202
design consideration, 15
design right, 1st time, 198
designing for, 195
designing in, 196
documentation, 201
external, 125
goal, primary, 196
guidelines, 196
improved with DFM, 10
incentives, 201
internal, 125
most effective way to achieve, 6
non-value-added, 125
parts, chosen for quality, 197
past quality problems, 196
predictive model, 205
problems without DFM, 2
processing, optimize, 197
product definition, 196
simplifying design, 197
simplifying processing, 197
strategies, 205
teamwork's role, 197
tolerances on target, 200
tolerances within spec, 199
TQM culture, 196
worst case, 198, 199
Quality example, cumulative effect, 203
Quality feedback, 275
Quality Function Deployment, 47
how it works, 49
Quality guidelines, PC boards, 265
Quality improvement
from group technology, 72
from inventory reduction, 72
from rapid feedback, 72
Quality strategies for products, 205
Quick disconnects, 216
Rapid prototyping, 10
Rationalization to cut part variety, 62
Rationalization of product lines, 16
Raw materials standardization, 89
Raychem Corporation
mastering implementing, 31
Re-inventing the wheel
how to avoid, 67
Re-usable engineering, 67
Realities about product development, 6
Recycling, 21
Redesign, less chance with DFM, 11
Redesigns, 8
Regulatory compliance, 40
Reinforcing loops
caused by poor costing, 145
Relevance Lost, The Rise and Fall of Management Accounting, 142
Reliability, 206
burn-in, 210
computer models, 207
concept simplification, 206
connections, electrical, 209
design consideration, 15
design features, proven, 208
designing in, 206
electronics, 209
failure mode analysis, 207
flex cable, 209
goal of design, 207
guidelines, 206
infant mortality phase, 211
inherent, 206
installation, 208
measurement of, 210
measurements, 210
minimizing errors, 208
mistake-proofing, 208
modules, pre-certified, 208
packaging, 208
part selection, 207
parts, proven, 208
past problems, understanding, 207
phases, 211
phases of, 211
Poka-Yoke, 208
processes, proven, 208
repair limits, 210
shipping, 208
simplicity, 206
simulations, 207
sockets, 209
soldering by hand, 209
wearout phase, 211
Removal aids, 219
Repair
damage, 218
ease of, 16
removal aids, 219
Repair tasks, 216
Repairability
designing for, 215
easy to perform, 216
Resistance to DFM, 25
Resistance to DFM, 4
Resources, drained without DFM, 2
Responsibility, 273
Responsiveness, 72
Results, group technology, 68
Retaining rings, 172
Return on Investment (ROI), 147
problems without total cost, 147
Reusable engineering, 69
Revisions
conveyed clearly, 230
ensuring implementation, 231
rules & guidelines, 288
Right/left hand parts
elimination of, 182
Risk
late introductions, 23
liability, 23
manufacturability, 23
market acceptance, 23
material availability, 23
minimizing all, 22
quality & reliability, 23
technical feasibility, 22
time-to-market, 23
Robust design, 189, 198
ROI (return on Investment), 147
problems without total cost, 147
Role in DFM, 34
Rule
definition, 277
Safety
design consideration, 18
of repair, 220
Sales, minimizing costs, 133
Scheduling, 72
and mass customization, 66
Screws, assembly motion, 170
Self-correction, 224
Self-tapping screws, use of, 171
Self-test, 224
Senge, Peter
reinforcing loops, 145
Sequence errors, 232
Series reliability model, 202
Service
ease of, 16
of snap together parts, 172
using modular design, 70
Service on design team, 38
Setup elimination
by design, 64
by design of products, 66
need for, 60
Shingling of parts, 191
Shipping
design consideration, 16
direct to customers, 61
direct to stores, 61
Shrink fits, tolerances, 173
Simplicity, key to reliability, 206
Simplify first, 62
Simulation, 9
Six Sigma, automatic soldering, 209
SKUs, and mass customization, 65
Slotted nuts, use of, 171
Snap together parts, 172
Snap-on fasteners, 172
Sockets, reliability impact, 209
Software, design for assembly, 15
Soldering, reliability impact, 209
Solid modeling, 10
Sources, DFM program, 275
spare parts, 107
availability, 217
replacement, 217
Spare parts availability, 107
Spontaneous build-to-order, 61
Spontaneous part procurement, 62
Spontaneous supply chain, 61
Standard part lists
consolidate duplicate parts, 84
consolidate tolerances, 85
education, 86
how to generate, 83
issuing the lists, 86
new generation parts, 84
ordering the list, 85
Pareto sorts, 83
results, 88
small % of old lists, 88
strictness of enforcement, 87
Standard parts
display boards, 98
total cost metrics, 99
use of, 179
Standardization, 75
bar stock, 89
benefits, 100
design features, 179
encouraging, 97
guidelines, 179
importance of, 99
linear materials, 180
of bend radii, 92
of casting metal, 89
of cutting tools, 93
of expensive parts, 94
of features, 92
of holes, 92
of linear materials, 90
of molding plastic, 89
of processes, 94
of programmable chips, 90
of protective coatings, 90
of punches, 92
of sheetmetal, 89
of tools, 92
of tubing, 89
overcoming resistance, 94
part count reduction, 81
prerequisites for, 99
printing wire while dispensing, 91
zero-based approach, 81
Standardization benefits
cost reduction, 100
delivery quicker, 103
flexibility, 101
floor space reduction, 100
inventory reduction, 100, 102
just-in-time, 100
overhead cost reduction, 100
parts availability, 103
purchasing leverage, 100
quality, 101
rationalizing suppliers products, 103
responsiveness, 102
setup elimination, 101
suppliers stronger, 103
Standardization of raw materials, 89
Statistically significant analysis, 9
Statistics, product quality, 202
Stock Keeping Units (SKUs)
and mass customization, 65
Store replenishment
and mass customization, 66
Strategies, quality, 205
Strategy
build-to-order, 61
do-it-right-the-first-time, 8
fastening, 168
PC board DFM, 257
product design, 163
test guidelines, 175
tolerances, 188
Strictness of enforcement, 277
Structuring DFM information, 277
Sub-assemblies
connections, 220
testing of, 175
Sub-assembly
access, 219
location, 221
orientation, 220
purchase and testing, 167
use in assembly, 166
Subsidization
consequences, severe, 145
cross subsidies, 143
custom by standard, 143
downward spirals, 145
enormous cross subsidies, 143
good products pay for losers, 141
low-volume by high-volume, 143
of custom by standard, 129
Suggestions, DFM program, 275
Summary, DFM, 1
Supplier involvement, early, 38
Supplier selection
low-bidder problems, 126
total cost basis, 126
Suppliers designing parts, 111
Suppliers on design team, 38
Supply chain, minimizing costs, 134
Supply chain management, 62
design consideration, 16
simplifying with standardization, 75
Supply chain simplification, 62
Symmetry
designing parts, 229
guideline, 183
Taguchi methods, 198
robust design, 189
Tangling of parts, guideline, 191
Team, focus, 41
Team leader, 41
Team members, 38
Teams, 6
all present early, 45
early formation, 41
key to success, 41
Teams, design, 37
Teamwork
early participation, 45
success factors, 45
Technology, transitioning to new, 136
Tektronix
overhead costs half from parts, 76
part count reduction, 80
varying material overhead rates, 98
variable material overhead, 151
Test, ability to, 15
Test diagnostics, 176
Test effort, relationship to quality, 176
Test guidelines, 175
Test ports, 224
Test strategy, 175
diagnostics or process controls, 177
Testing
of sub-assemblies, 175
PC boards, 267
sub-assemblies, 167
with standard instruments, 176
Testing parts in product, 218
Thinking out of the box, 28
Thruput reduction, 60, 72
Time
design, 71
documentation, 71
misconceptions about, 4
Time-to-market
competitive advantage of, 19
design consideration, 19
enhancing profits, 19
improved with DFM, 10
improved with group technology, 70
improving with modular design, 70
improved with purchased parts, 106
most effective way to achieve, 6
reducing 40%, 51
Timers, 224
Timing errors, 233
Tolerances, 186
block or blanket, 189
excessive, 187
for automatic handling, 191
philosophy, 188
stack-up, 187
step functions, 186
strategy, 188
worst-case, 187
Tolerances on target, 200
Tolerances within spec, 199
Tool changing, 93
Tool commonality, 216
Tool standardization, 92
Tooling complexity, minimizing, 184
Tools
access, 165
do-it-right-the-first-time, 9
specifying common, 64
Total cost, 141
decision making, 122
focus in NPD, 122
minimizing thru standardization, 95
to avoid arbitrary decisions, 122
Total cost accounting, 141
implementing, 154
implementing approaches, 147
Total cost measurement, 141
value, understanding, 146
Total cost thinking, 147
Trades, learning, 33
Training, 282
Transition into production, 106
Unscheduled maintenance, 222
Updating guidelines, 288
Upgrade, ability to, 166
Upgrades
using modular design, 70
with modular design, 70
Upgrading, design consideration, 19
Uptime, 223
Utilization improvements, 72
Utilization of machine tools, 130
Value-added services, 65
Variety, handling proactively, 65
Vendor partner relationships, 101
Vendor reduction, 101
Vendors, designing parts, 111
Virtual manufacturing
how to compete with, 61
VLSI, 53
Voice of the customer, 47
Wall-Mart, and supply chain costs, 134
Warning devices, 225
Washers, use of, 170
Waste, elimination of, 59
Wave soldering, 257
Wear parts, 217
Wearout phase, 212
Web sales, and mass customization, 66
WIP inventory elimination, 60
WIP inventory reduction, 72
Womack, James P., 59
Work-in-Process inventory, 72
Working capital, 128
Worst case tolerances, 187
Write-offs of inventory
eliminating with BTO, 136
Wrong part, guidelines to avoid, 229
Wrong position, avoiding errors, 230
Zero defects, 202
Zero-based standardization, 81
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