"Design for Manufacturability & Concurrent Engineering; How to Design for Low Cost, Design in High Quality, Design for Lean Manufacture, and Design Quickly for Fast Production," (2010, CIM Press, 456 pages).   This book has the latest from the author's 25 years of providing in-house DFM seminars; contact author for details at andersondm@aol.com .

    See DFM book description below; for information DFM Training click here.

    To order the DFM book, go to www.amazon.com 

BUILD-TO-ORDER & MASS CUSTOMIZATION

"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 David M. Anderson, (2008, CIM Press, 512 pages).  To view the complete table of contents or order, click here for the books page at www.build-to-order-consulting.com.  Seminars and consulting based on this leading-edge methodologies are available now through Dr. Anderson’s Mass Customization consulting and Mass Customization seminars.  A overview of the approach can be found in the article Build-to-Order.

To order the book, go to book order form or email anderson@aol.com with address.

Many product scenarios has been worked out for several industries and will be published later in "The Build-to-Order & Mass Customization Case book."  These specific methodologies are available now for Build-to-Order consulting and Build-to-Order seminar clients.

"Half Cost Products: How to Develop, Build, and Deliver Products at Half the Total Cost," which is still being written by Dr. Anderson. These ultimate cost-reduction strategies are available now through Dr. Anderson’s DFM seminars and DFM consulting. Many articles on Half Cost Products are available at www.HalfCostProducts.com

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Design for Low Cost. The book shows how to actually design low-cost products. Chapters 1, 2, and 9 show how to minimize the 80% of a product’s cost that is committed by the design and hard to remove later. Chapters 3 and 8 show how to optimize the concept/architecture stage where 60% of cost is committed. Chapters 6 and 7 show dozens of ways to minimize and measure total cost.

Design in High Quality. Chapter 10 shows how to design quality and reliability into the product with poka-yoke and 50 design guidelines for quality and reliability.

Design for Lean Manufacture. Chapter 4 shows how to design products for all the flexible paradigms: lean production, JIT, build-to-order, and mass customization. Chapter 5 presents very effective standardization tools.

Design Quickly for Fast Production. Chapters 2 and 3 shows how complete multi-functional teams and thorough up-front work is the key to quickly developing products, avoiding changes, and fast ramps.  This can cut in half the time to stabilized production.

Chapter 1, Design for Manufacturability, introduces the concept of design for manufacturability and shows the problems that can be avoided when products are designed for manufacturability. It also shows how to overcome resistance, understand the myths and realities of product development, and motivate engineers and managers to design for manufacturability and do it right the first time. The chapter concludes with benefits of DFM.

Chapter 2, Concurrent Engineering, shows how to use concurrent engineering to develop products in multi-functional design teams, which are most effective when they have early and active participation of all specialties. The chapter shows the problems when this does not happen and how to ensure availability of resources. The book shows how to get products to market in half the time by thorough design, especially the crucial concept/architecture phase. Product development phases are presented with the tasks that enable good DFM including: defining products to satisfy the voice of the customer with QFD; optimizing the product architecture and strategies for operations and supply chains; raising and resolving the issues early; concurrently designing the product and processes; and launching into production.

Chapter 3, Designing the Product, focuses early on a wide scope of design considerations. Early work on these considerations will minimize arbitrary decisions, which will reduce several categories of risk and minimize change orders. The chapter also shows how to use creativity and brainstorming to develop better products.

Chapter 4, Design for Lean Production & BTO, shows how to design products for lean production, build-to-order and mass customization by designing around standard parts, designing for to eliminate setup, optimal use of CNC, and modular design.

Chapter 5, Standardization, shows very effective procedures to standardize parts and materials and reduce their part numbers by two orders-of-magnitude.

Chapter 6, Minimizing Cost by Design, emphasizes the importance of minimizing the total cost and then shows many ways to minimize total cost by design.

Chapter 7, Total Cost, emphasizes the importance of quantifying total cost and then shows easy ways to measure total cost.

Chapter 8, DFM Guidelines for Product Design, presents 55 design guidelines for product design, including assembly, fastening, test, repair, and maintenance.

Chapter 9, DFM Guidelines for Part Design, presents 64 design guidelines for designing parts including how to design fabricated parts an parts to be handled by automation. The chapter also has a section on tolerance step functions and how to specify optimal tolerances.

Chapter 10, Design for Quality, shows how to design in quality and reliability with 47 quality guidelines and sections on mistake-proofing (poka-yoke) and designing to minimize errors. The chapter also shows product quality is affected by the cumulative exponential effect of part quality and part quantity.

Chapter 11, Implementing DFM shows how to implement DFM including: determining the current state of how well products are designed for manufacturability; estimating much could be improved by implementing DFM; getting management buy-in; arranging DFM training; forming a task force to implementing DFM; and implementing standardization and total cost measurements.

Chapter 12, DFM Summary, summarizes key DFM principles in a graphical or bulletined format including: definitions; myths and realities of product development; when cost is committed; how to cut in half the real time-to-market; best and worst resource allocations scenarios; summaries of several other DFM principles; summary of DFM methodologies; and a summary of DFM benefits.

Appendix A presents effective methodologies for Product Line Rationalization to maximize resource availability for product development and increase profits immediately.

Appendix B is a summary of all the guidelines in the book without discussion.

Appendix C presents forms to improve product development and manufacturability by soliciting input and feedback from customers, factory workers, vendors, and field service.

Appendix D provides resources about the reference books that were cited the most in this book and information about the author’s web-sites, customized in-house training, workshops, consulting, commercialization, and design studies.

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