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New   Consulting: Experience Guidance for Strategist

based 30 years of teaching DFM plus 6 book


The Thought-Leader of Product Development 
based on 30 years teaching and  writing 6 booksHouely 

Hourly consulting is now available on the following topics that were just published book  that are described on the Consulting page  which are listed here:

1) Reducing Cost in Half or more

2) Product or product family strategy / vision workshop sessions

3) Manufacturable Research & early design brainstorming sessions
on ways to: assure scalability without shortages and optimize up-front work 

4) Commercialization of acquired technology or product not benefiting from Manufacturable Research 

5) Backward-Comparable “Drop-in” Replacements, e.g. for frames and structures that can save a lot of money now replacing hard-to-build, high-skill versions 

6) Hourly Consulting for anagers,
project leaders, and team meetings (based pm 30 years teaching DFM and facilitating workshops) and management consulting (based on a year of experience on the faculty of the Haas-Berkeley Graduate School of Business).


See the Consulting page



Dr. David M. Anderson, P.E., CMC, fASME
(805) 924-0100; fax: (805) 924-0200 (San Luis Obispo county, California)
web site:

    Dr. Anderson is a California-based management consultant who specializes in thought-leader classes, workshops, , strategies. and consulting advice on Design for Manufacturability, Concurrent Engineering, Designing product families for Lean Production, Mass Customization, and Build-to-Order.

New, unique methodologies

He has developed the most effective methodologies  for getting new products out there fast including    Commercialization that ensures that already proven technologies are manufacturable enough for fast ramps to stable production .

   Scalability without shortages  has just been published to meet urgent demands at any quantity  and also  rapid growth  that ensure that the operations have been concurrently engineered to quickly scale up production and the selected parts and materials will be readily available for any growth scenario.  

His new 2020 DFM book presents these never-before-publsihed methodologies:

The most important applications of this, these methodologies will be rapid world-wide phase-in  of renewable energy.   

First see the page  Half-Cost  Solar page to show how to save the cost  of new Concentrated Solar Power (CSP "power towers) with DFM principles like how to avoid cumulative exponential degradation of quality and performanceshown in Figure 10.2  (in all DFM books) and in Section 3.3.11 on Concept Simplification.  For example, CSP arrays use hundreds of thousands of heliostat mirror trackers (just plug in that number into Figure 1.2).  Further, needing hundreds of thousands of electric systems would be hard to get in this time of chip  shortages -- all for one new solar field!

Strategy for

Highly  Concentrated  Solar  Heat   (HCSH)

The end of the advanced strategy  page on this site shows how to commercialize the "solar furnace,"   which concentrates sun rays several thousands times to produce "blast furnace" temperatures.   High concentrations can be achieved by design with the overall strategies presented in the page How to Design Precise  Assemblies and optimal tolerance Strategies (in 17 sections; 9 guidelines, and two figure in the 2020 DFM book  Such a low-cost design  would be scalable and would be able to:

(a)  provide 60% of all of the energy demands for industry, which is in the form of heat

(b) evolve  to  use higher temperatures (not valued in steam based generators) to convert abundant  solar  heat directly to electricity at twice the efficiency of all  current solar power (PV or CSP)  with no moving parts and 

(c) make solar hydrogen  as the ultimate clean transportation fuel, Which can be "burned" in existing vehicle engines (with only water vapor as the "exhaust") and be able to switch over  to the more expensive gas in the same old  gas tank if  the H2 tank might be close to  running low--  until the quick-filling fluid fuel can be trucked in (pr generated  locally) and  a new "gas" can be added to our existing network of gas stations.    See this and many product development  strategies at: 

Copyright  © 2021 by: 
Dr, David M Anderson, P.E., CMC
Fellow, American Society of Mechanical Engineers


This is how the leading Product development expert uses his 30 years experience and a 600 pave DFM book to teach companies how to the most advanced product development methodologies:

The full feedback form on the front page of all three web-sites start and end by asking about "Challenges, Goals, and Opportunities." However, many companies and broader initiatives don’t get further then contemplating their challenges.

Companies and imitative leaders will need to summarize their challenges and convey these so their expert can start formulating solutions.

This thought-leader expert can confidently claim to be able to show how to start solving all product development challenges.

His 600 page DFM book includes 70 discussions of challenges and over 100 on solutions including discussions and references.

The on-line white-paper is titled: "Concurrent Engineering of Challenging Projects."

GOALS: The next information to get conveyed to the expert are the goals. , which should be normalized compared to the current state, which will determine what advanced methodologies need to be learned applied, for instance;

Five or ten percent improvement might be done by doing the current system better with continuous improvement, but no more.

Twenty or thirty percent better would need to learn and apply most advanced NPD methodologies taught on this web-site on a new clean-sheet-of-paper project in its own micro-climate or skunk-works (Section 11.7.2 in 2020 DFM book). Specifically, see Section 3.11 (Generating Interest in DFM) and Section 11.7.4 (Ensuring Success for the First Team Project).

Over 50% better will need learning and implementing the most advanced methodologies available: For instance, for cost, this has just been published as section 3.8 in the 2020 edition of the DFM book, which shows how to save half the cost of product development (the budget), half of the Cost of Quality, half of direct labor cost, and one third of indirect labor costs. Strong enough standardization, Lean Production and Build-to-order techniques can save up to times the cost, as shown in Sections 3.8.10 through 3.8.13 .

Rather than just issuing "show-me -the-money goals, the ambitiousness of the goals must determine how many of these advanced methodologies must be learned and applied.

All of this will require optimal strategies. The 2020 DFM book has 22 sections with "Strategy"" in the title!  Section 3.1 (Design Strategy) recommends "starting early to solve major problems at the concept/architecture level/"


Books Written

      He wrote the definitive book on DFM: "Design for Manufacturability; How to Use Concurrent Engineering to Rapidly Develop Low-Cost, High-Quality Products for Lean Production" (2014, Productivity Press, 486 pages). He also wrote the opening chapter in the SME handbook on DFM (TMEH, Vol 6), and the chapter on DFM and Mass Customization in the Quality Function Deployment Handbook (Wiley, 1998). His DFM book has been print since 1990 when it was the ground-breaking book on DFM.  The book is in use in more than 450 companies. Hewlett-Packard, United Technologies, and Loral each ordered more than 100 copies.

 He also wrote the 2008 book "Build-to-Order & Mass Customization; The Ultimate Supply Chain Management  and Lean Manufacturing Strategy for Low-Cost On-Demand Production without Forecast or Inventory."  In 1997 he wrote the book, "Agile Product Development for Mass Customization, Niche Markets, JIT, Build-to-Order, and Flexible Manufacturing" (McGraw-Hill, 1997). He was the guest editor for the Mass Customization issue of the Agility Forum’s journal in 1998.

    At the Haas Graduate School of Business at the University of California at Berkeley, he created and twice taught the course "New Product Development, the Management and Design of Manufacturable Products" as part of the Management of Technology Program. He has taught "Spontaneous Build-to-Order" twice for AME before plant tours of Hoffman Engineering, who build a $30,000,000 plant to build on-demand a wide variety of standard and mass-customized sheetmetal enclosures to order.

Working Experience  See list of clients in: Aerospace, Electronics, Industrial Machines, Processing Equipment, Medical devices and Test Equipment, Vehicles, Power//Energy, and Robot Development

   Dr. Anderson has over 35 years of industrial experience and has presented dozens of public classes on Design for Manufacturability & Concurrent Engineering and hundreds of in-house DFM seminars at many leading companies including several divisions of Hewlett-Packard, Emerson Electric, Boeing, GE, NCR, FMC, BAE Systems, Smiths Aerospace (now GE Aircraft), John Deere, United Technologies, Loral, Freightliner, Korea’s LG Group, and many others. When he was Manager of Flexible Manufacturing at Intel’s Systems Group, he initiated successful programs for Design For Manufacturability and standardization of parts and tooling for electronics.    He has presented dozens of speeches at DFM conferences on product development and mass customization topics and at internal corporate conferences and summits at Hewlett-Packard, EDS consulting (now A.T. Kearney), Emerson Electric, and Schlumberger.  He has been a panelist at forums at Caterpillar and Johnson Controls.

    From 1977 to 1983, his company, Anderson Automation, Inc., generated design studies and built special production equipment and tooling for companies such as IBM, Clorox Manufacturing, and Optical Coating Labs.  As the ultimate concurrent engineering experience, he personally built the equipment he designed.  Having personally done machining and welding, he is well positioned to show companies how to replace expensive weldments with low-cost assemblies of CNC machined parts in his Large Parts Cost/Steel Reduction workshop.

He also did concept studies for SRI International and two divisions of FMC.  Based on his pioneering work in low-cost mechanisms and machine control using easy-to-build linkages, he made several proposals for low-cost mechanisms, including repetitive motion machinery for packaging and box making.

See Results Page for client engagements with the: Best results after seminar; est results after workshop: Best cost reductions; Best implementation planning; Most repeat engagements;  Best business model shifts;  Most seminars and workshops topics at one location;  Longest consulting engagement;  and the Greatest investment based on these principles:


    Dr. Anderson is a Fellow of ASME (American Society of Mechanical Engineers) and a Life Member in SME (Society of Manufacturing Engineers).  He has been certified as a Certified Management Consultant (CMC) by the Institute of Management Consultants.      See Dr. Anderson's article on Ethics for Consultants, which presents his own strict ethical code.

He holds professional engineering registrations (P.E.) in Mechanical, Industrial, and Manufacturing Engineering and a Doctorate in Mechanical Engineering from UC, Berkeley, where his thesis project was on creative linkages, which is shown on this site's linkage page.

To enquire about public and in-house DFM seminars, fill out the form.



by Dr. David M. Anderson, P.E., fASME, CMC



Upcoming April & Sept.  webinars  on Design for Lean  Manufacturing in Sept.

For  a preview of all of the above, attend the  Sept.  webinarr  on Design for Lean  Manufacturing 
2-day webinar: Sept 20-23 from 1-5 PM EST ; sponsored by QCG, who trains & certifies Bllack-Belts

Complete  description and sign-uo  at : .

Lean Champions and implementers  can also  bring  decision-maker and  Managers. A 15% discount is available (on request) for more then two people from the same company.



“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



Dr. Anderson was an internal speaker/panelist for:



 "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

Contact Dr. Anderson at 1-805-924-0100 (Pacific Time Zone) or

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