Design for Manufacturability
Overcoming supply chain management challenges begins with engaging the right suppliers during product research and development prior to manufacturing. This enables OEMs to identify local suppliers who can quickly deliver components during prototyping and the initial production run. The next step is to expand the supply base network to incorporate qualified suppliers, who can enable commercial scale-ups with optimal costs. The goal is to strike the right balance of local and global suppliers and negotiate the best prices possible to support mass production.
Too often, product development teams commit to a design before seeking input from manufacturing and process engineers because the design team has already invested a considerable amount of effort and time in conducting feasibility studies and testing to ensure robustness.
"At that point, it’s really painful to make design changes," says Kevin McFarlin, Design Engineering Director at Celestica. "If you discover an issue like a single screw interfering with a plastic enclosure after manufacturing has begun, you have to halt production, repeat design verification activities impacted by the change and repeat process qualification activities which will ultimately result in a longer time-to-market."
A comprehensive Design for Manufacturability (DFM) analysis requires following a complex, multi-day process to ensure a product is resistant to a wide array of factors that could cause malfunction or failure. This includes assessing extreme temperatures, electromagnetic discharge failures, constant vibrations, repetitive motions, and fluids.
Conducting DFM analysis after finalizing the functional design is not a nice-to-have. It’s critical to reducing the risk of having to perform costly redesigns after manufacturing has begun or in more extreme circumstances, after a product fails in the field.
Manufacturing engineers can contribute substantial value to product design.
"They know where operators might strain specific components, or have ideas on how to streamline production. They should be considered part of the design team."
Kevin McFarlin, Design Engineering Director, Celestica
DESIGN FOR MANUFACTURABILITY NO ROOM FOR ERROR
A single undiscovered design error can create a domino effect that culminates in costly production and delivery delays. Celestica applies its experience and expertise to avoid any costly surprises that require a re-design. Celestica’s team uses sophisticated analysis tools and guidelines the company has developed to identify all possible component issues. For example, it’s not uncommon to identify spacing violations on a circuit board that will cause solder defects during assembly. Identifying and mitigating those violations during the design phase is much simpler and cost-effective than after manufacturing has begun, or worse, if a faulty product fails while a customer is using it.
A comprehensive DFM process will dramatically increase yield, reduce test escape rates, and ensure the finished product meets all design specifications.
Design teams are often under the mistaken impression that manufacturing engineers don’t require their input until production begins weeks or months after the designs are finalized. That’s understandable.
Manufacturing engineers are busy with what’s happening on their assembly lines today, and designers are focused on creating the company’s next innovative new products. A smaller company may not have personnel dedicated to these specific roles. So they skip DFM and move into production as quickly as possible. But costly and time consuming delays are the inevitable results. Adding a manufacturing perspective to the design phase will reduce the risks and costs of surprises and delays that require subsequent redesigns.
Reduce Risk
Improve Quality
Lower Cost
Speed Time-to-Market