DFMA IMPLEMENTATION WORKSHOP ?· Boothroyd Dewhurst, Inc. DFMA Implementation Workshop Client Workshop…

  • Published on
    30-Jun-2018

  • View
    213

  • Download
    0

Embed Size (px)

Transcript

  • IMPLEMENTATION

    WORKSHOPS

  • BoothroydDewhurst,Inc. DFMAImplementationWorkshop

    DFMAIMPLEMENTATIONWORKSHOP

    ThesehandsonworkshopshelpteamsquicklyandeffectivelybegintouseandimplementDFMAProductCostingandSimplification.StartingwithanintroductiontotheDFMAmethodologyandtechniques,andconcludingwithanalysesofyourownproducts,it'saperfectmethodtobeginintegrationofDFMAintoyourcompany'sproductdevelopmentandcostreductionprocess.

    WORKSHOPOBJECTIVES

    UnderstandhowtoimplementDFMAaspartofproductdevelopmentandcostreductionactivities

    UnderstandhowDFMAenablesconcurrentengineeringandtheassociatedcost,quality,anddeliverybenefits

    UnderstandDFMAprinciplesandpractices HandsonexperienceusingtheDFMAsoftwaretoolsincluding:

    o DFAproductdesignsimplificationenablingbetter,earlierdesigndecisionmakingo DFMcostestimatingofpartmanufacturingoptionso Utilizationandcustomizationoftheembeddedlibraries(i.e.process,parts,

    materials,operations,etc.)o Interpreting&communicatingtheelementsofproductioncosts

    Achievemeasurableresultsfromtheworkshop Realizeimmediatedesignimprovements.

    Whoshouldattend?

    DFMAProductCostingandSimplificationworkshopsareintendedtohelporganizationsreviewaproductsdesigninordertodevelopconceptsforredesignthatwillachievecostreductionsorcostavoidance.Giventheirmission,companieschoosetohavedifferentdisciplinesrepresentedintheworkshops.Typicallyaworkshophasupto24attendeesthatarebrokenintoteamsoffourpeople.Oneachoftheseteamsarerepresentativesfromproductdesignandmanufacturing.Companiessometimesincluderepresentativesfrompurchasing,procurement,quality,service,assemblyjusttonameafewadditionaldisciplines.

    Whoisresponsibleforwhat?

    BoothroydDewhurst,Inc.willsupplyallofthetrainingmaterialsandsoftwaretobeusedduringtheworkshop.Theclientcompanywillsupplythevenue,computers,andtheproductstobeanalyzedduringthesession.

    Whatshouldbeanalyzed?

    DFMAistypicallyappliedtoelectromechanicalproducts.Dependinguponthelengthofthesessionandthetypesofproductstobeanalyzed,differingamountsofproductcomplexitycan

  • BoothroydDewhurst,Inc. DFMAImplementationWorkshop

    bereviewed.AroughruleofthumbtofollowisthatagroupoffourworkingwithDFMAcantypicallyanalyzeanassembly(orsubassemblyofalargerassembly)withabout30to60uniquepartsinaday.Thistimewillallowforthecreationofthebenchmarkanalysisandthegenerationofatleastoneredesignconceptwithaneyetoreducingthepartcount.Inproductsthatcontainalargenumberofpartsitsoftenworthdevotingagrouptoanalyzethemannerinwhichseveraldifferentsubassembliescometogether.

    Whatistheanalysisprocess?

    ThefirstpartofthefirstdayisdedicatedtolearningtheprinciplesofDFMAProductCostingandSimplificationandpreparingtheteamsfortheanalysisoftheirproductsduringtheworkshop.AftertheprinciplesareunderstoodthegroupsturntheirattentiontogeneratingabenchmarkDFMAanalysis.Thecompletionofthisfirstanalysiswillspawnmanyredesignideasthatcanbegroupedaccordingtothelevelofrisk&effortcommonlyreferredtoassafe,reach,andstretchconcepts.Theseredesignconceptscanthenbecomparedtothebaselineanalysistoquantifytheopportunityforthereductionofparts,assemblytime,secondaryoperations,reorientations,andoverallproductcost.

    Whatarethedeliverables?

    Inthelasthoursoftheworkshop,eachofthegroupsisexpectedtomakeashortpresentationtothelargergroupreviewingtheprocesstheyusedtoarriveattheDFMAredesignconceptsandpresentingtheideasthattheygenerated.Discussionsoftheassemblytimereductions,partcountreductions,andoverallpotentialforcostreductionaretypicallydiscussed.Hardcopiesofallthereportsgeneratedbythesoftwareduringtheworkshopcanbeprintedbytheattendeesatanytimeduringthesession.Thesereportsserveasdocumentationoftheideasandtheopportunityforsimplificationandcostreduction.

  • BoothroydDewhurst,Inc. DFMAImplementationWorkshop

    DFMATHREEDAYWORKSHOPAGENDA

    ThisistheoutlineofaDFMAImplementationWorkshopagendausingtheBoothroydDewhurstsoftwaretools.Thisisonlyanoutline;theagendacaneasilybetailoredtomeetyourspecificneeds.

    DayOneDFAProductSimplification

    08:0010:00OverviewofDFMA 10:0010:15Break 10:1512:00IntroductiontotheDFAmethodology&softwarebasics 12:0001:00Lunch 01:0004:30DFAsoftwareanalysisofyourproduct

    DayTwoDFMConcurrentCosting

    08:0008:30ReviewDayOneandansweranyquestions 08:3010:30IntroductiontoDFMConcurrentCosting&softwarebasics 10:3010:45Break 10:4512:00DFMAanalysisofyourproduct 12:0001:00Lunch 01:0004:30Continueanalysisofyourproductincludingbrainstormingandredesign

    evaluation

    DayThree

    08:0008:30Review 08:3003:00Completeredesigndevelopment&analysis 03:0004:30Presentationofresultsandworkshopwrapup

  • BoothroydDewhurst,Inc. DFMAImplementationWorkshop

    ClientWorkshopCoordinatorChecklist

    Reservehotelormeetingroom.Anoffsitelocationispreferablesothatoutsidedistractionswillbeminimized.

    Reservecomputersandprinters(see"SystemRequirements"fordetails).

    Ifneededandnotalreadycompleted,acquiresignedNonDisclosureAgreement(NDA)

    Inviteparticipants.Eachteamoffourshouldrepresentacrosssectionofproductdevelopmentresponsibilities.Ideally,atleastonedesignengineerandonemanufacturingengineershouldbeincludedineachgroup.Inviterespectivemanagementpersonneltoattendthefirstpresentationonthefirstdayandat3:00p.m.onthelastdayorwhentheleaderplansforteampresentationsofredesignsoftheproduct.Formanagementpersonnelwhoarenotintheworkshop,thiswillprovideagoodperspectiveofpotentialresults,anddemonstratemanagementsupporttotheworkshopparticipants.

    InformBDIaminimumofthreeweeksbeforeworkshopdatewhereworkshopmaterialsaretobemailed,theproperbillingaddress,andtheP.O.number.Workshopsorconsultingsessionscanceledwithlessthantwoweeksnoticefromoriginallyscheduleddateswillresultina20%fee($500minimum)whichcanbeusedasacreditforfutureworkshops.

    Informworkshopleaderoftheworkshopandhotellocation.Recommendedworkshophoursare8:00a.m.to4:30p.m.Theleaderwillarriveonehourearlythefirstdaytosetup.

    Atleastoneweekpriortotheworkshop,discusswiththeworkshopfacilitatortheprojectsplannedfortheworkshopincludingattributessuchaspartcount,assemblycomplexity,partmanufacturingspecifications,etc.

    Severaldayspriortotheworkshop,installthetrialDFMAsoftwareoncomputerstobeusedduringtheworkshop.

  • BoothroydDewhurst,Inc. DFMAImplementationWorkshop

  • BoothroydDewhurst,Inc. DFMAImplementationWorkshop

    WorkshopProductSelection

    ThefollowingguidelinesaresuggestedtoassistyouintheselectionofproductsthatwillbeanalyzedduringBoothroydDewhurst,Inc.DFMAWorkshops.Designinformationthatshouldbeavailableduringtheworkshopisalsosuggested.

    DFAProductSimplification

    FortheDFAProductSimplificationportionoftheworkshop,aproductorasubassemblyofaproductshouldhavethefollowingcharacteristicsandtheinformationlistedhereshouldbereadilyavailabletotheworkshopparticipants:

    Productsorsubassembliesshouldhaveauniquepartcountinthe3060range. Theproductshouldideallybeofasizethatcanbehandledwithoutmechanical

    assistance.(Notalwayspossibleifnotpossibleconsiderhavingassistanceavailablesotheteamscanmanipulatetheassembly)

    Ifavailable,abillofmaterials(BOM)forthecurrentdesign,ideallywithpartcosts,inExcelorasatextfile

    Assemblyinstructions,anassemblydrawing,orsomethingfromwhichtheteamcandeterminetheassemblysequence

    Anyspecialtoolsrequiredtoassembleordisassembletheproduct Currentassemblylaborrate($/hour)

    DesignforManufacture(ConcurrentCosting)

    ForpartsthatwillbeanalyzedwithDFMConcurrentCostingduringtheworkshop,youshouldhavethefollowinginformationavailablefortheteams:

    Detaileddrawingsofthecomponent(ifavailable) CADmodelofthecomponent(ifavailable) Thecurrentprocessandmaterialcombinationbywhichthepartsaremade Listsofanysecondaryoperationsthatarecarriedoutaftertheprimarymanufacturing

    process(includingspecificsecondarymachiningandfinishingoperations) Possiblealternativeprocessmaterialcombinationsfortheproductionofthepart

    DFMAandConcurrentCostingareregisteredtrademarksofBoothroydDewhurst,Inc.