E M 590  Design for Manufacturability

Fall 2003 Instructor:  Dr. Ray Ladd

Wednesdays 4:15-5:30

INTRODUCTORY VIDEO

COURSE QUESTION

How do we systematically design a product and/or process so that it can be realized with lowest cost, rapid response time, and meet customers’ expectations?

COURSE GOAL

Students will be able to: design a product and/or process systematically, that will be realized with lowest cost, rapid response time, and meet customers’ expectations.

COURSE DESCRIPTION

Various techniques to identify opportunities for improvement and development of a comprehensive product design will be explored.  Key issues and competitive product development and design optimization will include topics such as: quality function deployment, design for assembly and product variation; failure modes and effects analysis; reliability/serviceability, concurrent engineering; statistical process control, six sigma process and flexible process selection; tolerances design; rapid prototying; design and development management issues; reducing parts cost with DFM AND DFM team building.

UNIT GOALS

I.  Assessments

                Students will be able to

·         Identify opportunity for design

·         Make a business decision as to feasibility of design

·         Organize product development team

     Evaluation

Project items A through G

     Activities

                Project/Homework:

#1            A             Questions 1 through 5

#2            B, C, D     Questions 1 through 5

#3            E, F G -   Questions  1 through 3

                Review case study in CC Ch1-4

Resources

                C-C   Ch 1-4

                DFM Ch 1-3, Appendix C

                Supplement on concurrent engineering

                Video:  Re-engineering at Catapellar

II.  High Level Product/Process Design

Students will be able to:

·         Translate Customer Needs Into Design Requirements From A Product/Process                                         Level Through Manufacturing/Delivery Level

·         Generate New Approaches To The Product/Process Design

·         Perform Functional Analyses And Compare Function To Value 

·         Perform A Design To Cost Analysis

·         Analyze Communication Data

·         Identify Group Technologies And Standardization/commonality

·         Design For Flexible Agile Process

Evaluation 

                Project Items H through N and Midterm Project

Activities

                Project/Homework

                # 4           H Question 1

                # 5           I, Question 1 & 2

                # 6           J

# 7           K

# 8           L, M, N   Question  1 through 3

L          Question # 1 and 2

C-C Ch 5 & 6  Review Case Study

Midterm Report

Resources

                QFD Supplement

                Supplement on Pugh Method

                VA/VE Supplement

                C-C Ch 5 & 6

DFM Ch 4, 5, 6, 7

Video:

Agile Manufacturing

Design for Manufacturing

III.  Initial Detail Product/Process Design

Students will be able to

·         Perform Detail Design For Manufacturability On Group, Assembly, Part,                                           Process, Quality, Testing And Human Factors

·         Design For Flexible, Agile Process

·         Consider Design  For Product Variation

Evaluation

                Project Items O through T

Activities

Project/Homework

# 9           O, P, Q, RM           Question # 1 &2

# 10 S, T                 Question #1

Resources

                DFM Ch 8 & 9

IV.   Final Detail Product/Process Design

Students will be able to

• Perform A Failure Model And Effect Analysis
• Consider Environmental Product Design

• Identify How To Have A High Quality Control
• Identify Opportunities And Methods Of Rapid Prototyping
• Understand Methods Of Business Process Re-Engineering
• Validate Designs With Customer

Evaluation

        Project Items U-Y, Finish project report

Activities

        Project/Homework

# 11         U and V      

# 12         W

# 13         X             Question 1

# 14         Y             Questions 1 & 2,

C C Ch 7, 8, 10-Review Case Study

Resources

                C-C Chapter 7, 8, 10

                DFM chapters 10, 11, 12

                Failure mode & Affect Supplement

Videos

Design For Environment

Rapid Prototyping

REQUIRED TEXT:  Design for Manufacturability, 2^nd ed., Anderson, CIM Press, 2000, ASI

             Copied Materials Purchased from the Bookie

From Concept to Customer, ReVelle, Van Nostrant, Reinhold, 1995

Quality Function Deployment, 1992, ASI

Introduction to Value Engineering, 1993, ASI

Introduction to Failure Mode, 1993, ASI

GRADING:            Project & Problem Set                          70%

 Consulting & On-line Questions       30%

Total      100%

SUBMITTAL OF MATERIAL

All Material completed up through the midterm will be handed in at the midterm for review and comments.  All finished material for the entire class, including midterm, will be submitted at the end of class for grading. 

INCOMPLETE POLICY

Students must let the professor know that an Incomplete grade will be needed and the reason for the Incomplete.  Incompletes will only be considered if all materials through the midterm are totally completed and submitted at the end of the course.  Incompletes must be cleared by the end of the next semester.  If Incompletes are not completed by the end of the next semester, student must retake the class to have the grade change submitted.

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Copyright E. Ray Ladd 2001