Design for Manufacturability: How to Use Concurrent Engineering to Rapidly Develop Low-Cost, High-Quality Products for Lean Production

472 Pages·2014·3.53 MB·English

by  David M. Anderson

Product Development A
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D A V I D M . A N D E R S O N
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N DESIGN
Design for Manufacturability: How to Use Concurrent Engineering to Rapidly
Develop Low-Cost, High-Quality Products for Lean Production shows how to
use concurrent engineering teams to design products for all aspects of manufac-
turing with the lowest cost, the highest quality, and the quickest time to stable for
production. Extending the concepts of design for manufacturability to an
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advanced product development model, it explains how to simultaneously make
MANUFACTURABILITY
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major improvements in all these product development goals, while enabling
effective implementation of Lean Production and quality programs. S
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Illustrating how to make the most of lessons learned from previous projects, the G
book proposes numerous improvements to current product development N
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practices, education, and management. It outlines effective procedures to
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standardize parts and materials, save time and money with off-the-shelf parts,
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and implement a standardization program. It also spells out how to work with the
purchasing department early on to select parts and materials that maximize R PPrroodduuccttss ffoorr LLeeaann PPrroodduuccttiioonn
quality and availability while minimizing part lead-times and ensuring desired
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functionality.
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• Describes how to design families of products for Lean Production,
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build-to-order, and mass customization
• Emphasizes the importance of quantifying all product and overhead U
costs and then provides easy ways to quantify total cost F
• Details dozens of design guidelines for product design, including A
assembly, fastening, test, repair, and maintenance C
• Presents numerous design guidelines for designing parts for T
manufacturability U
• Shows how to design in quality and reliability with many quality
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guidelines and sections on mistake-proofing (poka-yoke)
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Describing how to design parts for optimal manufacturability and compatibility B
with factory processes, the book provides a big picture perspective that empha- I
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sizes designing for the lowest total cost and time to stable production. After
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reading this book you will understand how to reduce total costs, ramp up quickly T
to volume production without delays or extra cost, and be able to scale up Y
production rapidly so as not to limit growth.
K21414

DESIGN
for

MANUFACTURABILITY
How to Use Concurrent Engineering to
Rapidly Develop Low-Cost, High-Quality
Products for Lean Production

D A V I D M . A N D E R S O N
DESIGN
for

MANUFACTURABILITY
How to Use Concurrent Engineering to
Rapidly Develop Low-Cost, High-Quality
Products for Lean Production
Boca Raton London New York
CRC Press is an imprint of the
Taylor & Francis Group, an informa business
A PRODUCTIV ITY PRESS BOOK
CRC Press
Taylor & Francis Group
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© 2014 by David M. Anderson
CRC Press is an imprint of Taylor & Francis Group, an Informa business
No claim to original U.S. Government works
Printed on acid-free paper
Version Date: 20131217
International Standard Book Number-13: 978-1-4822-0492-6 (Hardback)
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Library of Congress Cataloging‑in‑Publication Data
Anderson, David M. (Engineer)
Design for manufacturability : how to use concurrent engineering to rapidly develop
low-cost, high-quality products for lean production / author, David M. Anderson.
pages cm
Includes bibliographical references and index.
ISBN 978-1-4822-0492-6 (hardback)
1. Lean manufacturing. 2. Concurrent engineering. I. Title.
TS183.A57 2014
670--dc23 2013048176
Visit the Taylor & Francis Web site at
http://www.taylorandfrancis.com
and the CRC Press Web site at
http://www.crcpress.com
Dedicated to my loving and supportive wife, Lin.

Contents
List of Figures .....................................................................................xxv
Preface .............................................................................................. xxvii
About the Author. .............................................................................xxxv
Section i Design Methodology
chapter 1 Design for Manufacturability............................................3
1.1 Manufacturing before DFM ............................................4
1.1.1 What DFM Is Not ................................................5
1.1.2 Comments from Company DFM Surveys .......5
1.2 Myths and Realities of Product Development ........6
1.3 Achieving the Lowest Cost ..............................................7
1.3.1 Toyota on When Cost Is Determined ...............7
1.3.2 Ultra- Low- Cost Product Development ............8
1.4 Designing for Low Cost ...................................................9
1.4.1 Design for Cost Approaches ..............................9
1.4.1.1 Cost- Based Pricing ...............................9
1.4.1.2 Price- Based Costing (Target
Costing) ...............................................10
1.4.1.3 Cost Targets Should Determine
Strategy ................................................11
1.4.2 Cost Metrics and Their Effect on Results .......11
1.4.3 How to Design Very Low Cost Products ........13
1.4.4 Cost Reduction by Change Order ...................14
1.5 Cutting Time- to- Market in Half ..................................16
1.6 Roles and Focus...............................................................18
1.6.1 Human Resources Support for Product
Development ......................................................19
1.6.2 Job Rotation .......................................................20
1.6.3 Management Role to Support DFM ...............20
1.6.4 Management Focus ...........................................22
1.6.5 Successful or Counterproductive Metrics
for NPD ...............................................................24
1.7 Resistance to DFM ..........................................................25
vii
viii • Contents
1.8 Arbitrary Decisions ........................................................25
1.9 DFM and Design Time ..................................................29
1.10 Engineering Change Orders .........................................29
1.11 Do It Right the First Time ............................................30
1.12 Strategy to Do It Right the First Time ........................30
1.13 Company Benefits of DFM ............................................32
1.14 Personal Benefits of DFM ..............................................33
1.15 Conclusions ....................................................................34
Notes ...........................................................................................35
chapter 2 Concurrent Engineering ..................................................37
2.1 Resources .........................................................................37
2.1.1 Front- Loading at Toyota ...................................41
2.2 Ensuring Resource Availability ....................................41
2.2.1 Prioritization .....................................................42
2.2.2 Prioritizing Product Portfolios .......................42
2.2.3 Prioritizing Product Development Projects ...43
2.2.4 Prioritization at Leading Companies ............43
2.2.4.1 P rioritization at Apple ......................43
2.2.4.2 Product Development
Prioritization at HP ..........................44
2.2.4.3 Prioritization at Toyota ....................44
2.2.4.4 Product Prioritization for Truck
Bodies .................................................44
2.2.5 Prioritizing Resources for Custom
Orders, Low- Volume Builds, Legacy
Products, and Spare Parts ...............................44
2.2.6 Develop Acceptance Criteria for Unusual
Orders .................................................................46
2.2.7 Make Customizations and
Configurations More Efficient ........................46
2.2.8 The Package Deal ...............................................47
2.2.9 Rationalize Products ........................................48
2.2.10 Maximize Design Efficiency of Existing
Resources ............................................................50
2.2.11 Avoid Product Development Failures .............52
2.2.12 Avoid Supply Chain Distractions ....................52