Design for manufacturability : How to use concurrent engineering to rapidly develop low-cost, high-quality products for lean production

K21414

Product Development

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

production. Extending the concepts of design for manufacturability to an

advanced product development model, it explains how to simultaneously make

major improvements in all these product development goals, while enabling

effective implementation of Lean Production and quality programs.

Illustrating how to make the most of lessons learned from previous projects, the

book proposes numerous improvements to current product development

practices, education, and management. It outlines effective procedures to

standardize parts and materials, save time and money with off-the-shelf parts,

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

quality and availability while minimizing part lead-times and ensuring desired

functionality.

• Describes how to design families of products for Lean Production,

build-to-order, and mass customization

• Emphasizes the importance of quantifying all product and overhead

costs and then provides easy ways to quantify total cost

• Details dozens of design guidelines for product design, including

assembly, fastening, test, repair, and maintenance

• Presents numerous design guidelines for designing parts for

manufacturability

• Shows how to design in quality and reliability with many quality

guidelines and sections on mistake-proofing (poka-yoke)

Describing how to design parts for optimal manufacturability and compatibility

with factory processes, the book provides a big picture perspective that empha￾sizes designing for the lowest total cost and time to stable production. After

reading this book you will understand how to reduce total costs, ramp up quickly

to volume production without delays or extra cost, and be able to scale up

production rapidly so as not to limit growth.

DAVID M. ANDERSON

How to Use Concurrent Engineering to

Rapidly Develop Low-Cost, High-Quality

Products for Lean Production

DESIGN

for

MANUFACTURABILITY

DESIGN FOR MANUFACTURABILITY ANDERSON

How to Use Concurrent Engineering to

Rapidly Develop Low-Cost, High-Quality

Products for Lean Production

DESIGN

for

MANUFACTURABILITY

CRC Press is an imprint of the

Taylor & Francis Group, an informa business

Boca Raton London New York

A P ROD U CT I V I T Y PR E SS BOOK

DAVID M. ANDERSON

How to Use Concurrent Engineering to

Rapidly Develop Low-Cost, High-Quality

Products for Lean Production

DESIGN

for

MANUFACTURABILITY

CRC Press

Taylor & Francis Group

6000 Broken Sound Parkway NW, Suite 300

Boca Raton, FL 33487-2742

© 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)

This book contains information obtained from authentic and highly regarded sources. Reasonable efforts

have been made to publish reliable data and information, but the author and publisher cannot assume

responsibility for the validity of all materials or the consequences of their use. The authors and publishers

have attempted to trace the copyright holders of all material reproduced in this publication and apologize to

copyright holders if permission to publish in this form has not been obtained. If any copyright material has

not been acknowledged please write and let us know so we may rectify in any future reprint.

Except as permitted under U.S. Copyright Law, no part of this book may be reprinted, reproduced, transmit￾ted, or utilized in any form by any electronic, mechanical, or other means, now known or hereafter invented,

including photocopying, microfilming, and recording, or in any information storage or retrieval system,

without written permission from the publishers.

For permission to photocopy or use material electronically from this work, please access www.copyright.

com (http://www.copyright.com/) or contact the Copyright Clearance Center, Inc. (CCC), 222 Rosewood

Drive, Danvers, MA 01923, 978-750-8400. CCC is a not-for-profit organization that provides licenses and

registration for a variety of users. For organizations that have been granted a photocopy license by the CCC,

a separate system of payment has been arranged.

Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are used

only for identification and explanation without intent to infringe.

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.

vii

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

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 Prioritization 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

Contents • ix

2.2.13 Optimize Product Development Project

Scheduling ..........................................................53

2.2.14 Ensure Availability of Manufacturing

Engineers............................................................53

2.2.15 Correct Critical Resource Shortages.............. 54

2.2.16 Invest in Product Development Resources.... 54

2.2.16.1 R&D Investment at Medtronic.........55

2.2.16.2 R&D Investment at General

Electric and Siemens..........................55

2.2.16.3 R&D Investment at Apple.................55

2.2.16.4 R&D Investment at Samsung...........55

2.3 Product Portfolio Planning .......................................... 56

2.4 Parallel and Future Projects..........................................57

2.5 Designing Products as a Team......................................59

2.5.1 The Problems with Phases, Gates,

Reviews, and Periodic Meetings......................59

2.5.2 Huddles.............................................................. 60

2.5.3 Building Many Models and Doing Early

Experiments.......................................................61

2.5.4 Manufacturing Participation...........................61

2.5.5 Role of Procurement .........................................62

2.5.6 Team Composition............................................63

2.5.7 Team Continuity............................................... 64

2.5.8 Part-Time Participation................................... 64

2.5.9 Using Outside Expertise.................................. 64

2.5.10 The Value of Diversity.......................................65

2.5.11 Encouraging Honest Feedback........................65

2.6 Vendor Partnerships.......................................................65

2.6.1 The Value of Vendor/Partnerships..................65

2.6.2 Vendor/Partnerships Lead to Lower Net

Cost..................................................................... 66

2.6.3 Vendor Partner Selection .................................67

2.6.4 Working with Vendor Partners...................... 68

2.7 The Team Leader.............................................................69

2.7.1 The Team Leader at Toyota ..............................70

2.7.2 The Team Leader at Motorola..........................71

2.7.3 Team Leaders and Sponsors at Motorola .......71

2.8 Co-Location.....................................................................71

x • Contents

2.8.1 Effect of Onshoring on Concurrent

Engineering ........................................................72

2.8.2 The Project Room (The “Great Room” or

Obeya) .................................................................72

2.9 Team Membership and Roles........................................73

2.9.1 Manufacturing and Service .............................74

2.9.2 Tooling Engineers..............................................74

2.9.3 Purchasing and Vendors...................................74

2.9.4 Marketing ...........................................................75

2.9.5 Customers...........................................................75

2.9.6 Industrial Designers..........................................76

2.9.7 Quality and Test.................................................77

2.9.8 Finance................................................................77

2.9.9 Regulatory Compliance....................................77

2.9.10 Factory Workers ................................................78

2.9.11 Specialized Talent..............................................78

2.9.12 Other Projects....................................................78

2.10 Outsourcing Engineering..............................................79

2.10.1 Which Engineering Could Be Outsourced?....81

2.11 Product Definition..........................................................82

2.11.1 Understanding Customer Needs.....................82

2.11.2 Writing Product Requirements.......................83

2.11.3 Consequences of Poor Product Definition ... 84

2.11.4 Customer Input................................................. 84

2.11.5 Quality Function Deployment ....................... 86

2.11.6 How QFD Works...............................................87

Notes ...........................................................................................89

Chapter 3 Designing the Product..................................................... 95

3.1 Design Strategy .............................................................. 96

3.1.1 Designing around Standard Parts.................. 96

3.1.1.1 Sheet Metal......................................... 96

3.1.1.2 Bar Stock .............................................97

3.1.2 Consolidation.....................................................97

3.1.3 Off-the-Shelf Parts.............................................97

3.1.4 Proven Processing .............................................98

3.1.5 Proven Designs, Parts, and Modules..............98

3.1.6 Arbitrary Decisions...........................................98

Contents • xi

3.1.7 Overconstraints ................................................ 99

3.1.8 Tolerances.......................................................... 99

3.1.9 Minimizing Tolerance Demands................... 99

3.1.10 System Integration.......................................... 100

3.1.11 Optimizing All Design Strategies................ 100

3.1.12 Design Strategy for Electrical Systems.........101

3.1.13 Electrical Connections: Best to Worst..........101

3.1.14 Optimizing Use of Flex Layers ......................103

3.1.15 Voltage Standardization .................................103

3.1.16 DFM for Printed Circuit Boards ...................104

3.2 Importance of Thorough Up-Front Work.................105

3.2.1 Thorough Up-Front Work at Toyota.............107

3.2.2 Thorough Up-Front Work at Motorola ........108

3.2.3 Thorough Up-Front Work at IDEO ..............108

3.2.4 Avoid Compromising Up-Front Work .........108

3.2.4.1 Slow Processes for Sales and

Contracts...........................................108

3.2.4.2 Rushing NPD for Long-Lead￾Time Parts.........................................108

3.2.4.3 Rushing NPD for Early

Evaluation Units...............................109

3.2.5 Early Evaluation Units....................................109

3.3 Optimizing Architecture and System Design ..........110

3.3.1 Generic Product Definition............................110

3.3.2 Team Composition and Availability.............110

3.3.3 Product Development Approach...................111

3.3.4 Lessons Learned...............................................111

3.3.4.1 Categories of Lessons Learned.......111

3.3.4.2 Methodologies for Lessons

Learned..............................................111

3.3.5 Raising and Resolving Issues Early...............112

3.3.5.1 Project Issues....................................113

3.3.5.2 Team Issues.......................................113

3.3.5.3 Mitigating Risk.................................114

3.3.5.4 New Technologies............................114

3.3.5.5 Techniques to Resolve Issues Early...114

3.3.5.6 Contingency Plans...........................115

3.3.5.7 Achieving Concurrence before

Proceeding ........................................115

xii • Contents

3.3.6 Manual Tasks...................................................115

3.3.7 Skill and Judgment..........................................116

3.3.8 Technical or Functional Challenges.............117

3.3.9 Commercialization..........................................118

3.3.10 Manufacturable Science .................................119

3.3.11 Concept/Architecture Design

Optimization....................................................119

3.3.12 Optimizing the Use of CAD in the

Concept/Architecture Phase ......................... 120

3.3.13 Concept Simplification ...................................121

3.3.14 Manufacturing and Supply Chain

Strategies.......................................................... 122

3.4 Part Design Strategies................................................. 123

3.5 Design for Everything (DFX)..................................... 126

3.5.1 Function........................................................... 126

3.5.2 Cost................................................................... 126

3.5.3 Delivery.............................................................127

3.5.4 Quality and Reliability....................................127

3.5.5 Ease of Assembly .............................................127

3.5.6 Ability to Test.................................................. 128

3.5.7 Ease of Service and Repair............................ 128

3.5.8 Supply Chain Management........................... 128

3.5.9 Shipping and Distribution..............................129

3.5.10 Packaging..........................................................129

3.5.11 Human Factors ................................................129

3.5.12 Appearance and Style .....................................130

3.5.13 Safety .................................................................130

3.5.14 Customers’ Needs............................................130

3.5.15 Breadth of Product Line .................................130

3.5.16 Product Customization...................................131

3.5.17 Time-to-Market...............................................131

3.5.18 Expansion and Upgrading .............................131

3.5.19 Future Designs.................................................132

3.5.20 Environmental Considerations .....................132

3.5.20.1 Product Pollution.............................132

3.5.20.2 Processing Pollution........................132

3.5.20.3 Ease of Recycling Products.............133

3.5.21 Summary ..........................................................133

Contents • xiii

3.6 Creative Product Development.................................. 134

3.6.1 Generating Creative Ideas............................. 134

3.6.2 Generating Ideas at Leading Companies.....135

3.6.3 Encouraging innovation at Medtronic.........136

3.6.4 Nine Keys to Creativity...................................136

3.6.5 Creativity in a Team........................................137

3.6.6 The Ups and Downs of Creativity .................138

3.7 Brainstorming...............................................................139

3.8 Half-Cost Product Development................................140

3.8.1 Prerequisites for Half-Cost Development....140

3.8.1.1 Total Cost..........................................140

3.8.1.2 Rationalization.................................140

3.8.2 Designing Half-Cost Products ......................141

Notes .........................................................................................142

Section II Flexibility

Chapter 4 Designing for Lean and Build-to-Order....................... 147

4.1 Lean Production ...........................................................147

4.1.1 Flow Manufacturing .......................................148

4.1.2 Prerequisites.....................................................149

4.2 Build-to-Order..............................................................149

4.2.1 Supply Chain Simplification ..........................150

4.2.2 Kanban Automatic Part Resupply.................150

4.3 Mass Customization.....................................................152

4.4 Developing Products for Lean, Build-to-Order,

and Mass Customization.............................................153

4.5 Portfolio Planning for Lean, Build-to-Order, and

Mass Customization.................................................... 154

4.6 Designing Products for Lean, Build-to-Order,

and Mass Customization............................................ 154

4.6.1 Designing around Standard Parts.................155

4.6.2 Designing to Reduce Raw Material Variety ...156

4.6.3 Designing around Readily Available

Parts and Materials .........................................156

4.6.4 Designing for No Setup ..................................157

4.6.5 Parametric CAD..............................................158