Design for Manufacturability

 Raise engineer’s design skill level  Improve quality of design  Improve quality of documentation  Enable higher quality, more cost effective manufacturing  Produce products more easily PRG/TBC2

 Simultaneous, Early Consideration Of All Design Goals & Constraints  Optimizes Efficiencies From Initial Concept Through Product Life.  Results In Lowest Total Cost & Shortest Time To Market. PRG/TBC3

Business Challenge

Elect. Design Ind./Mech. Design Software Dev. Proj. Mgmt. Bus. Process Test Dev.Proto Mfg. Packaging/ Logistics Vol. Mfg. Quality/ Reliability Fulfillment/Rep air FinanceMktg/Sales HR Cust. Reqn’tsProd. Def. Business Challenge

Lack of Technical Expertise: Internal resources often lack sufficient or appropriate technical expertise to support projects. Project Management and Integration: Internal resources have limited bandwidth to manage multiple outside partners effectively. Resource Availability: Internal resources are not always available in the timeframe required to meet project needs.

Spreadsheets s Faxes Changes BOMs New Part Requests Engineering ? Manufacturing Product Revisions? Current BOM? New Part Signoffs? Contract Manufacturers tied into change control?  Product is not what customer wants  Costs are too high  Product is not manufacturable or supportable  Unable to achieve compliance (ISO, FDA, RoHS, etc.)  Missed business plan targets

 Product Design Costs 5% Of Total Product.  Product Design Determines 70% Of Total.  To Reduce Costs - Focus On Design.  Allocate/Move Resources “Upstream”. PRG/TBC8

 Product Design ◦ Inventory cost impact ◦ Engineering documentation ◦ Customer service costs ◦ Quality risks ◦ Material & direct labor ◦ Administrative costs ◦ Customer response time ◦ Capital equipment costs PRG/TBC10

PRG/TBC11 Design Prototype First production Launch DEVELOPMENT STAGES COSTCOST Cost of changes multiplies By 10 with each step ,000

 Process Challenges  Guidelines for Assembly  Fundamental Considerations PRG/TBC12

 American Airlines ◦ Fleet of 12 different aircraft = 11 x cost  Southwest ◦ Fleet of 737 aircraft = streamlined cost

PRG/TBC14

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 Product Lifecycle Management (PLM) ◦ Supports the extended enterprise  Customers, design, and supply partners ◦ Integrates  People  Processes  Business systems and information 17

A set of capabilities that enables an enterprise to: – Manage its products and related services throughout the entire business lifecycle Total Business Consulting Group18

Manufacturing Planning Full Production Service and Support Concept and Planning Design and Engineering PLM provides a data platform for managing forward processing of data, AND recycling it back for subsequent products. CAD/CAE Web, Excel, Visio, etc. PDM cPD Visualization SCM/SRM CRM ERP/MRP What is Product Lifecycle Management (PLM)?

 Traditional serialized product development process ◦ When does the Mfg./Production Engineer see the final design? ◦ What happens next?  Changes begin  How many changes do you initiate? ◦ How do we classify the changes?  Mandatory vs. phase-in PRG/TBC Group 22

Resistance – Lack of familiarity and FEAR Global Issues – Distance/language Lack of Champion – Driving force Lack of Measurement – Where are we? – What is the ROI? 23

PRG/TBC24 Q and A