Companies may become more aggressive by adopting concepts like DFM and DFA. Basically, it entails coming up with designs that make manufacture of products efficient as well as less costly. DFA concentrates on developing designs that can be assembled easily and quickly. DFM and DFA can also reduce production cost, enhance product quality, and increase productivity when deployed. Such an approach enables them to keep their prices low compared to other competitors and this can be for the purpose of making high profits hardware pcb. This blog will talk about strategies of utilizing DFM and DFC for competitive advantage.
Simplify Part Counts
In order to improve assembly, with DFA, one could decrease the number of parts constituting the product. This leads to fewer parts which ultimately implies less time needed for searching for, carrying around, and connecting the components. It also minimizes error possibilities. Thus, it is important for companies to seek possibilities of integrating or consolidation of elements, without affecting the performance and appearance. Such a process would result in plastic parts that were injection molded as one complete piece, instead of being individual parts as they used to be. On assembly, this reduces the cost of labor as well.
Minimize Handling and Orientation
Overall assembly efficiency is highly affected by the duration of picking up, placing, and orientation of parts. With DFA, companies aim to design parts that can be easily grasped, aligned, and joined with minimal hand motions or repositioning. Features like tabs, slots, and guides can help self-orient parts and simplify assembly. Companies should also consider things like part size, weight, and ergonomics to minimize handling time and fatigue. Well-designed parts come together like puzzle pieces with little effort or thought from the assembler.
Use Self-Fastening Features
Eliminating or reducing the number of separate fasteners like screws and nuts can significantly improve assembly. With DFA, companies design parts with built-in snap-fits, press-fits, interlocks or threads to “self-fasten” during assembly. These features allow components to be joined together more quickly without additional assembly steps for separate fasteners. Self-fastening eliminates time spent locating, torquing or staking separate parts. It also reduces the number of small components that must be precision fed, handled and inserted during assembly.
Improve Accessibility
The ease of accessing joining areas and points of assembly greatly impacts efficiency. With DFA, companies ensure all mating surfaces and features are externally accessible without obstructions from other parts or the product pcb hardware. They also consider factors like part orientation, reach, and ergonomics. Good accessibility allows assemblers to easily see what they are doing and join parts without awkward angles, limited space or need to remove other components first. It avoids wasted time spent repositioning or disassembling other areas to access join points.
Simplify Joining Operations
The type of joining method used, whether welding, gluing, screwing, etc also impacts assembly time and difficulty. DFA focuses on selecting joining methods that are fast, require minimal skill levels and can be easily automated. For example, snap-fits that require no additional fasteners are generally much faster than screw assemblies. Adhesives or ultrasonic welding may be better choices than nuts and bolts if they reduce assembly steps. Simpler, self-contained joining operations allow for higher productivity.
Use Consistent Hardware
Having to use many different types and sizes of separate fasteners like screws or nuts increases assembly complexity. With DFA, companies standardize on a limited number of common hardware sizes to reduce SKUs and simplify logistics. Consistent hardware allows for pre-loaded feeders, more flexible labor and easier automation. Assemblers don’t have to sort through assortments to find the right parts. Common drive types or thread specifications make joining faster and less prone to errors.
Minimize Adjustments
The need to fine-tune positions or make adjustments during assembly wastes time. DFA focuses on designing parts that self-align and self-locate without position checks or tweaks. Tolerances are set to ensure snap-fits engage fully on their own rather than requiring prying or adjustment. Moveable components like hinges are designed so that they snap into their final positions without play. This avoids non-value-added adjustment steps during assembly.
Consider Assembly Sequence
The order that parts come together impacts efficiency. DFA evaluates the assembly sequence to ensure components join together progressing from larger subassemblies to smaller details. It avoids designs that require disassembling larger subassemblies to access points further along the sequence. The optimal sequence has parts coming together step-by-step with no backtracking. Companies may prototype different sequences to find the most efficient flow.
Use Modular Design
Modular designs that allow for product variations using common building blocks improve flexibility. With DFA, companies design products or product families with modular subassemblies that can be mixed and matched. For example, using the same chassis, power supply and interface modules across multiple SKUs means those subassemblies only need to be assembled once. Only the unique modules change to produce different end products. This approach leverages commonality to improve efficiency across a range of related products.
Apply DFM for Manufacturability
Finally, applying DFM principles at the design stage ensures parts are not only easy to assemble but also efficient to manufacture. Simple part shapes avoid complex tooling, molds can consolidate parts for lower costs, materials are conducive to high-volume production methods, and designs facilitate automation. DFM eliminates non-manufacturable features, ensures tight tolerances can be held and verifies designs can be reliably manufactured at high quality and speed. This reduces costs and improves competitiveness.
Conclusion
Implementing DFA and DFM principles during product development provides many opportunities to streamline production and gain a competitive advantage. From simplifying designing embedded hardware to optimizing assembly sequences, a focus on manufacturability and ease of assembly can significantly boost productivity and lower costs. Companies that harness DFA and DFM to continually improve efficiency through their designs gain an important edge over competitors with higher profit margins or ability to undercut on price. With smart application of these concepts, products become easier and less expensive to build, allowing companies to compete very effectively in their markets.
