April 8, 2024
In the competitive manufacturing world today, it is necessary to move a product from concept to production speedily and efficiently. When a product design is innovative, manufacturers may find that putting it into production is difficult, which can result in problems like delays, fixes or added expenses. When design plans are not matched by actual production, the business can make much less profit. An approach to link product design and manufacturing is with Design for Manufacturability (DFM), which ensures products are easy for the production line.
Design and manufacturing usually appear as different stages, though they are closely linked. The design of a product decides what it does, how it looks and also how labour-intensive and costly it is to create. When designing something that calls for specialised equipment, many assembly steps or tight measurements, the production cost may grow a lot. These problems tend to appear late on which can cause significant and expensive changes or redos.
When manufacturers add manufacturing concerns at the beginning of the design phase, the chance of risks is lower. By using this approach, development teams do fewer redesigns and it becomes easier to pass work to the production team. Design for Manufacturing means reviewing designs to check their feasibility in terms of ease, reliability and cost when making them with existing equipment and resources. The integration of design with production allows the company to earn better profits and launch new products faster.
New digital tools make it simpler to apply DFM principles. Computer-aided design (CAD) systems and simulation software help engineers see if the parts they are designing can actually be made. Even so, a key element in managing this process well today is using manufacturing ERP systems.
A manufacturing ERP organises and assembles data about materials, inventory, labour and production schedules in one place. If combined with DFM methods, manufacturing ERP software enables teams to choose the right design options using real information. By consulting their ERP system, engineers are able to assess the effects of using one material instead of another or whether design changes will affect when items can be produced.
If production considerations guide product design, it often makes the production process easier. If the number of parts in an assembly is reduced, if similar components are always used or if commonly available materials are selected, it can lower the cost a lot. Using simpler designs cuts down costs for materials, stocks, the time required for each cycle and makes it less likely for issues to happen.
DFM greatly helps in reducing the length of product development. More often, projects that go quickly from design to prototype to final production meet market dates and fulfill customer expectations. When production delays are caused by avoidable errors, chances for missed opportunities and using up resources increase. Working together from the beginning with production engineers, the design team can recognise and address problems that might prevent smooth production.
Achieving success with DFM mostly relies on good communication between design and manufacturing. Often, departments have separate goals, so designers think more about how the product looks or works, while manufacturers are burdened with building it. Getting rid of these barriers facilitates a better process when creating software.
When different areas of the company work together, feedback processes become fast and useful. If manufacturers involve tooling specialists, quality engineers and operators in the design process, they can spot and address most usual problems. By working together, the team ensures the quality is higher, less work has to be done over again and there is an increase in overall profit.
Being concerned about profitability, a manufacturer also has to be aware of Design for Manufacturability to remain competitive. Early application of DFM, teamwork and technology such as manufacturing ERP software helps manufacturers lower their costs, prevent delays and make sure the quality of their products is better. Organisations that carefully manage DFM usually end up providing new and improved products while running a profitable business.
