DFM & Innovation Consultant

Best Practice / Decision-making and Valuation

DFM & Innovation Consultant
Ramalingam K S , Management Consultant, India

Design For Manufacturability (DFM) is the need of the day.

DFM Solutions by Redesign/
by Er Ramalingam K S DFM & Innovation Consultant

The Need of the Day

Enterprises are getting increasingly pressurized with the modern-day demands related to competition getting stiffer, rising customer demands, margins getting lower, etc, engineering companies are no exception.

To improve the performance of the existing engineering product, often, it needs to be modified and updated, the important performance criteria being maintaining its speed and stability. As engineering products are facing ever-increasing competition, it is necessary to add more functionality in the same product... Sometimes an engineering product needs to be re-engineered to correct the existing bugs.

Product re-engineering defines the process by which an already released product keeps being

'Buildable, Manufacturable and Marketable

By applying DFM Concepts’.

Engineering companies are increasingly looking at the option of outsourcing their activities, as this leads to substantial savings. The savings are even higher for essential product lifecycle tasks from developing to maintaining engineering systems, which is fueling the rapid rise in

Outsourcing this kind of work.

The Automotive OEMs are now thinking of collaborating with the Auto-component suppliers in new product developments and existing products’ re-engineering.

We are now focusing on Re-engineering by incorporating DFM Concepts to meet the current challenges by our Re-design Services.

OEMs are into Co-Product Development / Product Re-engineering By Blending /Enabling DFM

Er Ramalingam K S is very glad to offer DFM Solutions for already Designed or being Manufactured Engineering /Automotive Products/Assemblies in India or abroad .
We will provide on –line services for the propagation as well as mentoring for DFM Solutions.
Our methodology is based on a home-grown

DFM Methodology of DMAM&M

Our Mission is to bring in DFM – Design For Manufacturability –enabled to the existing Designs.
} According to Dr D M Anderson , the Brain behind ‘Design For Manufacturability & Concurrent Engineering’ –
} ‘Design For Manufacturability is the process of proactively designing products to
} (1) optimize all the manufacturing functions: fabrication, assembly, test, procurement, shipping, delivery, service, and repair, and (2) assure the best cost, quality, reliability, regulatory compliance, safety, time-to-market, and customer satisfaction’.

Our own self -evaluation parameters will be on the following lines:
— Design Rules /Guidelines for Compliance to validate that they have been rightly understood and acted upon.
— Commonality in 3 measures like total number of parts , number of types of parts & commonality with other designs

— Number of Engineering Change orders.
— Actual Design Cost compared to target or that of similar projects from the past.

— Actual Product Cost compared to target or that of similar products from the past.
— Actual Time-to-Market [not the design time] compared to target or that of similar products from the past.

— Input from the Field on customer satisfaction & Serviceability.
— Subjective Judgments from factory workmen on Manufacturability


· Reduce the number of parts to minimize the opportunity for a defective part or an assembly error, to decrease the total cost of fabricating and assembling the product, and to improve the chance to automate the process.

Foolproof the assembly design (poka-yoke) so that the assembly process is unambiguous.
Design verifiability into the product and its components to provide a natural test or inspection of the item. Avoid tight tolerances beyond the natural capability of the manufacturing processes and design in the middle of a part's tolerance range.
Design "robustness" into products to compensate for uncertainty in the product's manufacturing, testing and use.
Design for parts orientation and handling to minimize non-value-added manual effort, to avoid ambiguity in orienting and merging parts, and to facilitate automation.
Design for ease of assembly by utilizing simple patterns of movement and minimizing fastening steps.
Utilize common parts and materials to facilitate design activities, to minimize the amount of inventory in the system and to standardize handling and assembly operations.
Design modular products to facilitate assembly with building block components and sub-assemblies.
Design for ease of servicing the product.


· Identify design alternatives and develop these alternatives economically.

Evaluate these alternatives against DFM objectives.
Establish standardized designs based on DFM principles which can be readily retrieved for new/old products. .
Utilize re-design reviews and include participation of Manufacturing in the design process to evolve the producibility guidelines based on feedback from Manufacturing & Marketing.
Design for Manufacturability and Re-Design & Development may require additional effort in the redesign process. However, the integration of product and process design through improved /re-engineered business practices, management philosophies and technology tools will result in a more producible product to better meet customer needs, a quicker and smoother transition to re-manufacturing, and a lower total program/life cycle cost.

In an increasingly competitive world, product re-designs and customer service may be the ultimate way to distinguish a company's capabilities. Because of the growing importance of product design, Design for Manufacturability and Integrated Product Development concepts will be critical. It will be the key to achieving and sustaining competitive advantage through the re-development of high quality, highly functional products effectively re-manufactured through the synergy of integrated product and process design.
We welcome Professionals, Organizations & Companies from the field of DFM and Design & Development to join us in this Mission which is the Need of the Day.

‘Let us move from the Best Practices to Next Practices ‘

v ‘’ There is no magic tool to implement DFM – no magic software, no magic shrink –wrapped solution, no magic ‘models with trademarked names.

To say this in a different way,’ you can’t buy DFM “- according to Dr David M Anderson who is the brain behind design4manufacturability.com and my Mentor for DFM.

¢ DFM is a must. The technologies to enable DFM already exist. We need to move DFM from ‘a notion to reality ‘ by implementing practical DFM-infused design flows.

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