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Last updated on 2024年6月14日

How can you optimize your design for cost-effective manufacturing?

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In manufacturing engineering, optimizing your design for cost-effective production is a critical step towards success. This process involves a series of considerations that can significantly reduce costs while maintaining product quality and functionality. By employing strategies such as material selection, simplification of design, standardization of parts, and considering manufacturing processes early in the design phase, you can achieve a balance between cost efficiency and performance. Understanding the principles of Design for Manufacture and Assembly (DFMA) is also essential. DFMA is an engineering practice designed to systematically reduce manufacturing costs by simplifying the product structure and optimizing the manufacturing and assembly processes.

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Dr. Pratosh Mishra

Poet, Speaker, Trainer , LSS Green Belt ,LSS Black Belt ,Delivered Guest lectures in more than 20 Engg/Management…

1 Material Choice

Choosing the right materials is fundamental to cost-effective manufacturing. It's not just about the material cost itself but also about how it affects the entire production process. You need to consider the availability, machinability, and compatibility of materials with your manufacturing methods. Sometimes, a slightly more expensive material can lead to lower overall costs if it simplifies the manufacturing process or reduces waste.

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SHASHIKANT NIMKAR-Engineering / Special Process

Engineering I Special Process Manager | 14+ Years in Aerospace, NADCAP, FAIR, MRO, DGCA, RCA, CI, CAR145, Lab I Lean Six Sigma Black Belt, Internal Auditor, AS9100, A9102, AS9145 I APQP, PPPA,8D, SCM, SD
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Selecting the right material is crucial for cost-effective manufacturing. Opt for materials that are readily available and cost-efficient while still meeting the necessary performance and quality standards. Consider the total cost of ownership, which includes not just the purchase price but also machining, finishing, and waste management costs. Lightweight materials can reduce shipping costs, but ensure they provide sufficient strength and durability. Recycled or composite materials might offer cost savings and environmental benefits. Engaging with suppliers early can help identify economical alternatives without compromising on quality.

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2 Design Simplify

Simplifying your design can lead to significant cost savings. Aim to minimize the number of parts and avoid unnecessary complexity. Complex shapes often require specialized tooling or processes that can drive up costs. By designing parts that are easy to manufacture, you reduce labor time, minimize errors, and speed up the production process. Always ask yourself if each feature of your design is necessary or if there's a simpler way to achieve the same function.

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Dr. Pratosh Mishra

Poet, Speaker, Trainer , LSS Green Belt ,LSS Black Belt ,Delivered Guest lectures in more than 20 Engg/Management institutes
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Yes , in some designs there are too many components placed without any specific reason,some for future design scope also but at the same time we should think from a production point of view also.More components means more production time means low productivity.I always asked our design team that before finalizing any design we should consult with manufacturing person.By proper coordination between Design and production we can minimise the manufacturing cost.

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3 Standard Parts

Using standard parts whenever possible is a smart way to cut costs. Custom parts are more expensive to produce and can increase lead times. By utilizing off-the-shelf components, you can benefit from economies of scale and reduce the need for additional tooling. This approach also simplifies inventory management and can improve the reliability of your product due to the proven performance of standard components.

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4 Process Integration

Integrating the right manufacturing processes into your design early on can prevent costly changes later. Consider the capabilities and limitations of your production methods when designing your product. This might mean altering your design to fit a more cost-effective manufacturing process or investing in technology that can produce your parts more efficiently. The goal is to create a design that can be manufactured with minimal modifications to existing processes.

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SHASHIKANT NIMKAR-Engineering / Special Process

Engineering I Special Process Manager | 14+ Years in Aerospace, NADCAP, FAIR, MRO, DGCA, RCA, CI, CAR145, Lab I Lean Six Sigma Black Belt, Internal Auditor, AS9100, A9102, AS9145 I APQP, PPPA,8D, SCM, SD
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Integrating multiple manufacturing processes can lead to significant cost savings. Combining operations, such as machining and welding, into a single process reduces setup times and handling costs. Implementing in-line inspection systems can catch defects early, reducing rework and scrap rates. Process integration often involves investing in multifunctional machinery, which, although initially expensive, can result in long-term savings through increased efficiency and reduced labor costs. Lean manufacturing techniques, such as just-in-time production, can further streamline operations and reduce inventory costs.

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5 DFMA Principles

Applying Design for Manufacture and Assembly (DFMA) principles is key to optimizing your product for cost-effective manufacturing. DFMA focuses on reducing the complexity of manufacturing operations by designing products that are easier to assemble and which require fewer parts and processes. By considering assembly and manufacturing challenges during the design phase, you can eliminate potential issues that might arise during production, saving time and money.

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6 Feedback Loop

Establishing a feedback loop between your design team and manufacturing floor is crucial. Regular communication can help identify design elements that are difficult or expensive to manufacture. By listening to the insights of those who work with the product every day, you can refine your design to be more cost-effective without compromising on quality. This collaborative approach bridges the gap between design intent and manufacturing reality, ensuring a smoother production process.

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SHASHIKANT NIMKAR-Engineering / Special Process

Engineering I Special Process Manager | 14+ Years in Aerospace, NADCAP, FAIR, MRO, DGCA, RCA, CI, CAR145, Lab I Lean Six Sigma Black Belt, Internal Auditor, AS9100, A9102, AS9145 I APQP, PPPA,8D, SCM, SD
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Establishing a feedback loop between design, manufacturing, and quality control teams ensures continuous improvement. Regularly review manufacturing data to identify recurring issues and areas for improvement. This feedback helps refine designs to enhance manufacturability and reduce costs. Encouraging open communication between departments can lead to innovative solutions and process optimizations. Implementing a closed-loop quality control system ensures that any defects are quickly addressed and prevented in future production runs, maintaining high-quality standards and reducing waste.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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How can you optimize your design for cost-effective manufacturing?

1

2

3

4

5

6

7

1 Material Choice

2 Design Simplify

3 Standard Parts

4 Process Integration

5 DFMA Principles

6 Feedback Loop

7 Here’s what else to consider

Manufacturing Engineering

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How can you optimize your design for cost-effective manufacturing?

1

2

3

4

5

6

7

1 Material Choice

2 Design Simplify

3 Standard Parts

4 Process Integration

5 DFMA Principles

6 Feedback Loop

7 Here’s what else to consider

Manufacturing Engineering

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