What are some common design for serviceability (DFS) challenges and how do you overcome them?

While being modular can help serviceability, within that is material science and material selection that can help not only optimize financials but to provide a better product catalog in regards to the environment its being deployed to. Whether its on the -50°F surface of Siberia, the 350°F of being 3 miles downhole along with 5000 psi hydrostatic pressure or a cool 70°F beachy day riding along with the top down, choosing the correct material is imperative. The cold makes your steel brittle, the hot makes it easier to deform and even on a perfect day in your convertible you have to make sure all your plastic parts aren't susceptible to UV. Nothing will last if its put in the wrong environment.

Designing for serviceability (DFS) can be a tough nut to crack. It’s not just about making your product easy to fix, but also about understanding the needs of those who’ll be doing the fixing. Think about the technicians who’ll be elbow-deep in your product. What tools will they have? What’s their skill level? And don’t forget about the environment where the maintenance will happen. Is it a clean, well-lit workshop or a cramped, dimly lit space? These factors can greatly influence your design decisions. So, keep your ears open for feedback from the field, and don’t be afraid to iterate on your design. Remember, a product that’s easy to maintain is a product that’s loved by customers.

Serviceability is a key aspect of a good product. Too many products are designed with the bottom line cost as a driving feature. Industrial products should always be not only serviceable but with standard parts as much as possible. Ensure designs allow maintenance personnel to efficiently service equipment, they will appreciate your forward thinking which pay dividends to your company in the future.

In the drone industry, optimizing modularity allows easy replacement of damaged propellers with standardized parts, while standardization ensures components like batteries fit across different models, enhancing serviceability and reducing downtime. For instance, using a universal battery pack design enables quick swaps and compatibility across various drone models.

Modularity and standardization are your best friends when it comes to Design for Serviceability (DFS). Think of your product as a Lego set. Each block, or module, can be easily removed and replaced without affecting the others. This makes maintenance a breeze. Standardization, on the other hand, is like using a common language. It ensures that parts fit together seamlessly and that tools and procedures are consistent. But remember, achieving optimal modularity and standardization requires a deep understanding of your product and its lifecycle. So, keep learning, keep iterating, and keep improving. Your customers (and your service team) will thank you.

Modularity is a key function of our products. Unforeseen things happen and parts can get damaged while in services. Modularity allows assemblies to replaced or reconfigured to achieve new goals as the customer's needs change over time.

Simple design elements can be very helpful for assembly and disassembly. Flanges can be sized at connection points that when aligned on certain edge surfaces the assembly person can use to know the parts are properly aligned. Minimize the number of different size fasteners in a design, even if some fasters are oversized. This allows the assembly to need fewer tools for assembly which cuts down on assembly time. The purchasing agent will be also be required to purchase fewer part numbers and inventory fewer parts.

Design for Assembly and Disassembly (DFA/DFD) is like a secret weapon in the world of maintenance. It’s all about making your product easy to put together and take apart. But here’s a pro tip: don’t just focus on the physical aspects. Think about the user experience too. Clear, intuitive instructions can make a world of difference. And consider using visual cues, like color-coding or labeling, to guide the process. It’s like a roadmap for maintenance. And remember, a well-designed product isn’t just easier to maintain - it’s also safer and more efficient. So, embrace DFA/DFD and make your product a joy to service.

Integrated service tools or indicators can be very helpful to maintenance personnel on different or intricate items that are out of the ordinary. A cover plate for a wear measurement area can also serve as thickness tool in a go/no distance measurement. If integration is not possible supply the thickness measurement tool with the product. Customers and maintenance personnel will appreciate and value the forethought.

Consider how the product must be assembled and maintained during design phase. Often times the most efficient design requires excessive assembly time, excessive equipment, shipping costs or too many different part numbers. This design mindset saves cost on one side of the business but cost more on the other. See the big picture. One domestic automaker has a engine with the coolant water pump inside the engine, why would anyone do that? Pumps are known a replacement item.