DFx
Design for Excellence (also known as Design for "x") is the philosophy that encompasses all aspects of product design optimization. DFx is broken down further into Design for Manufacturability (DFM), Design for Assembly (DFA), Design for Cost (DFC), Design for Servicing (DFS), Design for Test (DFT), Design for Quality (DFQ) and various other subcategories that focus on specific areas of a product lifecycle. Since these subcategories often have conflicting priorities (higher cost components may be required for ease of assembly), the designer must consider the entire product lifecycle to arrive at a truly optimized design.
DFM
Design for Manufacturability is the most well-known subcategory of DFx, and includes all aspects of design optimization at the component level.
Start with the end in mind: if you don't know how the part will be made, you don't know how to design the part. DFM capitalizes on the inherent strengths, and accommodates the inherent weaknesses, of the fabrication process. Can all machining be performed in a single setup? Does the die cast part require secondary operations? Does the injection mold tool require constant maintenance due to thin steel conditions dictated by the part design? These are all questions of design for manufacturability. |
DFADesign for Assembly ensures that a product can be easily assembled. The Japanese concept of "poke-yoke" (error-proofing) expresses the ideal of DFA, creating a product that cannot be incorrectly assembled.
In a word: Simplify. Overly-complex assemblies require more training and labor, consume more materials management, create more opportunities for errors or failures, require more tools and equipment, and drive more in-process inspections, all of which add cost, risk and headache. Ignoring DFA during the design process can cause tremendous pain to an organization looking to increase production volumes through line duplication or implementing automation. |
DFC
As early as design architecture definition, 60-70% of a product's ultimate production cost is already fixed. This means the fiscal success of a business rests firstly on the product design team to develop products with cost-effective architectures. Cost reduction is not primarily a manufacturing activity. Nor is it best accomplished through supply chain.
Your product requirements should include the COGS target the market can support. By the time you have a first functional prototype, you should have a preliminary cost estimate. Ultimately, every DFx question is a cost question. Without a product designed for cost, you don't have a product.
Your product requirements should include the COGS target the market can support. By the time you have a first functional prototype, you should have a preliminary cost estimate. Ultimately, every DFx question is a cost question. Without a product designed for cost, you don't have a product.