[DFM Consulting]    [DFM Seminars]    [DFM Books]    [Credentials]    [Clients]   [Site Map] 

[DFM article]     [Half Cost Products site]   [Standardization article]   [Mass Customization article]   [BTO article]   [Rationalization article]

the 2020   DFM    book  is now   also   KNOWM  as   tje

optimizing    everything

This 600 page book adds what the publisher says is already the definitive work on
 product development and now the Second Edition adds 100 new and unique pages that
have never been published before, thus resulting in the following: 

Thorough manufacturability can be  complete products in h
alf the budget with  savings ranging from half to one-tenth in nine categories (3.8). 

Research and early product development start with  Manufacturable Research (3.9), that optimizes concept/architecture (3.3.9), assures part availability (3.9.7) and  process availability, (3.9.10),  achievable tolerances (3.9.8), and  avoids work force challenges (4.8.4.2) on hard-to-build products  (3.9.9), all of which can start providing  immediate scalable, commercialization results. The design process emphasizes   thorough up front work (Chapter 3) in   complete multi-functional tams (Chapter 2) that cane  quickly scale up production without limits, delays, or extra cost (4.8)) to   avoid shortages by design by design.

Product development improvement champions and implementers will also benefit from Section 3.11 (and its 10 sub-sections) on  generating interest in designing better products for manufacturability.   All this can be applied right away on a project team (11.7) in its own micro-climate (3.11.6.1).

  LEADING-EDGE BOOKS BY 
DR. DAVID M ANDERSON, P.E., CMC, fASME     

New 2020 book to be published June 2, 
which can be pre-ordered now AT:
https://www.amazon.com/Design-Manufacturability-Concurrent-Engineering-High-Quality/dp/0367249944/ref=sr_1_2?dchild=1&keywords=MANUFACTURABILITY&qid=1589596590&s=books&sr=1-2- 

"Design for Manufacturability: How  to Use Concurrent Engineering to Rapidly Develop Low-Cost, High-Quality Products for Lean Production," Second Edition (690 pages, Productivity Press)

BACK   COVER   TEXT:

Design for Manufacturability: How to Use Concurrent Engineering to Rapidly Develop Low-Cost, High-Quality Products for Lean Production is still the definitive work on DFM – this second edition extends the proven methodology to the most advanced product development process with the addition of the following new, unique, and original topics, which have never been addressed previously. These topics show you how to:      

·       Cut cost from 1/2 to 1/10 in 9 categories -- with ways to remove that much cost from product charges and pricing.

·       Commercialize innovation --  starting with Manufacturable Research and learning from the new section on scalability, you will learn how to design products and processing equipment to scale quickly to any growth levels.

·       Design product families that can be built “on-demand” in platform cells that also “mass customize” products to-order

·       Make Lean production easier to implement with much more effective results while making build-to-order practical with spontaneous supply chains and eliminating forecasted inventory by including updated chapter on “Designing  Products for Lean Production.”

  The author’s 30 years of experience teaching companies DFM based on pre-class surveys and plant tours is the foundation of this most advanced design process. It includes incorporating dozens of proven DFM guidelines through up-front concurrent-engineering teamwork that cuts the time to stable production in half and curtails change orders for ramps, rework, redesign, substituting cheaper parts, change orders to fix the changes, unstable design specs, part obsolescence, and late discovery of  manufacturability issues at periodic design reviews. This second edition is for the whole product development community, including:   

·       Engineers who want to learn the most advanced DFM techniques   

·       Managers who want to lead the most advanced product development   

·       Project team leaders, who want to immediately apply all the principles taught in this book in their own micro-climate

·       Improvement leaders and champions who want to implement the above and ensure that the company can design products and versatile processing equipment for low-volume/high mix product varieties    

  Designing half to a tenth of cost categories can: avoid substituting cheap parts, which degrades quality, and encourage standardization and supply chains supply chains, which will encourage Lean initiatives.  Using cellular Manufacturing to shift production between lines for mixed production of platforms and build-to-order to offer the fastest order fulfillment can beat any competitors’ delivery time.   

To enquire about public and in-house DFM seminars and webinars, fill out the form.

BUILD-TO-ORDER & MASS CUSTOMIZATION  (available now)

"Build-to-Order & Mass Customization; The Ultimate Supply Chain Management and Lean Manufacturing Strategy for Low-Cost On-Demand Production without Forecasts or Inventory,"  by David M. Anderson, (2008, CIM Press, 512 pages).  To view the complete table of contents or order, click here for the books page at www.build-to-order-consulting.com.  Seminars and consulting based on this leading-edge methodologies are available now through Dr. Anderson’s Mass Customization consulting and Mass Customization seminars.  A overview of the approach can be found in the article Build-to-Order.

Free BTO book, signed by the author, for US callers.  Just call Dr. Anderson at 805-924-0100 (after 8:30 am Pacific) for a free assessment of how much these methodologies can help your company

To order the BTO book, go to this book's order page at http://www.amazon.com

Many product scenarios has been worked out for several industries and will be published later in "The Build-to-Order & Mass Customization Case book."  These specific methodologies are available now for Build-to-Order consulting and Build-to-Order seminar clients.

ADVANCES IN PRODUCT FAMILY AND PRODUCT PLATFORM DESIGN
(pages 589-604 )

Dr. Anderson's "how to" chapter from the  forthcoming book, "Advances in Product Family and Product Platform Design,"  shows how to develop product families, "Building, Supplying, and Designing Product Families." can be downloaded now for $29.95 at the Springer Publishing site at http://link.springer.com/chapter/10.1007/978-1-4614-7937-6_23
 

ERSON:

In 1983 Dr. Anderson wrote an essay on “The Future of Robotics” in the Industrial Robotics Handbook, by V. Daniel Hunt (1983, Industrial Press, 432 pages)

 Dr. Anderson can be reached at 805 924 0100 (Pacific Time Zone) or e-mail: anderson@build-to-order-consulting.com

Table of Contents of 2020  DFM book, second edition:

Design for Manufacturability: How to Use Concurrent Engineering
to Rapidly Develop Low-Cost, High-Quality Products for Lean Production" Second Edition;
Published by Productivity Press, 2020

(Sample  TOC entries:   Red  and italic type  below indicate unique or not puibhed anywhere else)

Section I Design Methodology

1.1 Manufacturing before DFM
1.1.1 What DFM is Not
1.1.2 Comments from Company DFM Surveys
1.2 Myths and Realities of Product Development
1.3 Costs, When they Are Determined
1..4 Designing for Low Cost9
1.5 Time-to-Market, Cutting it in Half
1.6 Roles and Focus.
1.7 Resistance to DFM
1.8 Arbitrary Decisions
1.9 Design Time, Reducing it with DFM
1.10 Engineering Change Orders
1.11 Do it Right the First Time
1.12 Strategy to Do it Right the First Time
1.13 Benefits of DFM for the Company
1.14 Personal Benefits of DFM
.15 Conclusions of DFM Intro.

Chapter 5 Standardization............................................................... 239

5.1 Part Proliferation
5.2 Part Proliferation Cost
5.3 Part Proliferation, Why it Happens
5.4 Part Proliferation Consequences
5.5 Part Standardization Strategy
5.6 Early Standardization Steps
5.7 Zero-Based Approach
5.8 Standard Part List Generation
5.9 Part Standardization Results
5.10 Raw Materials Standardization
5.11 Standardization of Expensive Parts
5.12 Consolidation of Inflexible Parts
5.13 Tool Standardization
5.14 Feature Standardization
5.15 Process Standardization.
5.16 Encouraging Standardization
5.17 Reusing Designs, Parts, and Modules
5.18 Off-the-Shelf Parts
5.19 Procurement, New Role Needed
5.20 Standardization Implementation

he book Table of Contents has 814 entries in four levels, two of which are shown in four sample chapters above.

The Index is fullly cross-indexed with 2511 entries, with unique or never-before-published topics in italics, as is also done in the Table of Contes.  This is especiallly useful for people upgrading from the 2014 first edition.

[Home]    [DFM Consulting]    [DFM Seminars]    [DFM Books]    [Credentials]    [Clients]

[DFM article]     [Half Cost article]   [Standardization article]   [Mass Customization article]   [BTO article]   [Rationalization article]

Copyright © 204 by David M. Anderson

BOOK    OF    STANDARDS

                                                        for     universal   needs    for

Timely article: How to avoid most shortages now 
AND design new products for unlimited Scalability

see revised article at:  http://design4manufacturability.com/scalability.htm 

If you don't know who your customers are going to be
 or what they will want, you must Build-to-Order.
see: www.build-to-order-consulting.com

If you don't have enough resources to develop good products fast,
make that twice as efficient as possible* and don't "take all orders." 
* see: http://www.design4manufacturability.com/concurrent-engineering.htm

Timely Article on The Case against Orrshoring:  http://www.design4manufacturability.com/offshoring.htm

Companion article on this site on  hidden  offshorIng costs

Pivotal Article   How to Design Half-Cost Products

The age shows nine categories of cost reduction ranging from 1/2 cost to 1/10 of the previous costs 
. Each cost category has one to two hyper-links that present the principles.

New Article on strategy:  http://www.design4manufacturability.com/strategy.htm

Alphabetical listing to to 26  Articles                 Site locator to 50 pages on this site       

Feature articles: Commercialization   and Half-Cost Solar

                 New 2020 Secomd Edition book: "Design for Manufacturability: How to Use Concurrent Engineering
to Rapidly Develop Low-Cost, High-Quality Products for Lean Production" 

Also, the most thorough book ever written on Build-to-Order & Mass Customization

Cost reduction can result in significant product cost saving, manufacturing cost saving, and life cycle cost saving when companies interested in cutting cost implement all 8 the elements of the following cost reduction strategy:

article on HALF COST PRODUCTS

• Product development determines 80% of product cost. The concept/architecture phase alone determines 60% of cost! See how Design Determines Cost
• See article on  How-Cost Architectural Breakthroughs can reduce 60% of cost at: http://www.design4manufacturability.com/designing_low_cost_products.htm 
• which shows    how-Cost Architectural Cost Breakthroughs
   shows the top 5 design strategies to lower cost: breakthrough concepts, designing out quality costs, eliminating change orders, vendor-partnerships, and designing to minimize part cost and material overhead.
• Article shows why cost is very hard to remove later after products are designed
• Advanced product development with new opener: Becoming an innovative company on the next project, with achievable goals based on rational etrics at:   https://www.design4manufacturability.com/advanced_npd.htm 

• Significant cost reductions by design for parts, labor, material overhead, quality, and product development; designing for lean production can maximize lean savings (See # 2 Lean Production Cost Reduction below).

• Practice Concurrent Engineering with early and active participation of manufacturing, purchasing, vendors, etc.
• Implement Design for Manufacturability ( DFM ), Design for Lean, and Design for Quality
• For dramatic cost reduction - half cost to order-of-magnitude - optimize the concept/architecture phase
• To convert ideas, research, or prototypes into viable products, use commercialization techniques to ensure success.
• Convert expensive welded frames to assemblies of CNC machined parts that are assembled rigidly and precisely using various DFM techniques.  The Steel & Cost Reduction Workshop shows how design more manufacturable frames, like the illustration on the right: 

• Co-locating Engineering with Manufacturing ensures the best teamwork; avoid distant offshoring
• If outsourcing, choose local vendors which ensures early and active vendor participation in product development teams
• Pre-select Vendor/Partners who will help develop products; avoid low-bidding
so that vendors will help with design
• Implement standardization and good product portfolio planning for the best focus
• Total cost measurements (#8) to quantify all costs affected by design
• Correcting Counterproductive Policies.  New ventures and startups will be able to implement these principles right away. Established companies may have to first correct counterproductive policies, by prioritizing portfolio planning, scrutinizing high-overhead sales, emphasizing thorough up-front work, quantifying all costs, and avoiding time-draining attempts to reduce cost after design, going for the low-bidder, or moving production offshore. See full article on counterproductive policies.
  
  New article on "Concurrent Engineering of Challenging Products" at http://www.design4manufacturability.com/concurrent-engineering.htm
  
  New article on "Results" at:  http://www.design4manufacturability.com/results.htm
•  

• Lean production benefits include doubling labor productivity, cutting production throughput times by 90 percent, reducing inventories by 90 percent, cutting errors and scrap in half errors

• Significant cost reduction possible by raising labor productivity and eliminating waste
• Even greater returns when lean is extended to a Build-to-Order business model (See # 3 Overhead Cost Reduction below)

• Implement Lean Production

• Design product families for lean production
• Concurrently Engineer flexible processes
• Implement standardization (#4) to enable dock-to-line distribution
• Rationalize products (#5) to eliminate the most unusual products with the most unusual parts and processes
• Total cost measurements (#8) to quantify all costs related to manufacturing
• Keep control of manufacturing in-house or with vendor/partners; avoid offshoring,  avoid long and distant supply chains
   

THis is presented at the web page: Designing Half Cost Products at:  https://www.design4manufacturability.com/designing_half_cost_products.htm 

See article on "How to Build-to-Order Product Families"
and DFM and Build-to-Order for high-mix/low-volume environments at  http://www.design4manufacturability.com/low-volume-high-mix.htm

• Standard products can be build to-order without forecasts or inventory and specials can be mass-customized on-demand; see articles on Build-to-Order and Mass Customization

• Cut order fulfillment time in half while lowering inventory: see http://www.design4manufacturability.com/order-fulfillment.htm
• Inventory carrying costs can be eliminated
• Procurement costs can be reduced with automatic, on-demand resupply
• Better responsiveness leads to more sales

• Implement Build-to-Order and Mass Customization to build products on-demand without forecasts or inventory

• Implement lean production (#2)
• Rationalize products (#5)
• Total cost measurements (#8) to quantify overhead costs
• Keep control of manufacturing in-house or with vendor/partners; avoid long and distant supply chains; avoid off shore manufacturing
•  

• Standard part lists can be 50 times less than proliferated lists; see Standardization Results
• Standard parts are easier to get and fewer types need to be purchased; see Standardization Benefits

• Economies of scale result from larger purchases
• Material overhead of the standard parts can be one-tenth that of proliferated lists

• Implement Standardization with a practical procedure has been developed to standardize part and materials for new designs

• Rationalize products (#5) to eliminate or outsource the most unusual products that have the most unusual parts and materials
• Total cost measurements (#8) to justify standardization efforts and encourage picking standard parts
• Don’t merge acquired products into the same plant or build others’ products; see article on Negative Effects of Mergers and Acquisitions
   

5. Product Line Rationalization Cost Reduction

• Implement Product Line Rationalization and focus on the most profitable products as discussed in the section: How Rationalization can Triple Profits!

• Eliminate the "loser tax" on cash-cows to subsidize low-margin products
• Identify and remove products that are losing money on a total cost basis
• Reduce overhead demands and costs for hard-to-build "loser" products
• Free up valuable resources to work on cost saving efforts in engineering (#1), operations (#2 and #3), and supply chain management (#6)

• Implement Product Line Rationalization to eliminate or outsource low-profit products that have high overhead demands and are not compatible with cost reduction strategies

• Product Portfolio Planning focuses new product development
• Total cost measurements (#8) to identify opportunities and supports rationalization decisions
   

• Supply Chain Simplification can greatly simplify Supply Chain Management
• Spontaneous supply chains can pull parts into production on-demand without forecasts or inventory

• Material overhead can be reduced by a factor of 10 for standard parts and materials
• Purchasing leverage results from high quantities of standard parts
• Automatic resupply eliminates forecasts, purchase orders, inventory, and expediting costs

• Design products around standard parts to simplify Supply Chain Management
• Standardize parts to focus Supply Chain Management on high-volume, easy to get parts
• Rationalize away the most unusual products which have the most usual, hardest-to-get parts
• Establish Vendor/Partnerships, which saves more money than low-bidding

• Total cost measurements (#8) to encourage and justify standardization and rationalization
• Don’t merge acquired products into the same plant or build others’ products; see article on Negative Effects of Mergers and Acquisitions
   

• The Cost of Quality can be 15% to 40% of revenue;

• Quality costs can be greatly reduced; in some cases reducing quality costs can double profits

• Eliminating quality costs starts with designing in quality
• Quality costs in manufacturing can be eliminated with Six-Sigma programs
• Rationalizing away unusual products raises net factory quality and avoids wasting quality resources on inherently lower quality products

• Total cost measurements (#8) to quantify the Cost of Quality
   

• Total cost measurements are imperative to encourage and support the above activities to reduce all cost categories

• All the above cost reduction activities are encouraged and supported; the results are quantified, thus encouraging more total cost reductions.

• Implement total cost measurement with the easy-to-implement cost driver approach

• Until total cost can be quantified, everyone must make decisions based on total cost thinking
• Senior management understands the importance of quantifying total cost, implements total cost measurements, and encourages all cost decisions to be made on basis of total cost
   
•  

OTHER VALUABLE ARTICLES:

 New 2021 article: Design to scale up millions When Needed
without supply shortages or production bottle-necks
If busy, go to: http://design4manufacturability.com/scalability.htm 
 If  busy, go to http://www.build-to-order-consulting.com/scslsbility.htm 

Don't try to remove cost after the product is designed because cost is designed into the product and hard to remove later; see article on How Not to Lower Cost.  See new article on Seven Resons why "cost reduction" after design doesn't work at http://www.design4manufacturability.com/cost_reduction.htm

Don't use low-bidding, which only appears to save one category of cost, but can substantially raise many less-obvious costs and compromise other important goals like quality, delivery, and missing out on the major contributions that vendor/partners can make when they help product development teams design products; see article on Low-Bidding.

Don't offshore manufacturing for cost, which will not result in a net cost savings because of hidden overhead costs and because it inhibits, compromises, or thwarts 6 out of the 8 cost reduction strategies (presented on the home page) due to the following reasons:

Offshoring manufacturing separates manufacturing from engineering and thus thwarts Concurrent Engineering and compromises the 80% of the cost determined by the design.  Further, transferring, supporting, and dealing with quality and delivery problems of remote manufacturing absorbs many resources in engineering (in one case, 75%), manufacturing, and purchasing whose time would be better spent developing low-cost products.  See Cost Reduction by Design summary and the article Design for Manufacturability

Offshoring manufacturing to distant contract manufacturers increases the delivery time, which makes it hard to pull parts just-in-time and makes build-to-order impossible.  Further, parts may be batched for shipping, which is opposed to the one piece flow aspects of Lean Production.  Finally, offshoring manufacturing removes production from the control of the OEM manufacturer. All of these effects conspire to:

• Compromise Lean Production; see Lean Production Cost Reduction summary and the article on Lean Manufacturing

• Make if impossible to implement Build-to-Order and Mass Customization; see Overhead Cost Reduction summary and the Build-to-Order article and Mass Customization article.

• Make it hard to implement standardization because contract manufacturers' preferred parts probably won't correspond to your standard parts, so, in order to realize the production benefits of standardization, part numbers may have to be changed, which may increase a company's part proliferation.

• Make it hard to optimize supply chains; see Supply Chain Management Cost Reduction summary and details in the article on offshoring.

• Make if hard to maximize quality and implement Six Sigma without data and control over manufacturing; see Quality Cost Reduction summary and the article Designing in Quality.

If all 8 cost reduction strategies are implemented, the cost savings will be much greater than appeared possible through offshoring. For more, see read the article on offshore manufacture.

Don't take prototypes into production without commercialization; Also see article on "How not to commercialize products"

Correcting counterproductive policies may be a prerequisite to designing Half-Cost Products.

Don't try to save cost with unethical business practices.  See the article: Good Ethics is Good Business.
====================================ies can help your company

Copyright 2441  by David M. Anderson

 For moformation call or e-mail:

Dr. David M. Anderson, P.E., fASME,
www.HalfCostProducts.com
phone: 1-805-924-0100
fax: 1-805-924-0200
e-mail: anderson@build-to-order-consulting.com

  Seminars   Consulting    Credentials  Client List  Articles    Books     Site Map