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DFMA with Current Product: It’s never too late
S t e p h a n i e F re i e r
9/11/2018
“The time for action is now. It’s never too late to do something.”
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Agenda• Early Insights
• Rework
• Quoting
• Product Improvement
• Process Improvement
• Conclusion
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New Product Integration
• Bring voice of manufacturing to New Product Development Teams
• Adoption of DFMA
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FRFaucet Assembly Manufacturing
Engineering
➢ Rework➢ Quoting➢ Product
Improvement➢ Process
Improvement5
Rework
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Choices
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DFA Results
Scrap Full Assembly Costs Rework Costs Salvage Costs
Assembly Labor Time per unit 0 10 min 4.5 min
Time to Replenish Inventory 4+ weeks 2 weeks 3 weeks
% Cost of product value (including labor
for rework) 100% 18% 53%Notes/Risks: -Will run short on some
parts - Potential for damage to finished components during rework- Potential for new packaging needed
- Potential for damage to finished components during rework
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ReworkLabor Estimates
Risks
Customer/Business Impact
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Quoting
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FR
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Enable Success Through Quoting
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FR
Additional Benefits
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QuotingAccuracy
Data Driven Rates
Faster RFQ response
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ProductImprovement
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Assembly Time Reduced
Assembly Efficiency
Per Unit Savings
25.3% 34.9% 27%
Product Improvement in Action
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Product ImprovementIdea generation
Justification
Validation
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ProcessImprovement
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FR
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Process ImprovementLean
Idea Generation
Quick Analysis
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σ
FR
Summary
• Rework
• Quoting
• Product Improvement
• Process Improvement
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