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Make Informed Design Decisions Avoid Costly Design Mistakes Joe Barkai July 24, 2014

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Page 1: Make Informed Design Decisions Avoid Costly … Informed Design Decisions Avoid Costly Design Mistakes Joe Barkai July 24, 2014

Make Informed Design Decisions

Avoid Costly Design Mistakes

Joe Barkai July 24, 2014

Page 2: Make Informed Design Decisions Avoid Costly … Informed Design Decisions Avoid Costly Design Mistakes Joe Barkai July 24, 2014

Waste in Design, Fabrication and Assembly

2 Joe Barkai

0%

20%

40%

60%

80%

Preventable Other Issues

Assembly Issues

Costing Issue

Error Discovered During Simulation / PrototypingError: Geometry, Drawing, BOMManufacturability

Mistake Proofing

Production Line Problems

Supplier Capabilities

Source: Geometric Global

Page 3: Make Informed Design Decisions Avoid Costly … Informed Design Decisions Avoid Costly Design Mistakes Joe Barkai July 24, 2014

Too many product variants

New technologies, materials and

processes

Multiple domains / multidisciplinary

constraints

Too many disconnected design tools

Inability to capture and implement best practices

Aging workforce – the big brain drain

Manufacturing topics come little too late in the design

process, other considerations even later

Never enough time (or budget…)

It Isn't That Easy

3 Joe Barkai

Page 4: Make Informed Design Decisions Avoid Costly … Informed Design Decisions Avoid Costly Design Mistakes Joe Barkai July 24, 2014

Direct costs

Design iterations

Manufacturing and assembly ramp up

Tooling and tool breakage

Scrap, energy and other waste

Poor quality!

Cost of poor quality

Service & warranty

Brand image

Money Down The Drain

4 Joe Barkai

Page 5: Make Informed Design Decisions Avoid Costly … Informed Design Decisions Avoid Costly Design Mistakes Joe Barkai July 24, 2014

Why Is It So Difficult To Make Better Decisions?

5

Your processes are ad-hoc

Your systems are fragmented

Your data is messy

Your expertise networks are disconnected

You make critical decisions too late in the process

Joe Barkai

Page 6: Make Informed Design Decisions Avoid Costly … Informed Design Decisions Avoid Costly Design Mistakes Joe Barkai July 24, 2014

Formalize and apply design and manufacturing

process knowledge uniformly and consistently

Drive up reuse

Frontload decisions

Automate decisions

Leading Manufacturing Companies Get It

6

Source: Joe Barkai, 2013

6%

16%

19%

19%

39%

0% 5% 10% 15% 20% 25% 30% 35% 40%

Maximize Design Reuse

Use Knowledge Based Design Rules

Maximize Communication and Collaboration

Implement Best Practices

Frontload Decisions

Joe Barkai

Page 7: Make Informed Design Decisions Avoid Costly … Informed Design Decisions Avoid Costly Design Mistakes Joe Barkai July 24, 2014

Design for Manufacturing In Practice

7 Joe Barkai

3D Model

Manufacturability report

Geometric’s DFX solution

Manufacturability and Cost drivers

Optimized

design

Ready

For Manufacturing

Design

Sourcing

Supplier Capability

Global Best practices

Input Output Create

Modify

Competency

Knowledge Capture

Elements of cost

Manufacturing Service

Knowledge database

Page 8: Make Informed Design Decisions Avoid Costly … Informed Design Decisions Avoid Costly Design Mistakes Joe Barkai July 24, 2014

Design for Manufacturing Excellence

Page 9: Make Informed Design Decisions Avoid Costly … Informed Design Decisions Avoid Costly Design Mistakes Joe Barkai July 24, 2014

Capture and share knowledge throughout

the organization

Encapsulate best practices as design, process

and business rules

Validate downstream requirements early in the

design phase

Eliminate unnecessary features in designs

Drive design and process standardization

Early and systematically

Design for Manufacturing Excellence

9 Joe Barkai

Page 10: Make Informed Design Decisions Avoid Costly … Informed Design Decisions Avoid Costly Design Mistakes Joe Barkai July 24, 2014

Accelerating Design Time

10 Joe Barkai

We have integrated GeomCaliper into our design process and it has resulted in a

75% reduction in the time taken to check wall thickness of complex models.

Scott Lanski

Design Manager

Chrysler

As a result, we successfully reduced 75% of the checking time of the wall

thickness to enhance the efficiency and effectiveness of our design improvement

before the release of drawings.

Kaoru Mizoroki

Group Manager Design & Development Center

Toshiba

The net reduction in total time for checking of product design by using DFMPro

software is approximately 15%.

Amol Mane

Manager, Engineering Department

Sulzer India

Page 11: Make Informed Design Decisions Avoid Costly … Informed Design Decisions Avoid Costly Design Mistakes Joe Barkai July 24, 2014

Improving Manufacturability and Quality

11 Joe Barkai

Our designers are able to detect & correct 80-85% of the issues that they

couldn't detect earlier in the CAD software. Due to this we are able to see a

significant improvement of quality levels in the design process.

Kamalakar Muralidhar

Asst. Manager – Design

L&T MPS

[The software] is allowing us to discover those hidden critical areas that

otherwise may have gone undetected.

Scott Lanski

Design Manager

Chrysler

[The software] helped us to reduce our part checking time by almost 60% while

ensuring robust quality of design.

Randy Scherger

Senior Tool Designer

Rockwell Automation

Page 12: Make Informed Design Decisions Avoid Costly … Informed Design Decisions Avoid Costly Design Mistakes Joe Barkai July 24, 2014

Tooling

Supply chain

Downstream Processes

12 Joe Barkai

This analysis has helped us to identify critical issues during the design stage and

also has helped us to design feasible tools for the assembly process.

Hugo Cisneros

Global DFA Engineer

Jabil Circuits de Mexico

[The software] helped us to develop analysis … to perform and validate that

sheet metals or molded parts can be cleaned up in order to receive reliable parts

from vendors… We can identify, correct, fix or clean all features on a part that

has an issue and help, and educate customers for best practices in terms of

design.

Hugo Cisneros

Global DFA engineer

Jabil Circuits de Mexico

The results of tools aid us in improving our design reducing issues downstream.

Paul LaLinde

Principle Staff Engineer

Motorola Solutions

Page 13: Make Informed Design Decisions Avoid Costly … Informed Design Decisions Avoid Costly Design Mistakes Joe Barkai July 24, 2014

Capturing and Sharing Knowledge

13 Joe Barkai

Earlier we were using a manual process for DFM reviews which involved

using checklists and knowledge from experienced engineers. The process

required lot of time from experienced engineers and still was error prone.

Also, the designer had difficulties in checking the design for issues related to

draft angle, wall thickness etc. due to limitations of the CAD software itself.

Kamalakar Muralidhar

Asst. Manager – Design

L&T MPS

This tool helps our design teams understand the process involved in

manufacturing. In other words, helps them understand how to design for

manufacturing. This leads to a significant reduction in design iterations due to

issues with manufacturability and reduction in design checking time.

SK. Pradeep Kumar

Director - E&T Capabilities

whirlpool

Page 14: Make Informed Design Decisions Avoid Costly … Informed Design Decisions Avoid Costly Design Mistakes Joe Barkai July 24, 2014

The Knowledge Based Enterprise

14 Joe Barkai

Source: Duncan Greenman, Airbus UK

Page 15: Make Informed Design Decisions Avoid Costly … Informed Design Decisions Avoid Costly Design Mistakes Joe Barkai July 24, 2014

The Knowledge Based Enterprise

15 Joe Barkai

Since 2005, Disher Design has employed GeomCaliper on every plastic part

design to ensure that we have optimized every possible area in our product

designs prior to tooling.

Mike Yandell

Design Manager

Disher Design & Development

Page 16: Make Informed Design Decisions Avoid Costly … Informed Design Decisions Avoid Costly Design Mistakes Joe Barkai July 24, 2014

What To Expect

16

Rework reduction 5%-15%

Tooling savings 5%-12%

Productivity improvement 5%-10%

Collaboration efficacy 2%-7%

Scrap reduction 1%-2%

Warranty savings 1%-2%

Joe Barkai

Page 17: Make Informed Design Decisions Avoid Costly … Informed Design Decisions Avoid Costly Design Mistakes Joe Barkai July 24, 2014

Where Do I Start?

17 Joe Barkai

Optimized

•Simulation and

analysis tools

•Design for X

optimization

•Continually analyzed

and optimized

•Retire stale/incorrect

rules

Managed

•Enterprise-wide

knowledge base

•Cross-product tool

integration

•Automated

validation&

recommendations

Standardized

•DFX Program Office

established

•Integrated into PDP

•Design rules & best

practices applied

systematically

•Incl. manufacturing &

supplier capabilities

•Begin integration with

CAD tools

Formalized

•DFX metrics

established

•Design rules and

best practices

defined

•Little cross-product

sharing and

collaboration

Ad-Hoc

•No formal process

•Some rules of thumb;

used inconsistently

•Incorrect “best

practices” exist

Page 18: Make Informed Design Decisions Avoid Costly … Informed Design Decisions Avoid Costly Design Mistakes Joe Barkai July 24, 2014

Approach DFM systematically

Identify weaknesses to establish a baseline

Outline a continuous improvement plan

Establish an ROI framework

Build DFM into your product development process

Best Practices

Maintain cross-product centers of competence (COC)

Use advanced software tools for simulation, analysis and design validation

Maintain a “live” knowledge base of design rules and best practices

Automate decisions

Promote systems and data interoperability, including master data management and common taxonomies

Essential Guidance

18 Joe Barkai