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Moving from Reactive to Proactive Design: Adopting a Holistic Approach to Design for
Manufacturability (DFM)
November 19, 2015
Confidential 2
About Geometric
Financial Year – Apr to Mar
104.8122.82
137.15 130.11 132.98
31.67
44.6950.42 51.28 47.62
0
40
80
120
160
200
FY11 FY12 FY13 FY14 FY15
Revenues in USD Mn
Geometric 3DPLM
180.61 187.57 167.51
136.48
181.39
• Software Services: PLM/ PDM/ CAD/ CAM/ CAE/ Digital Mfg. and geometry applications
• Engineering Services: Product, Manufacturing and Industrial Engineering
• Geometry Technology Solutions: For efficiencies in design, manufacturing and visualization
• Electronics and Embedded Systems: Software and hardware design, development and validation
Services and Solutions Portfolio
Gold Tier Partner since 2004
Geometric is a specialist in the domain of
Engineering IT, Engineering Services and
Embedded Systems. Our portfolio of solutions
powered by IP tools and technologies, helps
global manufacturers achieve their business
goals and stay ahead of competition.
Confidential 3
Global Presence
Delivery locations: 13
Scottsdale, AZ
Detroit, MI
Moline, IL
Peoria, IL
Dallas, TX
Montreal, Canada
Toulouse, France
Gothenburg, Sweden
Stuttgart, Germany
Brasov, Romania
Tokyo, Japan
Shanghai, ChinaBengaluru
ChennaiPune
MumbaiCorporate Headquarters
Paris, France
Bristol, UK
Munich, Germany
Eindhoven, Netherlands
Workforce Distribution
INDIA4200+ N. AMERICA540+ EUROPE175+ APAC140+
Hyderabad
Sales locations: 8
Confidential
Our Marquee Customers Include…
of the top 10 Global Fortune automotive OEMs
of the world’s leading aerospace
OEMs and suppliers
of the top 10 offhighway equipmentmanufacturers
of the world’sleading Industrial Equipment
Manufacturers
Over decade long relationships with our top 10 customers
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Partnering with our customers in all major manufacturing and engineering zones
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Services and Solutions Portfolio
PLM Solutions and Services
• PLM Consulting
• PLM Implementation, Upgrades & Migration
• PLM Customization
• Interoperability Solutions
• Application Management Services
CAx Solutions and Services
• Software Product Engineering
• CAD/ CAM/ CAE Solutions
• KBE Solutions
• Web based Solutions
• Quality Engineering & Testing
Global EngineeringSolutions
• Product Engineering
• Manufacturing Engineering
• Industrial Engineering
• Lifecycle Services
• Value Services
Embedded Systems
• Functional and Detailed Design
• Simulation and Modeling
• Development and Implementation
• Test Automation, V&V
• Development support
IP Products and Technologies
• CAMWorks®
• DFMPro®
• *MBEWeb™
• eDrawings® Publishers
• Glovius®
• FeatureRecognition
• GeomCaliper®
• NestLib®
Consulting and development of software products and solutions for Geometry intensive applications
Global provision of outsourced
solutions & customer team augmentation
Consulting and systems
integration services for enterprise
solutions on all leading PLM applications
OOTB software products and technologies for efficient engineering
Design and development of domain specific embedded and electronic software systems
*MBEWeb is our joint solution with Anark Corp.
Moving from Reactive to Proactive Design: Adopting a Holistic Approach to Design for
Manufacturability (DFM)
November 19, 2015
Confidential 7
A design engineer’s life is tough - Address multiple downstream requirements during design
Is the thread engagement sufficient for the joint?
Is the required clearance maintained between the parts?
Is the fastener accessible for serviceability?
Can this fillet radius be achieved through the casting process?
Is the hole aligned properly?
Is the correct draft angle applied?
Is uniform wall thickness maintained?
Can this contact area lead to corrosion because of incompatible materials?
Quality
Environment
Reliability
Manufacturing Service
Assembly
Manufacturing
Assembly
Confidential 8
The ‘reactive’ design approach : let the supplier take care of manufacturability…
Design Guidelines
Confidential 9
The traditional DFM ‘checklist’ method addresses these issues but…
Traditional Method of handling DFM Reviews
• Maintaining DFM checklists, guidelines-handbooks
• Periodic training of designers
• Manual reviews of design (by self / peers / seniors)
• Consultations with manufacturing experts
Problems
• Manual reviews are time consuming
• Inconsistent design quality
• Need for proximity between design and
manufacturing engineers
Confidential
30% of all work effort was due to engineering changes… – Fricke et al
ECOs represent 20 to 50% of tool costs (around 100M USD in large projects) – Lincke, W. Simultaneous Engineering
ECOs consume one third to one half of engineering capacity – Soderberg, L.G. , Facing up to the engineering Gap. McKinsey Quarterly
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Traditional ‘reactive approach’ to DFM leads to expensive and time consuming engineering changes
Design & Engg
• Best Practice missing or in handbooks, hence not easily accessible!!
• 30%~50% Engg Capacity lost in making Engg Changes-ECs
Mfg. Engg
• Manual reviews & reporting is time consuming & error prone
• Smaller teams hence cannot review every design
Contract Mfg.
• Communicating engg changes to OEM is tedious
• Global manufacturing locations
• High cost of tooling & mfg. rework & production delays
Concept Design Development Production
Tooling
10X50X 100X
1000Xe.g. Recalls
e.g. Supplier toolingX
Source:
Confidential 11
DFMPro for Creo parametric ‘Proactive’ approach helps designers to make decisions early during design stage
SupplierCapabilities
EngineeringBest practices
Industry Best Practices Organizational Best Practices
Sourcing Manufacturing Service
Design Feedback
Prevent late changes
DFMPro for CreoParametric
EngineeringEfficiency
Rework Reduction
Knowledge Capture
Confidential
Addressing common manufacturing processes
Injection Molding
Sheet Metal
Machining
Castings
Assembly
Confidential 13
Demo : DFMPro for Creo Parametric
Confidential 14
Delivering benefits through ‘proactive’ DFM approach
Competency
• Reduction in design iterations• Savings in DFM analysis time
• Output with reduced number of defects by identifying at earlier stage in design
• Availability of global best practices• Framework to capture knowledge within
organization
• Central knowledge repository• Clear communication through
reports within departments and vendors
• Identification of areas in design which are difficult, expensive or impossible to manufacture
• Reduction in Rework cost
Confidential
Thank you!
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