DFA Evaluation Points

Components

One of the main objectives of DFA is to design the device with as few individual components as possible, as fewer individual components will make the device easier to assemble. A top tip is to list all your components and their primary functions. If there are duplicates and they are close to each other in the system spatially, then you can work to eliminate one of them by moving them closer together so they share this component. Another approach is to look at each component of a system and ask what else it can do i.e. dual functionality. For example, a silicone hose can not only act as a fluid pathway but may also as a spring along its length. Trying to achieve dual functionality with every component in the system where possible will ensure your product design is as lean as possible.

Assembly Operations

Minimising the number of operations required to assemble the product makes the process more efficient and saves time. This includes minimising how often the components need to be reorientated during assembly. Reorientation is a non-value add operation and so should be eliminated where possible. It also extends to how the components are fixed together. Can they be clipped together using features on their surface or do they require another additional process, such as welding?

Component Handleability

Components that are difficult to work with will slow down the assembly process and increase the potential for mistakes. Therefore, the components of your new product should be as easy as possible to hold, move, insert, and fasten during assembly. Don’t forget the use of jigs and tools to help!

Assembly Process

The overall assembly process layout and flow should be as lean as possible. Remember to include quality inspection points so you capture defects at the earliest opportunity before you add any more value to a defective item. Error-proofing techniques such as employing jigs, asymmetric components, genderless components etc. allow for quick and easy assembly steps.

Packaging

DFA should be extended to include the product packaging to avoid bottlenecks and ensure the product is delivered to the intended user undamaged.

DFA vs DFM

DFA and DFM (design for manufacture) are often treated together, but they are in fact distinct processes. DFM focuses on optimising the manufacturing of the individual product components, prior to assembly.

Design for Automated Assembly

Design for automated assembly (DFAA) involves all the DFA considerations mentioned above, but including evaluating each element against the capabilities and limitations of robots and vision systems.

Key take-aways

Incorporating an effective DFA process into your development project brings the following benefits:

• Faster to assemble final product
• Reduced material costs
• Optimised manufacturing and assembly costs
• Improved assembly process reliability
• Enhanced product quality
• Fewer mistakes
• Improved productivity

DFA brings an end-end solution to development of products as it enables creation of products that not only performs as intended but are also commercially viable.