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An Introduction to Design for Manufacture and Assembly

Course Overview

The key difference between FMEA and DFMEA is that FMEA is used for products, processes and services in organizations whereas DFMEA is used only for designs of products.

Design for Manufacture and Assembly (DFMA) can be the difference between making a loss and making a profit. This course aims to introduce the quantitative assessment of not just DFMA but Design for cost effective DFMA.

The course is particularly valuable for Engineers and Engineering Managers who are unfamiliar with formal DFMA assessment. The Participants will gain an understanding of Design for Manufacture (DFM) and Design for Assembly (DFA) focusing on numerical assessment leading to Part Minimization and Design Efficiency. The training focuses on DFMA techniques which reduce product cost through Design and Manufacture improvements.

FMEA stands for Failure Mode Effects Analysis. FMEA is an approach to identify all possible failures in a design, in operations or assembly processes and in a product or service. The methodology of FMEA categorizes all failures based on the likelihood and severity of the failure. “Failure mode” refers to any defects or errors in design, process, or item, which affect the customer. Meanwhile, effects analysis refers to the study of the consequences of the failures.

Furthermore, FMEA documents existing knowledge and actions related to risks of failures and uses them to motivate continual improvement. FMEA usually begins at the earliest theoretical stages of design and continues throughout the life span of the product or service.

The course is supported by comprehensive notes and DFMA analysis templates to enable the attendees to undertake their own formal DFMA process post training. Multiple DFMA worked examples are undertaken to ensure the attendees gain a broad comprehension of the methods.

Course Structure

The course is broken down into four 1-hour Webinar sessions, an overview follows:

Session 1

Introduction to the course

Design for Assembly

Design for Manufacture

Principles of Design for Manufacture and Assembly

Design for Manufacture and Assembly Process

Summary and Q&A

Session 2

Worked DFMA example
Complexity
Functional Assessment
Assembly Error Assessment
Handling Assessment
Orientation Assessment
Secondary Assessment

Summary and Q&A

Session 3

Live DFMA creation worked example Part 1

Summary and Q&A

Session 4

Worked example part 2
Numerical Assessment
Re-Design
Re-Assessment

Summary and Q&A

Tailored programs to your Company’s needs, with company specific examples, are available upon request.

NB: Tunley Engineering will issue course notes to all Attendees prior to the training, questions during the Webinar training can be submitted through the live chat and or via email.

  • “I am currently on my first run of ladder in management in the manufacturing industry, I found the root cause analysis session a great tool to have learnt, the learning was delivered in a confident approach, and the content was well thought out and structured and no question was overlooked, not only did I get an insight into problem solving, but a lesson in how to deliver in a confident and professional approach without being too ambiguous."

    Richard Corp, Manufacturing Team Leader, Optima Systems

  • “Tunley Engineering has delivered a thorough review of our Engineering process and performance in a very short period of time with the key steps identified that we need to take in order to move our team to the next level. Our Engineering function is critical to ensuring we deliver what our customer needs, on time and to the highest standards – our work with Tunley Engineering is part of our continuous improvement strategy for this area of our business.”

    Louise Hazel, Managing Director, IPU Group Ltd

  • “Tunley Engineering is a great way to sharpen any engineering team, whether they are part of a massive corporate structure or a smaller team. Their method of instruction strays far from the dry methods of old, in which you are simply spoken to and not engaged. With Tunley Engineering, the teaching process is much more interactive with lessons being structured more like workshops than university-style classrooms."

    Jordan Pulido, Project Engineer II, Ausco Inc

  • "We hired Tunley to help debug our engineering processes and to improve delivery time for our custom engineered systems. William Beer took the time to do a thorough survey of our existing engineering activities and was able to quickly understand the nature of our processes. He recommended changes that were easy to implement and which gave us immediate positive results."

    Thomas Mee, CEO, Mee Industries Inc.

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