Design For Manufacturing

Design for ManufacturingDFM with SuppliersCopyright 2003-2007 Raytheon Company. All rights reserved.R6σ is a Raytheon trademark registered in the United States and Europe.Raytheon Six Sigma is a trademark of Raytheon Company.R6s is a trademark of Raytheon Company.

Supplier DFM Objective Leverage supplier domain expertise Eliminate design modifications required for schedule, cost and/orproducibility Align to supplier capabilities and strengths Improve quality Reduce total costQuestions? Ask the expert at mailto::dfss@raytheon.comCopyright 2003–2007 Raytheon Company. All Rights Reserved.Page 00 - 2

Cost, Quality & Cycle Time System requirements10 0 Materials90 Tolerances 8 0 Test specifications70 Component count60 Competitive bidding Spec exceptions Learning curve Automation Process optimization SPC Lean50ActualInfluence onTotal Cost403020%201015%5%70%%Courtesy of Monroeand g30%TraditionalUnderstandingof Total CostTheThe designdesign phasephase providesprovides thethe bestbest opportunityopportunity toto reducereduce totaltotal costcostCopyright 2003–2007 Raytheon Company. All Rights Reserved.Page 00 - 3

Maximizing Customer Value Through DFM We have a shared responsibility to provide the best value to ourcustomers Optimum design aligns to both the customer requirements and themanufacturing capabilities DFM connects the designers responsible achieving customerrequirements to the manufacturing and supplier teams responsible fordelivering the pyright 2003–2007 Raytheon Company. All Rights Reserved.ManufacturingCapabilitiesDFMPage 00 - 4

The Yield Impact from Improving MarginRelax requirements and/or improve processSigma Level Impact on First Pass Yield# of parts/steps 3σ 4σ 5σ right 2003–2007 Raytheon Company. All Rights Reserved.Page 00 - 5

Some Root Causes for Redesign Insufficient performance margin– Design requirements are not matched to existing supplier or manufacturingcapabilities– Design is too sensitive to manufacturing variation Cost is too high– Design is difficult to fabricate– Design is difficult to assemble– Requirements drive utilization of expensive manufacturing processes– Poor yield– Designers are unfamiliar with commodity cost drivers Raw materials are difficult to procure Poor communication and/or inadequate review of requirementsCopyright 2003–2007 Raytheon Company. All Rights Reserved.Page 00 - 6

The Help We Need From Our Suppliers Provide a DFM review of incoming designs and clearly communicateyour manufacturing capabilities, design cost drivers, concerns,exceptions and any opportunities for cost and risk reduction– Designers have the system performance expertise—how variation in thedesign affects performance Suppliers have no visibility into system performance– Suppliers have the fabrication, assembly and test expertise—how muchvariation their processes create Tolerance defines method! Method impacts cost! Designers have little visibility into supplier process capabilities System performance expertise and knowledge of supplier processcapabilities are both necessary to optimize any design for cost andperformanceSuppliersSuppliers cancan helphelp designersdesigners understandunderstand howhow theirtheir requirementsrequirements drivedrive productproduct cost,cost,scheduleschedule andand qualityquality risk—andrisk—and wherewhere improvementimprovement opportunitiesopportunities existexistCopyright 2003–2007 Raytheon Company. All Rights Reserved.Page 00 - 7

Performance-Cost TradesSystem PerformanceDesigners know performance vs. tolerance, suppliers know cost vs. tolerance; neither knowperformance vs. cost—communication between the two teams is necessarySensitive design, sufficient marginavailable to relax design spec andachieve target costRobust design, significant marginavailable to relax design spec andachieve cost well below tMarginal design, solution throughredesign, spec rebalance, and/orincreased costSupplier/manufacturingcost at design specificationCostCan the targetcost be achieved?Copyright 2003–2007 Raytheon Company. All Rights Reserved.Page 00 - 8

Performance-Tolerance Trades:Design ExpertisePerformance margin defines the design tolerance required; different designs have differentcharacteristics; only designers will know if the performance-tolerance sensitivity is highSystem PerformanceRobust design, significant marginavailable to relax design spec andachieve cost below targetSensitive design, sufficient marginavailable to relax design spec andachieve target costMarginal design, solution throughredesign, spec rebalance, ortighter tolerancesMinimumfunctionalrequirementWill this toleranceachieve target cost?DesignspecificationCopyright 2003–2007 Raytheon Company. All Rights Reserved.TolerancePage 00 - 9

Cost-Tolerance Trades: Supplier ExpertiseCostDesign tolerance defines the process required; small changes in tolerance may allow alignmentto lower cost processes; only suppliers will know if the cost-tolerance sensitivity is highHigh precision, high cost processBest value inthis tolerancerangeModerate precision, moderatecost processBest value inthis tolerancerangeLow precision, low cost processBest value inthis tolerancerangeToleranceFlexibilityFlexibility inin tolerancingtolerancing cancan provideprovide opportunitiesopportunities toto alignalign toto lowerlower costcostprocesses;processes; designersdesigners needneed toto understandunderstand thethe cost-tolerancecost-tolerance tradetrade spacespaceCopyright 2003–2007 Raytheon Company. All Rights Reserved.Page 00 - 10

DFM Review Content Communicate knowledge of your process capabilities where there isconflict between capability and requirement Provide estimates of cost opportunities if requirements are relaxed– How will relaxation affect yield and yielded unit cost?– How will relaxation affect process selection and process cost/unit? Highlight manufacturability concerns and propose alternatives if possible––––Unique or special processesDifficult to use/procure materialsDifficult to measure performance requirementsLack of commonality Low volume designs—incorporate supplier concerns and ideas forimproving manufacturability Moderate to high volume designs—incorporate cost impact estimates ofprocess capabilities, yields, scrap and rework cost relative tospecificationsCopyright 2003–2007 Raytheon Company. All Rights Reserved.Page 00 - 11

DFM Example: Low VolumeDFMA ReviewTemplateUse the template to highlight to designers the cost-drivers caused byspec requirements, assembly requirements, special and/or expensiveprocesses, etc.; propose your ideas on how to reduce cost, touch time,etcCopyright 2003–2007 Raytheon Company. All Rights Reserved.Page 00 - 12

DFM Example: Med-High VolumeUse the template to highlight to designers the cost-drivers and yieldissues caused by spec requirements, process capabilities, assemblyrequirements, etc.; propose your ideas on how to reduce cost, touchtime and/or improve yieldCopyright 2003–2007 Raytheon Company. All Rights Reserved.Page 00 - 13

Call to Action Provide a DFM review of incoming designs to clearly communicate yourmanufacturing capabilities, design cost drivers, concerns, exceptions andany opportunities for cost and risk reduction– Suppliers have the fabrication, assembly and test expertise—how muchvariation each of their processes create– Designers have the system performance expertise—how variation in thedesign affects performance– Both inputs are required to optimize cost and minimize risk Share knowledge of your process capabilities with our designers tooptimize any design for producibility, cost and performanceSuppliersSuppliers mustmust helphelp designersdesigners understandunderstand howhow theirtheir requirementsrequirements drivedrive productproductcost,cost, scheduleschedule andand qualityquality risk—andrisk—and wherewhere improvementimprovement opportunitiesopportunities existexistCopyright 2003–2007 Raytheon Company. All Rights Reserved.Page 00 - 14

References and ResourcesTextbooks: Product Design for Manufacture & Assembly: Boothroyd, Dewhurst &Knight The Mechanical Design Process: Ullman & UllmanOn the Web: www.dfma.comQuestions? Ask the expert at mailto::dfss@raytheon.comCopyright 2003–2007 Raytheon Company. All Rights Reserved.Page 00 - 15

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Cost-Tolerance Trades: Supplier Expertise Tolerance Cost High precision, high cost process Design tolerance defines the process required; small changes in tolerance may allow alignment to lower cost processes; only suppliers will know if the cost-tolerance sensitivity is high Moderate precision, moderate cost process Low precision, low cost process