Curriculum
- 8 Sections
- 46 Lessons
- 2 Days
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- Introduction to Design for Excellence (DFX)6
- 1.1What is DFX? Understanding DFMARST (Manufacturing, Assembly, Reliability, Serviceability, Testability)
- 1.2Benefits: Cost Reduction, Time to Market, Quality Improvement
- 1.3Why DFX is a strategic advantage in competitive industries
- 1.4Real-Life Examples: Aerospace, Automotive & Consumer Electronics case studies
- 1.5Real-Life Examples: Early DFX implementation vs. reactive redesign cost curves
- 1.6Group Discussion: “What failures have you seen due to lack of DFX in your products?”
- Design for Manufacturing (DFM)7
- 2.1Principles: Simplification, Modularity, Standardization, Tolerance, Material Choice
- 2.2Early design involvement and manufacturability checks
- 2.3DFM in scaling automotive vs. aerospace production
- 2.4Cost impact of overdesign and underdesign
- 2.5Example: Modular design in aircraft and vehicle manufacturing
- 2.6Example: Design simplification to avoid secondary operations
- 2.7Process Mapping Simulation: Redesign an existing part with DFM principles
- Design for Assembly (DFA)7
- 3.1Principles: Reduce part count, symmetry, mistake-proofing (Poka Yoke), self-fastening
- 3.2Top-down assembly planning
- 3.3Ease of assembly in high-mix/low-volume production
- 3.4Impact of poor DFA on throughput and quality
- 3.5Example: Consumer electronics vs. industrial assemblies
- 3.6Example: Modular assembly lines and labor cost reduction
- 3.7Activity: Component Re-Engineering: Apply DFA to improve an assembly process
- Design for Cost (DFC) & Total Lifecycle Economics5
- 4.1Target costing, part value analysis, cost drivers in material and logistics
- 4.2Total Cost of Ownership (TCO) across product lifecycle
- 4.3Example: Cost trade-off matrix: Local vs. imported materials
- 4.4Example: Boeing’s strategy for composite material cost vs. weight saving
- 4.5Cost Breakdown Activity: Participants estimate cost savings via design changes
- Design for Reliability (DFR)6
- 5.1Systematic reliability design, redundancy, early failure mode prediction (FMEA)
- 5.2Lifecycle focus: MTBF, MTTR
- 5.3Comparing failure rates in automotive vs. medical devices
- 5.4Redundancy in helicopters vs. single-point systems
- 5.5Example: Dashboard lifecycle design; FMEA on turbine components
- 5.6Exercise: FMEA Table: Map failure points in a familiar system
- Design for Serviceability (DFS)5
- 6.1MTTR, Predictive Maintenance, Ease of access in field repair
- 6.2Environmental impact and sustainability in service lifecycle
- 6.3Example: Modular servicing in consumer electronics
- 6.4Example: Predictive analytics for planned maintenance in heavy machinery
- 6.5Case Study Review: Compare field vs. shop-level serviceability designs
- Design for Testability (DFT)5
- Integration, Application & Cross-functional Alignment5
- 8.1Cross-functional DFX reviews
- 8.2System engineering mindset in DFX adoption
- 8.3Early vs. late-stage design reviews: Impact on schedule, cost, rework
- 8.4Collaborative design involving engineering, procurement, quality
- 8.5DFX Challenge Simulation: Teams solve a hypothetical product issue using DFMARST; Output: Identify changes across design for mfg, assly, cost, testing