Program Overview
This program helps experienced automotive engineers transform product designs by integrating DFM and DFA principles. Through real-time analysis of starter motors and alternators, engineers will identify flaws, streamline manufacturing and assembly, and enhance design quality. The course promotes practical learning through cross-functional collaboration, case studies, and live in-house component reviews—equipping teams to deliver leaner, more cost-effective, and assembly-friendly automotive products.
Features
- Understand core DFM and DFA concepts and their interdependencies.
- Understand core DFM and DFA concepts and their interdependencies.
- Identify design inefficiencies that impact cost, quality, and assembly.
- Apply integrated DFM/DFA strategies for cross-functional collaboration.
Target audiences
- Product Engineers
- R&D Engineers
- Operations Engineers
Curriculum
- 5 Sections
- 19 Lessons
- 1 Day
Expand all sectionsCollapse all sections
- Introduction to DFM & DFA5
- 1.1DFM & DFA Fundamentals: Key concepts, objectives, and benefits
- 1.2DFM vs. DFA: Key differences & interdependencies
- 1.3Automotive Industry Challenges: How DFM & DFA impact cost, quality, and efficiency
- 1.4Case Study 1: Analyzing a real-world automotive DFM/DFA failure (e.g., poor manufacturability leading to high scrap rates)
- 1.5Activity: Group Discussion – Participants identify DFM/DFA challenges in their own projects
- Advanced DFM Principles & Case Studies4
- 2.1DFM Considerations for Automotive Components: Material selection (lightweighting, cost vs. performance trade-offs); Manufacturing processes (casting, machining, injection molding, etc.); Tolerance stack-up & process capability; Surface finish & coating considerations
- 2.2Case Study 2: Optimizing manufacturability of starter motor housings; Analysis of a conventional vs. DFM-optimized design; Cost & defect rate comparison
- 2.3Live Study: Reviewing in-house starter motor components for DFM improvements
- 2.4Hands-on Exercise: Propose DFM changes for the in-house starter motor design
- Advanced DFA Strategies for Automotive Assembly4
- 3.1DFA Principles for Automotive Components: Part count reduction strategies; Standardization & modular design; Ease of handling, orientation, and joining methods (fasteners vs. snap fits); Design simplifications for robotic & manual assembly
- 3.2Case Study 3: Redesigning alternator assembly for ease of assembly; Original vs. optimized design comparison; Impact on assembly time & cost
- 3.3Live Study: Identifying DFA improvements in in-house alternator subassemblies
- 3.4Team Activity: Redesign a subassembly for DFA optimization
- Integrated DFM & DFA Approach4
- 4.1Combining DFM & DFA for holistic design improvements
- 4.2Case Study 4: Cost-benefit analysis of DFM/DFA-optimized starter motors & alternators
- 4.3Prototyping & Validation: Simulation tools & testing methodologies; Design reviews & feedback loops
- 4.4Interactive Exercise: Analyze a new automotive component design and present DFM/DFA improvements
- Conclusion & Action Plan2
Instructor
