SAE Professional Development Resource Guide 2013 - 28

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Design Engineering and Styling
DFM+A analysis leads to signiﬁcant reductions in production cost, without compromising product time-to-market goals, functionality, quality, serviceability, or other attributes. This seminar will include information on how DFM+A ﬁts in with QFD, Concurrent Engineering, Robust Engineering, and other disciplines. Each participant will receive and use the hard-bound authoritative reference textbook “Product Design for Manufacture and Assembly”, written by Geoffrey Boothroyd, Peter Dewhurst and Winston Knight. You are also asked to bring a calculator capable of making simple calculations.

Who Should Attend
Product engineers, manufacturing engineers, quality engineers, supplier quality engineers, validation and test engineers, and FMEA facilitators, trainers and consultants primarily in, but not limited to, the automotive industry may be interested in the update this webinar offers. Beginning engineers and advanced/senior engineers who must participate in FMEA, as well as those that manage FMEA activity, will also gain valuable insights. If you have a copy of the SAE J1739 standard, we recommend that you have it at hand for all three sessions of the webinar. If you do not own the standard and wish to purchase a copy, go to SAE J1739 Standard.

Topical Outline
Session 1 • Introduction and Potential Failure Analysis • Concerns about FMEA usage • Key change points applicable to Design FMEA • Terms and deﬁnitions • Pre-Analysis Preparation • DFMEA product functions and requirements • Failure Modes and Effects • Failure Causes • Current design controls - prevention • Current design controls - detection Session 2 • Risk Assessment • Severity ranking criteria - emphasis on vehicle level • Occurrence ranking criteria - emphasis on what’s known and unknown about design • Detection ranking criteria - emphasis on method and timing of evaluation • Risk Priority Numbers - secrets RPN won’t tell • Severity x Occurrence - back to the beginning • Severity AND Occurrence - go for a meaning, not a number • Other risk assessment criteria Session 3 • Risk Mitigation • FMEA general requirements • DFMEA outputs • DFMEA form and example • Special characteristics and DFMEA • Writing effective action plans to mitigate risk

Learning Objectives
Upon successful completion of this course, you will be able to: • Perform Design for Assembly (DFA) Analysis using the BDI Manual (Worksheet) Method • Perform DFM Analysis (manufacturing cost estimation) • Apply Design for Service (DFS) Principles • Reduce your company’s production costs by analyzing and eliminating the factors that greatly affect the time, cost, and quality of manufacturing, assembly and service processes • Utilize effective analysis, brainstorming, and trade-off techniques for redesigning assemblies and subassemblies

Who Should Attend
You should attend if you are a product designer, product engineer, or manufacturing engineer. Individuals involved in a new or ongoing product development process will beneﬁt by learning how to help synchronize and optimize fabrication and assembly activities. This course is most effective when attended by product development teams. However, this is not a requirement for attendance.

Topical Outline
DAY ONE • What is DFM+A • The history of DFM+A • The various “Design fors” • Why companies are using DFM+A • DFM+A success stories • DFM+A beneﬁts • Key factors in ensuring DFM+A success • DFA Good Design Principles • The Boothroyd Dewhurst Design for Manual Assembly Method • Using the manual handling and insertion tables • Determining theoretical minimum part count • Filling in the BDI DFA worksheet • Computing the DFA Index • DFA Baseline Analysis Exercise (Pneumatic Piston) • Redesign Project (Pneumatic Piston Assembly) • Developing design concepts • Identifying conservative and “stretch” designs • Selecting the best DFA concept • Analysis of redesign • Presentation of team results • General Approach to Manufacturing Cost Estimation • Manufacturing cost drivers • Estimating piece cost • Cost calculation exercise • BDI Design for Manufacture (DFM) Cost Estimation • Injection molding cost algorithms • Sample calculation • Exercise (analyzing part from pneumatic piston)

Instructor: Bill Haughey
Fee $525

.6 CEUs

Design for Manufacturing & Assembly
1 Day - I.D.# 95032 2 Days - I.D.# 92047

This seminar is available in one-day or two-day formats. The two-day format includes an in-class workshop project which consumes most of the second day. Design for Manufacturing and Assembly (DFM+A), pioneered by Boothroyd and Dewhurst, has been used by many companies around the world to develop creative product designs that use optimal manufacturing and assembly processes. Correctly applied,

3 ways to get a no-obligation price quote to bring a course to your company • Call SAE Corporate Learning at 1-724-772-8529 • Fill out the online quote request at www.sae.org/corplearning • Email us at Corplearn@sae.org
SAE Professional Development Resource Guide 2013

Table of Contents for the Digital Edition of SAE Professional Development Resource Guide 2013
