Design for Manufacture (DfM)
Does this sound familiar? Our customers tell us that they need:
- to capture customer requirements,
- show feature level method of manufacture and inspection,
- proof that requirements have been fulfilled.
The challenges often include issues such as:
- customer requirements are unclear, often just a model is provided, drawings have errors or missing data, the drawing and model do not align.
- method of manufacture via the router lacks clarity, operation narratives are unclear, mistakes are made.
- visual and dimensional inspection lacks clear standards and gauge choices, often with no measurement verification.
We have developed a simple yet highly effective process to address these issues.
DfM – HERE’S THE DETAIL
Many businesses we see operate requirement capture through to manufacture engineering processes but when we look closer we find gaps in the rigour of these processes that result in rework, scrap and customer returns. The big worries are that customers do not always see some non-conformances and when they eventually find them a large scale problem takes place, threatening the credibility of the inspection and processes in the supplying company.
These issues exist in many businesses. We have a proven process to capture and control requirements, the translation into method of manufacture and the resulting measurement plan. Used in full this process leads to capturing data to prove measurement and manufacturing capability, reducing scrap, returns and getting a handle on true rework.
Most, if not all businesses, conduct measurement of their products. For most businesses there is the belief that the dimensions measured can be recorded as measured. Many businesses do not recognise the level of variation in the equipment, people and approach used to measuring features. This can introduce substantial error that exceeds the tolerance of the features being measured.
If your business does not have Gauge R&R data for the measurement systems you use, then you will subject to this variation and the risk that comes with it. The risks are generally summarised as reworking or scrapping conforming product and despatching non-conforming product in the belief that it conforms.
This is the just part of the challenge, however at UK | QMS we can help you assess your capabilities and solve measurement capability problems so that you can be confident in your measurement and to what extent it consumes tolerance. This is a key step before considering improving manufacturing capability.
Once the measurement system is capable, the big gains can take place, that is, improving manufacturing capability. At UK | QMS we take you through how to prove your machine capability, your setups and controls and proving your manufacturing capability. With reliable statistical data we can help you reduce variation and implement the right checks to improve quality.
FAIR (First Article Inspection Reports)
If you have First Article Inspection Reports that need processing and do not have the time or resource, we can help. Our team of Manufacturing Engineers will help you process the FAIRs, we can do this off site too to keep your costs down.
NPI (NEW PRODUCT INTRODUCTION)
When asked about NPI, many companies use copy and paste techniques and a very conservative approach to understand requirements. This is a risky business as we have seen many customers provide drawings and models that are misaligned or conflict and when it comes to pricing, many businesses make a best guess. The NPI process we offer is best used once we have completion the DfM process and is matured from the Manufacturing Capability process. It helps you define your product features, your costs and thus predict with confidence your profit margins and areas of profit risk.
With customer demands being increasingly stringent, this process helps gain confidence for your business through the eyes of your customer.
Contact us – how can we help your business….?