Design for Manufacturing
Design for Manufacturing
DFM with Suppliers
Copyright ? 2003-2007 Raytheon Company. All rights reserved. R6 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/or
producibility ? Align to supplier capabilities and strengths ? Improve quality ? Reduce total cost
Questions??? Ask the expert at mailto::dfss@
Copyright ? 2003?2007 Raytheon Company. All Rights Reserved.
Page 00 - 2
Cost, Quality & Cycle Time
? System requ1ir0e0ments ? Materials 90 ? Tolerances 8 0 ? Test specifica7t0ions
? Component c6o0unt
? Competitive bidding ? Spec exceptions
50
Actual 40 Influence on 30
20
Total Cost 1 0
70%
20%
%
Courtesy of Monroe and Associates
Design 5%
? Learning curve ? Automation
? Process optimization ? SPC ? Lean
5% 15%
Manufacturing
Labor
30%
Materials
15%
50%
Traditional
Understanding
of Total Cost
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Copyright ? 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 our customers
? Optimum design aligns to both the customer requirements and the manufacturing capabilities
? DFM connects the designers responsible achieving customer requirements to the manufacturing and supplier teams responsible for delivering the products
Customer
Design
Requirements Process
Manufacturing Capabilities
QFD/VOC
DFM
Copyright ? 2003?2007 Raytheon Company. All Rights Reserved.
Page 00 - 4
The Yield Impact from Improving Margin
Relax requirements and/or improve process
# of parts/steps
1 10 30 50 100 150 200 219 250 300
Sigma Level Impact on First Pass Yield
? 3
? 4
? 5
? 6
93.3%
99.4%
99.98%
99.999966%
50.1% 12.6%
94.0% 83.0%
99.77% 99.30%
99.9966% 99.99%
---
DFM 73.2%
98.84%
99.98%
---
53.6%
97.70%
99.97%
---
39.4%
96.61%
99.95%
---
28.8%
--- DFA 25.6%
95.45% 95.03%
99.93% 99.92%
---
21.1%
94.35%
99.91%
---
15.4%
93.26%
99.90%
Copyright ? 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 manufacturing capabilities
? 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 requirements
Copyright ? 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 communicate your manufacturing capabilities, design cost drivers, concerns, exceptions and any opportunities for cost and risk reduction
? Designers have the system performance expertise--how variation in the design affects performance
Suppliers have no visibility into system performance
? Suppliers have the fabrication, assembly and test expertise--how much variation their processes create
Tolerance defines method! Method impacts cost! Designers have little visibility into supplier process capabilities
? System performance expertise and knowledge of supplier process capabilities are both necessary to optimize any design for cost and performance
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Copyright ? 2003?2007 Raytheon Company. All Rights Reserved.
Page 00 - 7
Performance-Cost Trades
Designers know performance vs. tolerance, suppliers know cost vs. tolerance; neither know performance vs. cost--communication between the two teams is necessary
System Performance
Performance margin
Minimum functional requirement
Can the target cost be achieved?
Copyright ? 2003?2007 Raytheon Company. All Rights Reserved.
Sensitive design, sufficient margin available to relax design spec and achieve target cost
Robust design, significant margin available to relax design spec and achieve cost well below target
Marginal design, solution through redesign, spec rebalance, and/or increased cost
Supplier/manufacturing cost at design specification
Cost
Page 00 - 8
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