Unlocking Profit: How Neglecting DFM Could Cost You Thousands

Designing a product for manufacturing (DFM) isn't just about making sure your part looks good; it's about making sure it’s easy, cost-effective, and efficient to produce. Failing to incorporate DFM principles can lead to hidden costs that snowball throughout the production process.

What seems like small oversights in the design phase can quickly turn into expensive rework, delays, and even failed products. In fact, studies show that poor design choices can increase production costs by up to 30% or more.

In this post, we’ll explore why DFM is crucial for your product’s success and how applying it from the beginning can save you thousands of dollars in the long run.

What is Design for Manufacture (DFM)?

DFM refers to the practice of designing a product with its manufacturing process in mind. By understanding the manufacturing methods and materials used in production, you can make design decisions that reduce costs, enhance production efficiency, and avoid common pitfalls like defects, assembly delays, and excessive labor costs.

Simply put: DFM is about designing products that are easier and cheaper to manufacture while maintaining product quality and performance.

The True Cost of Overlooking DFM

When product designs don’t align with manufacturing processes, costs can quickly spiral out of control. Here are some of the hidden costs that can accumulate:

1. Increased Production Costs:

   • Every additional step or part in the production process adds cost. By designing your product with ease of assembly and manufacturing in mind, you reduce labor hours, tooling costs, and materials waste.

   • Example: A part with poorly aligned features may need to be reworked or require additional operations, adding $2,000 to $10,000 to production costs, depending on complexity.

     
     

2. Tooling and Machine Setup Fees:

   • Parts with overly complex geometries or tight tolerances often require specialized tooling, which can be expensive to develop. These costs could range from $1,000 to $50,000, depending on the complexity and scale of production.

   • Example: If the part design isn't optimized for the molding process, the manufacturer may need to create specialized molds or machines, which could delay your project by weeks or months.

     
     

     

     
     

3. Assembly Issues:

   • Parts that don’t fit together well or require manual intervention to assemble cost time, money, and resources.

   • Example: If a plastic housing isn’t designed for easy assembly, extra parts like clips, screws, or adhesives may be necessary, adding $500 to $5,000 to assembly costs per product, depending on the volume.

     
     

4. Quality Control and Rework:

   • Parts that are difficult to manufacture or prone to defects often need to be inspected and reworked. This takes up valuable time and resources.

   • Example: If the part is not designed with draft angles or radii, it may get stuck in the mold, leading to scrap or rework. Rework could add 20% to 30% to your total production costs.

     
     

5. Post-Production Modifications:

   • Changes made after production has begun, often due to design flaws, can lead to significant delays and additional costs.

   • Example: Modifying a product to accommodate unanticipated issues with manufacturing can cost an additional $5,000 to $20,000 for each change, including engineering time, tooling adjustments, and material changes.

     
     

How DFM Can Save You Money

Applying DFM principles from the start can prevent many of these problems. By designing for manufacturability, you can avoid costly mistakes and ensure that the product goes from concept to reality smoothly.

Here’s how:

1. Reduce Production Time:

   • DFM encourages the use of design elements that make the part easier to machine, assemble, and inspect. This streamlines production, reducing both labor costs and time.

   • Example: By ensuring parts fit together easily without additional tools or processes, assembly time can be reduced by as much as 20%, saving $500 to $5,000 per production run.

     
     

2. Lower Tooling Costs:

   • By selecting materials and features that align with the capabilities of standard manufacturing equipment, you avoid expensive custom tooling or machinery.

   • Example: A part designed with uniform wall thickness reduces the need for expensive molds, saving $1,000 to $20,000 in tooling costs.

     
     

3. Decrease the Risk of Rework:

   • Ensuring that your design is easy to manufacture can significantly reduce defects and the need for rework. Fewer defects mean fewer returns and less waste.

   • Example: Using proper tolerances can reduce defects by up to 30%, saving $1,000 to $10,000 in rework costs.

     
     

4. Optimize Material Usage:

   • DFM helps reduce material waste by suggesting design adjustments that use materials more efficiently. This can lower material costs and reduce environmental impact.

   • Example: By designing parts to fit into standard sheet sizes or using materials that are easy to source, material costs can drop by as much as 10% to 25%.

     
     

Key DFM Features to Focus On

1. Wall Thickness Consistency:

   • Ensure uniform wall thickness to prevent warping or uneven cooling during molding.

   • Cost Savings: Prevents up to 30% in scrap material and reduces rework.

     
     

     

     
     

2. Draft Angles:

   • Drafts on vertical surfaces make parts easier to eject from the mold, reducing mold wear and improving part quality.

   • You can see them everywhere in your daily life. Some draft angles are prominent while others not so much. For example, look from the bottom of your TV remote. The sides will be at an angle.

   • Cost Savings: Avoids $2,000 to $5,000 in additional mold work.

     
     

     

     
     

3. Mounting Features:

   • Adding proper mounting bosses or clips can save time in assembly and reduce the number of additional fasteners needed.

   • Cost Savings: Reduces assembly time by 20% to 30%, saving $500 to $3,000 per part.

     
     

     

     
     

4. Tolerances:

   • Avoid overly tight tolerances unless absolutely necessary. Tighter tolerances increase manufacturing costs.

   • Cost Savings: Loosening tolerances can save 10% to 15% in manufacturing costs.

     
     

     

     
     
     
     

5. Material Selection:

   • Use materials that are not only suitable for the part’s function but also cost-effective and easy to process.

   • Cost Savings: Choosing the right material can save $1,000 to $10,000 in production costs.

     
     

Conclusion

Design for Manufacture is more than just a principle – it’s a strategy for saving money and ensuring the success of your product. Overlooking DFM can lead to unnecessary costs, delays, and failures that could easily be avoided with thoughtful design. By implementing DFM principles early in the design process, you can reduce production costs by as much as 30% and streamline your product's journey from concept to market.

Remember, the goal is to design smarter, not harder. Save time, money, and frustration – and let DFM lead you to success.

If you’re ready to design products that are optimized for manufacturing, let’s talk! At iNSPIRE design, we specialize in guiding you through every step of the product development process, ensuring cost-effective solutions that bring your ideas to life.

Contact Us