If you want to launch a robust and successful product, it requires a seamless integration of ideas and frameworks of advanced design and manufacturing. A framework for product development known as “manufacturing design” places a strong emphasis on the relationship between manufacturing results and product performance. This blog is aimed to give you a proper understanding of this complex topic explained in a layman’s perspective.
Let’s start from the basics
What is Manufacturing Design?
Manufacturing design is a combination of different but very important things like principles, techniques, and some other key considerations. These combinations are key in transforming a product idea to a reality.
If anyone wants to understand in-depth about manufacturing design, one must have profound knowledge in the fields of material science, mechanical engineering design, process engineering, and the latest industrial design. Manufacturing design involves creating products that are feasible, functional, and affordable. Also, the key considerations include cost, scalability, process, materials, and functionality of the product.
Importance of Manufacturing Design
The manufacturing design serves as a backbone for great product development. Here is why:
Greater cost reduction:
About 70% of the manufacturing costs are associated with the material selection and manufacturing process alone. This means, that most of the cost can be minimized by a perfect planning of manufacturing design.
Simplified, streamlined, and fast process of production:
DFM (Design for Manufacturing), a systematic approach to the manufacturing process, eliminates redesign work and improves the TTM (Time-to-Market).
Minimizes waste:
As the process of manufacturing design eliminates the need for rework, it reduces waste.
Reliability, high quality, and affordability of products will depend on the process manufacturing design.
Finally, all the afore mentioned benefits lead to great profits.
Process or Criteria of Manufacturing Design
The following is the process of manufacturing design in product design.
I. Conceptualization of idea
It is the beginning stage of a manufacturing design. It starts with the conceptualization of a product. If you have a great idea and want to make it a product, make a thorough research on it, make a market study, analyze how the market will accept your product, study about possible substitutes of your product and most importantly how your product can be a substitute for the existing products in the market.
II. Product requirements and specifications
Second stage is about implementation. Hold a series of discussions with marketing and product development teams and note down their take on the product. This step reveals aesthetics, features, functionalities, project scope, performance, timeline, and estimated cost of the product development. Next, we will go to engineering design.
III. Bringing the product to life
Vision is laid out, requirements are defined, features are outlined, and goals are set. Now, it’s the responsibility of the entire development team to enable the product. They including product design engineers, manufacturing engineers, etc. must go hand-in-hand with their expertise and experience throughout the design process until the product finishes.
IV. Selection of 2Ms (Manufacturer and Material)
To avoid technical complexities in the manufacturing design, you must choose a reliable and experienced manufacturer who can provide high-quality spare parts for your product. And choose a vendor who can address your queries swiftly and proactively and provide industry insights. In addition, if the manufacturer who is partnered with you has internal engineering capabilities, it will be an add-on for you. Because they can provide both BIW fixture design and build activities. This eases the task of your in-house quality control team in inspecting the parts they provide.
Coming to material selection, factors such as thermal properties, mechanical properties, chemical resistance, and environmental properties will play a crucial role. Because. These factors can impact manufacturability, performance, and cost of the product. Keep yourself updated about the new trends in the market as material science is fast advancing and there are numerous number of innovative materials available in the market that can enhance your products
V. CAD Software
CAD software is an advanced computer aided design and software platform that allows the manufactures and the designers to create accurate 3D models of the product. It helps you to visualise, simulate and analyse the design and gauge its performance well before it is put for production. The advantage is, you can easily iterate and refine the design if required for better outcomes thus helping you save your resources going to waste.
VI. Design for Manufacturing and Assembly (DFMA)
This DFMA process in product manufacturing consists of two approaches –
DFM (Design for Manufacturing)
DFA (Design for Assembly)
In the first approach, DFM reduces the production complexity through optimization while minimizing the assembling time to improve the readability and quality of the product. This optimization in design impacts in reducing the number of components, standardization of components, and simplifying the product’s parts.
In the second approach, the assembly process was optimized by DFA to reduce money, time, and effort. To achieve such effective and efficient assembly, design principles like simplification of the assembly process, modularization, and standardization of components are helpful.
Thus, DFMA guidelines ensure that products are developed and upgraded for efficient manufacturing and assembly. It connects both manufacturing engineers and designers.
VII. Manufacturing Processes
The manufacturing process will have a lasting effect on the product. So, it is paramount for you to be aware of various manufacturing processes such as Casting & Molding, Machining, Additive Manufacturing (3D Printing), Joining, and Shearing & Forming. Material, complexity, volume, and cost are all factors that influence the process chosen.
VIII.Prototyping
Prototyping is like a mock test which is practiced before attending the final exam. The product is designed partially with key functionalities before developing a final design. This process can go through many iterations to check how the product will appear and how users will interact with it. If we do this process in the early stages, we can save time and money.
IX.Quality Assurance
Quality assurance is a systematic procedure in manufacturing design that assures products satisfy customer expectations and defined standards. It entails enforcing strict quality control methods throughout the manufacturing process, from inspecting raw materials to testing the final product.
X.Sustainability
In order to cope with environmental impact, many manufacturing designers are adopting sustainable practices while designing the product.
The purpose here is to create a product 1.)Energy efficient and 2.) recyclability. This will help us to do better waste management and reduce carbon footprint.
XI. Continuous Enhancement
Continuous improvement is the key to better performance. It means the product in design should be able to adapt to changes. Designers should regularly seek feedback from the public and users. The feedback received should be used for extensive analysis and implementation of the information gained. It will improve the quality and efficiency of the product.
XII. Design changes
Most importantly, the designs created are prone to changes. Design changes are an inevitable part of any manufacturing design. Make sure your product is capable of adapting to the changes. However, with the right approach, and experienced partners, you can cope up with the challenges associated with it such as added time, unplanned costs, and other headaches without hassles.
Trends in Manufacturing Design
The emerging trends in manufacturing design such as Advanced Robotics and Automation, Smart and Sustainable Manufacturing, Digital Twins, Artificial Intelligence, 3D printing, XR (Extended Reality), and Generative Design have changed the way the products are developed from design to manufacturing to maintenance. Leveraging these technologies is the key to your success. It gives you a great advantage to you over your competitors as you can easily take advantage of the increased use of technology. It gives you greater return, increased efficiency and better penetration on the market.
Wrapping Up
Manufacturing design is no doubt an indispensable part of creating innovative and high-quality products, meeting the requirements of its owners or consumers. Manufacturing design is indispensable for gaining a competitive edge over the competitors and designing a great product without compromising on best practices or the latest trends in the market.
