Idea to product

SYNERGIZE DESIGN WITH MANUFACTURABILITY

TO ENERGIZE INNOVATION

Presented by Er Ramalingam

BEST DESIGN AND THE BEST DESIGNER The best design on this earth is only the Body Machine –Human being . Mankind has survived millions of years on this earth . Some of the other creations of nature have become extinct . We don’t know who is the Designer of these ? Human being is the Best Biological Product with Two Genders .

Is it by natural selection or by fate or survival of the fittest ?

And the best example for survival of the fittest also .

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BEST DESIGN AND THE BEST DESIGNER But these best products are brought to this earth by procreations by men and women for millions of years.

By synergizing between the eligible male adult and a female adult .

It is for the new born to be nursed by the parents well or society .

The Person has to self protect and grow by Proper foods . Knowledge additions and Maintenance .


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BEST DESIGN AND THE BEST DESIGNER . In this world of intense competition money has become a common scale of capability index for the individuals as age grows and Man has to learn & un-learn.

The basic secrets are the continuous Renewal of the life cells , the mini power plants - an important point to be noted by

Design Engineering Professionals while designing for products of higher life cycles.


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ENGINEERING PRODUCTS & BODY MACHINE

Most of the engineering products right from ordinary levers to robots are only reflections or reverse engineered products or systems from the Body Machine

This design has all examples for : Symmetry and Style Balancing & Stabilizing , Engineering Machines & Chemical Process Equipments Electronics & Computers Telecommunications & Media. Chemical Plants & Battery Charging Energy & Renewable Energy ,


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Ships and Material Handling .. Standby Tools like two hands ,two legs two ears, two kidneys ,two eyes & a virtual eye for blind persons.

But only one Brain with two functions –Analytical and Creative And Single Heart with two functions – Pumping & Suction of Blood

In short the Body Machines are having the ‘Yang’ or ‘Yin’. 1-Human intellects have developed systems like Computers to multiply the human capacity in knowledge &

2- ‘Yoga’ to synergize the breathing ( media of life )with the body .. Cloning by scientific means have proved man’s ability to research and innovation in creations – but at huge costs .


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In short ,this Body Machine is the best designed ‘animal on earth ‘having acquired powers to create and destroy also .

It is the best reliable product out of ‘Tao of DFM ‘- Designed to be a Reliable Product with higher Quality at lower cost ( if out of normal delivery ) in faster time (about ten months standard time )

All born are supposed to be of better quality by birth . Due to the DNA factors or Genetic Factors some in-born features are passed on to generations down the line.


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AVERAGE OF REDUCTIONS OBTAINED THROUGH DFMA

“ Labor Costs - 42% , Parts Count - 54%, Separate Fasteners - 57% , Weight - 22% , Assembly Time - 60% , Assembly Cost - 45%, Assembly Tools - 73% , Assembly Operations - 53% , Product Development Cycle - 45% & Total Cost - 50% “ By adopting Design for Manufacturability & Assembly –DFMA - the above

reductions were made possible ,as per www.dfma.com , the world’s first software entity on DFM from USA based on the average of net results produced for 100 Clients by them.

Tell me which other methodology is able to deliver this kind of results.?


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http://www.dfma.com/

DEFINITION OF DESIGN FOR MANUFACTURABILITY-DFM

According to Dr David M Anderson( my mentor for DFM) 'Design For Manufacturability' is the process of proactively designing products to:

(1)optimize all the manufacturing functions: fabrication, assembly, test, procurement, shipping, delivery, service and repair,

(2) assure by design, the best cost, quality, reliability, regulatory compliance, safety, time-to-market and customer satisfaction &

(3) ensure that lack of manufacturability doesn't compromise functionality, styling, new product introductions, product delivery, improvement programs, strategic initiatives and unexpected surge in demand. www.design4manufacturability.com


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http://www.design4manufacturability.com/

STARTING POINTS FOR THIS ‘TAO OF DFM’ Dr Sanjay Ramaswamy in his Arizona State University’s report on DFM Methodologies has expressed that “Insufficient Scientific base under the softwares and enormous data are compiled within the computer or software.

Human intervention and feedback are rare.,DFMA methods have little efforts at the conceptual stage where most of the product cost is fixed .&Insufficiency due to the inability to provide RE-DESIGN suggestions to modify shapes in the case of unsuitable designs.”

The above inputs are the starting points for this ‘Tao of DFM” .


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INSPIRATIONS FOR TAO OF DFM

Inspirations came from Dr Fritjof Capra (The author of 'The Tao of Physics')

‘The Taoist saw all changes in nature as manifestations of the dynamic interplay between the polar opposites YIN & YANG, and thus they come to believe that any pair of opposites constitutes a polar relationship where each of the two poles is dynamically linked to each other.

At the balancing point, the two energies are found to be in harmony and create conditions for new forms to merge.”


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INNOVATION’S DOUBLE HELIX


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“A Technology without a Market is as valuable As a Market without a Technology – They are both worthless ! At one end of the spectrum you have something interesting running in the lab and at the other end you have an interesting insight around a new market..

But one won’t do ,and from the either end of the rainbow your quest is to find the pot of gold at the other end “- thanks to Dr Shipulski


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“ Innovation is always a clustered –jumble of two extremes . In fact it’s more like a double helix where the customer strand winds around the technology and the technology strand winds around the customer .

One strand takes the lead and mutates the other ,which in turn spirals learning in unforeseen directions.”

There is no getting around it-market & technology co-evolve … Instead of spending time and money sequencing the innovation genome ,take your cue from nature- try stuff and do more of what worked and less of what didn’t ,

And remember the cardinal rule – the organization with the best genes wins”- thanks to Dr Shipuski


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TAO OF DFM

Here comes the methodology of ‘Tao of DFM’ which stipulates that the organization should have the best genes as members of the Concurrent Engineering Team of cross functional experts with a golden mix of Holistic Minds & Creative Minds

“ Thirty spokes join in one hub In its emptiness ,there is the function of a vehicle. Mix clay to create a container. In its emptiness ,there is the function of the container. Cut open doors and windows to create a room In its emptiness ,there is the function of a room. Therefore ,that which exists is used to create benefit That which is empty is used to create functionality”- from reflections of the Tao Te Ching.


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TAO OF DFM

Sixty-four spokes join in one hub -Tao of DFM . In its emptiness , the Design or the Yang There is the function of Manufacturability, the Yin. That which exists is the manufactured product used to create benefits :

That which is empty, the Design is used to create Product /functionality – This is Tao of Design For Manufacturability


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TAO OF DFM


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In the well known symbol of the yin and yang, two fishes encircling one another, is a picture of the complementary nature of the sexes, Their need for one another and their interdependence. The two eyes of the fish show that even within the masculine there is some of the feminine, and vice versa.

TAO OF DFM


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According to Chinese philosophy, harmony between the sexes is not only a problem for those who are married: Half of life is best understood from the feminine point of view and the other half by the masculine.Both poles are needed to get at the whole "great mystery" of life. .

TAO OF DFM


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Complementary is a better word to use than opposites in describing the differences between the sexes remembering also that this phenomena does teach equality of the sexes. The generic term men or brothers unless otherwise stated means men and women because the two sexes are the same in spirit, the innermost core of our being.

TAO OF DFM

TDFM provides the Rules & Guidelines of assuring Design For Manufacturability and TDFM provides basic Rules & Guidelines ..

Tao of DFM directs to synergize Creative Minds with Holistic Minds to bring Innovative Products /Processes by a viable Gap Analysis and by adopting DMAIC type Analysis.

Mantras of TDFM are to make the holistic minds & creative minds to think and work together under a common platform of Concurrent Engineering.

It has to be a golden blend of the West with the East and vice versa. This is the essence of TDFM, a dynamic interplay/synergy between Design & Manufacturability .


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TAOISM & ARTHANAREESWARA

In typical Hindu /Indian words 'Design' is the function of Shiva and 'Manufacturability' is the function of Parvathy.’.

In other words 'Design' is the function of Shiva (YANG ) and 'Manufacturability' is the function of Parvathy (YIN) under my 'Tao of DFM’.


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TAOISM & ARTHANAREESWARA

Some of you might be perplexed to find that a scientific/technical method of design/development is being interpreted through a mystical thought of Taoism.

I expect the Designer’s understanding of TDFM should progress steadily & simultaneously, re-engineering their thoughts and actions through understanding the Eastern Schools of Taoism and Arthanarishvara – which are to be experienced and not merely learning from books.

A deeper understanding of TDFM can only be felt when one decides to become actively involved in TDFM by doing TDFM analysis by adopting both holistic & creative approaches and then a Gap Analysis through an integrated Taoist Approach through a CET comprising of cross-functional experts.


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COMPARISON OF GAPS

The Gaps between Design & Manufacturability are the reflections of Gaps between the following:

Between Theory & Practice, Between Man & Woman, Between Lord Shiva & Parvathy, Between Yang & Yin, Between Voltage & Current, Between Software & Hardware,


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COMPARISON OF GAPS

Between the Positive & Negative Polarities in Electricity ,

Between North & South Polarities in Magnetism , Between the Right & Left Halves of human brain, Between the Conscious Mind & the Sub-conscious Mind &

Between the Body & Mind


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‘BERLIN WALL’ BETWEEN DESIGN & MANUFACTURABILITY

You can find in-built attractions between the above kind of opposing entities due to nature /science.

Mission of TDFM is to embed similar attractions between Design & Manufacturability which are having a ‘Berlin Wall’ in between them .

In our planet, there are numerous things of dual forces or entities that are complementary to each other and are also independent of each other; the integration of these two opposing forces alone can create the essentials of life & matter..


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BERLIN WALL BETWEEN DESIGN & MANUFACTURABILITY

Each has a destined role to play and without proper integration /synergy between the two opposing entities, nothing can be created on earth.

Design & Manufacturability are equated to these dual entities under TDFM..


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“BERLIN WALL” BETWEEN DESIGN & MANUFACTURABILITY

TDFM arrives here to break the ‘Berlin Wall’ between ‘Design’ & 'Manufacturability' by adopting TDFM.

'Design' and 'Manufacturability' have to dance together 'not merely with arms to arms’

But also with cheek to cheek’ with ‘Music ' from Innovation Engineering & ‘Lyrics ' from 'Concurrent Engineering'.


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EIGHT CRITERIA OF TDFM

Both the holistic & creative minds of the CET will do a Gap Analysis − Criteria-wise/Pillar-wise – of the assurances for Design as per the following Criteria :

Design for Best Cost (DFBC), Design for Best Quality (DFBQ), Design for Best Reliability (DFBR),


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EIGHT CRITERIA OF TDFM

Design for Best Compliance to Regulations/Sustainability (DFBCRS),

Design for Best Safety (DFBS), Design for Best Time-to-Market (DFBTM), Design for Best Function/Style (DFBFS) & Design for Best Satisfaction to Customer (DFBSC).


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EIGHT SYSTEMS OF MANUFACTURABILITY The above Pillars/Criteria will be synergized with the following Systems for Optimization :

Best System for Procurement (BSP), Best System for Manufacturing (BSM) , Best System for Assembly (BSA) , Best System for Testing (BST),


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EIGHT SYSTEMS OF MANUFACTURABILITY Best System for Packing/Shipping (BSPS) , Best System for Supply/Delivery (BSSD) , Best System for Service/Maintenance ( BSSM) &

Best System for Repair (BSR) as per the Taoist recommendations of the Concurrent Engineering Team.


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T-SHAPED PROFESSIONALS NEEDED

This is an honest attempt to bring DFM-knowledge based Rules/Guidelines to Design Engineers which will require less time to implement, in the long run.

It will also help new professionals who would like to take up DFM as a profession by , T-Shaped Professionalism with strengths in Design & Manufacturing Engineering as well as QMS & Resources Management.


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SIMPLICITY THE MANTRA OF TDFM

DFM itself is a vast subject. In the true spirit of Lean, this TDFM calls for tools or practices by applying Simplicity .

Simplicity is the main mantra under TDFM . The main focus is on the TDFM methodology by applying Holistic, Creative, Taoist Practices and the simple Gap Analysis way of TDFM Analysis for 8 x 8 = 64 Modules ( spokes) − 8 Criteria &. 8 Systems.


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TO BRING ALL OUT-OF-BOX INTO-THE-BOX The Goal is to get reliable products of better quality @ lower costs through rapid development .

Innovation is brought out by allowing ‘out-of-box ‘ ideas/designs/solutions “into-the-box ‘ by a team of cross functional experts of the Concurrent Engineering Team.


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SUPERMAN

We need a Superman as the next evolution of Man on earth . We have seen Electronics & CNC Occupying Mechanical Equipments to have flexibility& accuracy & repeatability .

In a similar manner we need synergizing of Medical Specialties with Design Engineering and vice versa .

Let Design Engineering synergize with Medical Sciences to bring out more out-of-box ideas /solutions designs to launch an innovation revolution !

Let Mechanical Engineering gain lot of additional /new energy to serve the society and Medical Sciences also gain more by synergizing with engineering to serve the society more efficiently .

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SUPERMAN

. By proper application of TDFM and with the Collaborative / Co-creation Efforts we can integrate the best out of the human systems in engineering systems through a new Design Thinking in tune with the customers 'needs and aspirations and by utilizing the best out of technology to overcome the spiraling effects of the twin helixes .

Let a superman be evolved with twin brains and twin hearts to multiply the human potential and proactively rule the present world by bringing reliable/innovative engineering products with faster speed and lower costs with higher quality ..


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“NIAGEN-GOD VITAMIN “BY DR DAVID SINCLAIR

We are hearing good news of breakthrough in cell research which claims that they can can help individuals to live longer by providing the proper vitamins directly to the cells by initiating better communications in between cells .

http://livecellresearch.com/livelonger-v21.php


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PRODUCTS DEVELOPED BEFORE DFM INITIATIONS


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Design for State Govt Approval Development & Manufacture of Trailers for Tractors /Tillers Tipper Bodies for Leyland Chassis While @ Arasan & Co/- Tirunelveli – 1974-76


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Bogie Type Tipping Trailer to OE for TAFE-Massey Fergusson

Developed for TAFE while @ Arasan & Co/- Tirunelveli - 1976

Done Innovations in Tow-bar Design to suit easy manufacturability at the vendor end which even the OE accepted for the sake of improved strength


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Design & Development of Smart Rotary Tablet Press for Pacific Tools Pvt Ltd – Chennai- 2005


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The objectives of DFM were reached with minimum variety of materials, tooling, taps & drills and spanners for assemblies.

Maximum test runs were done using a variety of input chemistry of tablet powders and a low cost automation for the feeding of powders into cavities/dies.


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Other Engineering Products for OE -Developed :

Rocker Levers /Rocker Shafts / Rocker Brackets / Shifter Shafts / Lub Oil Pumps/

Replacement Parts for Textile Machineries through Reverse Engineering/ Replacement Parts for Chemical Engineering through Reverse Engineering .

1977 to 1995


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MENTORED FOR DESIGN & DEVELOPMENT FOR AN UNIVERSITY PROJECT @ ANNA UNIVERSITY


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Basics of DFM applied while mentoring The PG Student in Product Design @ AU. Because of the novelty in Design & Execution

National Institute of Design- had sanctioned Rs 1.20 Lakhs for the Project -2013


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PRODUCTS UNDER DESIGN AFTER DFM INITIATIONS

Developing an eco- friendly Energy Independent Vehicle –EIV Objective : Eco-friendliness - Zero Effects as per ‘Make-in-India ‘& Almost -Nil Operating Cost


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SOLICITS ENQUIRIES FOR CO-CREATIONS Engineers InnoVentures Solicits enquiries To Innovate –by-co creations

EIV is a registered Design Firm under Design Clinic Scheme –DCS -of National Institute of Design – NID .


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TDFM TRAINING AND IMPLEMENTATIONS

Engineers InnoVentures Offers to bring home a Viable Tao of DFM To your Organization.


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REDESIGN THROUGH TDFM

EIV is open to Redesign Through Co-creations through Faster Time with better Quality @ Lower Cost

And by signing Confidentiality MOU with Clients


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DFM HANDBOOK FOR DESIGN ENGINEERING PROFESSIONALS


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My book titled as “ Taoist Directions for Design & Development” Sponsored by NDRF – www.ndrf.res.in Released during Indian Technology Congress 2014 @ Bangalore on 21st August 2014 by former PM of India Hon. Deva Gowda .


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http://www.ndrf.res.in/



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THANK YOU

Welcome to a Dance where Design & Manufacturability will Dance together Not merely with Arms to Arms - but Also with Cheek to Cheek. Music by Innovation Engineering . Lyrics by Concurrent Engineering . Please call 97899 65421 Email: [email protected] Web: http://dfmsolutionsbyredesign.blogspot.in/ www.dfmhandbook.com

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Engineers Innoventures

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