INTRODUCTION

Many products, notably equipment, machines, tooling, and devices for industrial use, products for niche markets, and pilot lots, are inherently limited in production volume. The question arises, Is it worthwhile, even possible, to apply DFM techniques successfully to products that are manufactured in these limited quantities? The answer is Yes, but the approach and the improvement guidelines in such cases will vary from that used in high-production applications.

The cost of tooling is perhaps the most important factor in choosing a design suitable for lower-quantity production, but it is not the only factor. Others are the cost and lead time for development of the manufacturing process, the selection of production equipment, and the selection of material. These factors may be compounded if the design is innovative. Tooling cost is significant because it must be amortized over the production life of the product. High tooling costs mean high manufacturing costs unless the production run is long enough so that the unit amortized cost is no longer a major factor. The same is true of any development costs for production equipment, materials, or other design characteristics. Development of new production equipment and of innovative materials and designs requires time and cost. If these innovations apply only to one product, that product must bear the cost. Lower production volumes limit the degree to which they can be amortized.

When expected production quantities are...