Design for Manufacture and Assembly DFMA
You’re under pressure. Projects are behind schedule. Costs are creeping up. Stakeholders are questioning every decision. And you’re stuck trying to balance innovation with feasibility, all while avoiding costly rework that could’ve been prevented at the design stage. Manufacturing delays, assembly bottlenecks, and unanticipated costs don’t happen because of bad engineers. They happen because design decisions were made without full visibility into how parts would come together on the shop floor. The gap between concept and production is where ROI evaporates - and careers stall. The Design for Manufacture and Assembly DFMA course closes that gap. This isn’t theoretical. It’s not academic. It’s a proven system used by leading engineering teams to cut production costs by up to 40%, slash assembly time, and accelerate time-to-market - all without sacrificing quality. Take Ana Rodriguez, Senior Design Engineer at a Tier 1 automotive supplier. After applying the DFMA framework, her team reduced component count by 32% on a major transmission project, cutting per-unit manufacturing cost by $18.75. Her solution was fast-tracked for executive presentation, and she was promoted within six months. That’s the power of disciplined, process-driven design. This course gives you the exact methodology, tools, and decision frameworks used by top performers. You’ll go from vague design ideas to a fully optimised, production-ready proposal - in as little as 30 days - with a board-ready package that justifies every choice through hard metrics. Here’s how this course is structured to help you get there.Course Format & Delivery Details Self-Paced, Immediate Online Access
The Design for Manufacture and Assembly DFMA course is designed for professionals who need results, not rigid schedules. You gain on-demand access to the full curriculum, allowing you to progress at your own pace, during your hours, from any location. Most learners complete the core modules in 20 to 30 hours, with many reporting actionable insights within the first 72 hours. Real-world application begins immediately, meaning you can start reducing waste, simplifying assembly, and improving manufacturability on your current projects from day one. Lifetime Access, Zero Expiry
You’re not buying temporary access. You’re investing in a permanent resource. Once enrolled, you receive lifetime access to the entire course, including all future updates and enhancements. As DFMA practices evolve and new industry benchmarks emerge, your knowledge stays current - at no additional cost. Accessible Anywhere, On Any Device
Whether you’re in the office, on site, or reviewing designs remotely, the course platform is fully mobile-optimised and compatible with all modern devices. Learn during transit, reference frameworks during team meetings, or pull up checklists mid-review - seamless access ensures learning integrates into your workflow, not disrupts it. Expert Guidance with Direct Support
You’re not navigating this alone. Enrolment includes direct access to industry-experienced DFMA practitioners who provide feedback on your application exercises, answer technical questions, and help you adapt principles to your specific sector - be it medical devices, consumer electronics, or heavy machinery. Official Certification with Global Recognition
Upon completion, you’ll receive a Certificate of Completion issued by The Art of Service - a globally recognised authority in engineering process excellence. This certification carries weight with employers, auditors, and design review boards, and verifies your mastery of industry-standard DFMA methodology. No Hidden Fees. No Surprises.
Pricing is straightforward. What you see is exactly what you pay - one inclusive fee with no recurring charges, no add-ons, and no mandatory certifications. What you get is permanent access, world-class content, and an outcome-focused learning journey. Trusted Payment Methods
We accept all major payment options, including Visa, Mastercard, and PayPal - processed securely with end-to-end encryption to protect your data. 100% Money-Back Guarantee: Satisfied or Refunded
We remove all risk. If you complete the first two modules and don’t find immediate value, simply request a full refund. No questions, no delays, no hassle. This is our promise to you: you either gain real skills or you walk away with your investment intact. Confirmation and Access Protocol
After enrollment, you’ll receive a confirmation email acknowledging your registration. Your course access details will be delivered separately once your materials are fully prepared and ready for engagement. This ensures you receive a seamless, error-free learning experience from the start. Will This Work for Me?
Yes - even if you’re: - New to formal DFMA and unsure where to start
- Working in a regulated environment (medical, aerospace, automotive)
- Part of a cross-functional team where alignment between design and manufacturing is inconsistent
- Under pressure to deliver faster while reducing cost and complexity
This course works even if your organisation doesn’t yet have a formal DFMA policy. The tools are designed to be implemented incrementally, regardless of company size or maturity. In fact, many learners use the templates and scorecards to introduce DFMA practices from the ground up, gaining visibility and influence in the process. This is the structured, repeatable, evidence-based approach that turns experienced engineers into indispensable leaders.
Extensive and Detailed Course Curriculum
Module 1: Foundations of DFMA - History and evolution of Design for Manufacture and Assembly
- Core principles: Simplicity, standardisation, symmetry
- Understanding the cost drivers in assembly and manufacturing
- Quantifying the impact of poor design decisions on production
- DFMA vs. traditional design: A comparative framework
- The role of design in overall product lifecycle costs
- Key performance indicators for DFMA success
- Common misconceptions and myths about DFMA
- Integrating DFMA early in the product development cycle
- Defining design efficiency metrics
Module 2: DFMA Methodology and Framework - Overview of the Boothroyd-Dewhurst method
- Manual handling and insertion time estimation
- Design efficiency formula and target setting
- Part count minimisation strategies
- Design for ease of orientation and insertion
- Use of symmetry to reduce assembly complexity
- Passive vs. active assembly features
- Design for self-locating and self-fixturing components
- Material selection guidelines for manufacturability
- Fastening method evaluation and substitution
Module 3: Advanced Cost Analysis Tools - Cost breakdown structure for mechanical assemblies
- Estimating labour time per part
- Automated time estimation using standard databases
- Material cost sensitivity analysis
- Tooling and fixture cost allocation
- Overhead rate integration in cost models
- Bottleneck identification in assembly lines
- Calculating total cost per assembly operation
- Cost impact of design variations
- Scenario modelling for alternative designs
Module 4: Design for Manual Assembly - Ergonomic principles in manual handling
- Graspability and pinch-point reduction
- Visual identification and part differentiation
- Minimising reorientation during assembly
- Use of chamfers, tapers, and guides
- Design for one-handed assembly operations
- Avoiding tangling, nesting, and jamming in feeds
- Reducing fine motor skill requirements
- Standardising torque and force requirements
- Designing for error-proofing in manual steps
Module 5: Design for Automated Assembly - Understanding automation constraints and capabilities
- Part feedability and bowl feeder compatibility
- Design for robotic gripper compatibility
- Minimising part flipping and orientation steps
- Tolerance stack-up in robotic assembly
- Sensor integration and feedback requirements
- Repeatability and precision in automated handling
- Avoiding features that require vision correction
- Design for high-speed pick-and-place systems
- Automated fastening compatibility (screwdrivers, crimping)
Module 6: Design for Manufacturability by Process - Injection moulding design rules (draft angles, ribs, bosses)
- Sheet metal forming: bend allowances, cutouts, flanges
- Casting design: parting lines, undercuts, cores
- Extrusion: profile symmetry, thickness consistency
- 3D printing: support structure reduction, overhangs
- Machining: tool access, feature complexity, fixturing
- Stamping: nest efficiency, scrap minimisation
- Welding: joint accessibility, fit-up requirements
- Adhesive bonding: surface preparation, gap control
- Assembly sequence compatibility with downstream processes
Module 7: Component Integration and Part Count Reduction - Functional decomposition and consolidation
- Merging parts with similar materials and processes
- Redesigning subassemblies as single components
- Using snap-fits instead of fasteners
- Designing for two-shot or overmoulded features
- Integrating bearings, seals, or gaskets into housings
- Replacing screws with press-fits or tabs
- Combining electrical and mechanical features
- Assessing trade-offs between integration and serviceability
- Using design morphology charts for innovation
Module 8: Tolerance and Fit Optimisation - Understanding clearance vs. interference fits
- Tolerance stack-up analysis in assemblies
- Statistical vs. worst-case tolerance methods
- Designing for maximum allowable variation
- Using generous tolerances without sacrificing function
- Specifying geometric dimensioning and tolerancing (GD&T)
- Selecting fit classes based on assembly method
- Minimising sensitivity to thermal expansion
- Designing for easy adjustment and shimming
- Conducting sensitivity analysis on critical dimensions
Module 9: Standardisation and Modular Design - Creating company-wide component libraries
- Standardising fasteners, bearings, and O-rings
- Developing modular architecture for product families
- Designing for platform scalability
- Using common mounting interfaces
- Reducing SKU proliferation through modularity
- Capturing reusable design patterns
- Aligning with enterprise parts databases
- Benefits of supplier rationalisation
- Change management for introducing standards
Module 10: Design for Disassembly and Serviceability - Reverse DFMA: Planning for end-of-life
- Designing for tool access in maintenance
- Use of access panels and inspection hatches
- Minimising part removal complexity
- Designing for quick-replace modules
- Labelling and colour-coding for service identification
- Designing for reusability and remanufacturing
- Service interval compatibility with disassembly effort
- Avoiding permanent bonding in serviceable areas
- Creating service procedure guidelines from design
Module 11: Cross-Functional Collaboration & Integration - Engaging manufacturing engineering early in design
- Setting up Design for Manufacturing reviews (DFM)
- Facilitating joint design-manufacturing workshops
- Using checklists for interdisciplinary alignment
- Translating manufacturing feedback into design changes
- Managing resistance to design simplification
- Building trust between design and production teams
- Documenting assumptions and trade-offs
- Creating a shared language for manufacturability
- Linking DFMA to Design for Six Sigma and Lean
Module 12: DFMA in Regulated Industries - Applying DFMA in medical device design
- Aerospace compliance and traceability requirements
- Automotive safety-critical component considerations
- Validating design changes under ISO 13485 or AS9100
- Managing risk analysis (FMEA) alongside DFMA
- Justifying design simplification in audit contexts
- Documentation standards for design rationale
- Working with contract manufacturers under regulatory oversight
- Design freeze and change control integration
- Ensuring patient or user safety during simplification
Module 13: Software and Digital Tools for DFMA - Overview of DFMA analysis software tools
- Importing CAD models for evaluation
- Automated part count and handling time estimation
- Using built-in cost databases for material and labour
- Generating comparative reports across design variants
- Exporting scorecards for team reviews
- Integrating with PLM and ERP systems
- Version control for DFMA studies
- Collaborative review features and markup tools
- Training your team on digital DFMA workflows
Module 14: Building a DFMA Culture - Developing internal DFMA guidelines and playbook
- Creating department-specific checklists
- Defining gate reviews in the product development process
- Training new engineers in DFMA principles
- Recognising and rewarding design efficiency
- Linking DFMA metrics to performance goals
- Presenting DFMA results to senior leadership
- Securing budget for DFMA software and training
- Measuring the return on DFMA initiatives
- Scaling DFMA across multiple product lines
Module 15: Project: Apply DFMA to Your Real Product - Selecting a current or past product for analysis
- Creating an as-built bill of materials
- Mapping the current assembly sequence
- Estimating current handling and insertion times
- Calculating baseline design efficiency
- Identifying opportunities for part reduction
- Proposing alternative fastening or joining methods
- Redesigning one critical subassembly
- Re-evaluating cost and assembly time post-redesign
- Documenting improvement rationale and projected savings
Module 16: Certification, Next Steps & Career Impact - Preparing your final DFMA project submission
- Review criteria for Certificate of Completion
- Presenting your analysis to stakeholders
- Adding DFMA certification to your professional profile
- Updating LinkedIn and resume with verified skills
- Leveraging certification in performance reviews
- Negotiating higher responsibility based on DFMA expertise
- Joining the global Art of Service engineer network
- Accessing exclusive job boards and mentorship
- Planning your next DFMA initiative with confidence
Module 1: Foundations of DFMA - History and evolution of Design for Manufacture and Assembly
- Core principles: Simplicity, standardisation, symmetry
- Understanding the cost drivers in assembly and manufacturing
- Quantifying the impact of poor design decisions on production
- DFMA vs. traditional design: A comparative framework
- The role of design in overall product lifecycle costs
- Key performance indicators for DFMA success
- Common misconceptions and myths about DFMA
- Integrating DFMA early in the product development cycle
- Defining design efficiency metrics
Module 2: DFMA Methodology and Framework - Overview of the Boothroyd-Dewhurst method
- Manual handling and insertion time estimation
- Design efficiency formula and target setting
- Part count minimisation strategies
- Design for ease of orientation and insertion
- Use of symmetry to reduce assembly complexity
- Passive vs. active assembly features
- Design for self-locating and self-fixturing components
- Material selection guidelines for manufacturability
- Fastening method evaluation and substitution
Module 3: Advanced Cost Analysis Tools - Cost breakdown structure for mechanical assemblies
- Estimating labour time per part
- Automated time estimation using standard databases
- Material cost sensitivity analysis
- Tooling and fixture cost allocation
- Overhead rate integration in cost models
- Bottleneck identification in assembly lines
- Calculating total cost per assembly operation
- Cost impact of design variations
- Scenario modelling for alternative designs
Module 4: Design for Manual Assembly - Ergonomic principles in manual handling
- Graspability and pinch-point reduction
- Visual identification and part differentiation
- Minimising reorientation during assembly
- Use of chamfers, tapers, and guides
- Design for one-handed assembly operations
- Avoiding tangling, nesting, and jamming in feeds
- Reducing fine motor skill requirements
- Standardising torque and force requirements
- Designing for error-proofing in manual steps
Module 5: Design for Automated Assembly - Understanding automation constraints and capabilities
- Part feedability and bowl feeder compatibility
- Design for robotic gripper compatibility
- Minimising part flipping and orientation steps
- Tolerance stack-up in robotic assembly
- Sensor integration and feedback requirements
- Repeatability and precision in automated handling
- Avoiding features that require vision correction
- Design for high-speed pick-and-place systems
- Automated fastening compatibility (screwdrivers, crimping)
Module 6: Design for Manufacturability by Process - Injection moulding design rules (draft angles, ribs, bosses)
- Sheet metal forming: bend allowances, cutouts, flanges
- Casting design: parting lines, undercuts, cores
- Extrusion: profile symmetry, thickness consistency
- 3D printing: support structure reduction, overhangs
- Machining: tool access, feature complexity, fixturing
- Stamping: nest efficiency, scrap minimisation
- Welding: joint accessibility, fit-up requirements
- Adhesive bonding: surface preparation, gap control
- Assembly sequence compatibility with downstream processes
Module 7: Component Integration and Part Count Reduction - Functional decomposition and consolidation
- Merging parts with similar materials and processes
- Redesigning subassemblies as single components
- Using snap-fits instead of fasteners
- Designing for two-shot or overmoulded features
- Integrating bearings, seals, or gaskets into housings
- Replacing screws with press-fits or tabs
- Combining electrical and mechanical features
- Assessing trade-offs between integration and serviceability
- Using design morphology charts for innovation
Module 8: Tolerance and Fit Optimisation - Understanding clearance vs. interference fits
- Tolerance stack-up analysis in assemblies
- Statistical vs. worst-case tolerance methods
- Designing for maximum allowable variation
- Using generous tolerances without sacrificing function
- Specifying geometric dimensioning and tolerancing (GD&T)
- Selecting fit classes based on assembly method
- Minimising sensitivity to thermal expansion
- Designing for easy adjustment and shimming
- Conducting sensitivity analysis on critical dimensions
Module 9: Standardisation and Modular Design - Creating company-wide component libraries
- Standardising fasteners, bearings, and O-rings
- Developing modular architecture for product families
- Designing for platform scalability
- Using common mounting interfaces
- Reducing SKU proliferation through modularity
- Capturing reusable design patterns
- Aligning with enterprise parts databases
- Benefits of supplier rationalisation
- Change management for introducing standards
Module 10: Design for Disassembly and Serviceability - Reverse DFMA: Planning for end-of-life
- Designing for tool access in maintenance
- Use of access panels and inspection hatches
- Minimising part removal complexity
- Designing for quick-replace modules
- Labelling and colour-coding for service identification
- Designing for reusability and remanufacturing
- Service interval compatibility with disassembly effort
- Avoiding permanent bonding in serviceable areas
- Creating service procedure guidelines from design
Module 11: Cross-Functional Collaboration & Integration - Engaging manufacturing engineering early in design
- Setting up Design for Manufacturing reviews (DFM)
- Facilitating joint design-manufacturing workshops
- Using checklists for interdisciplinary alignment
- Translating manufacturing feedback into design changes
- Managing resistance to design simplification
- Building trust between design and production teams
- Documenting assumptions and trade-offs
- Creating a shared language for manufacturability
- Linking DFMA to Design for Six Sigma and Lean
Module 12: DFMA in Regulated Industries - Applying DFMA in medical device design
- Aerospace compliance and traceability requirements
- Automotive safety-critical component considerations
- Validating design changes under ISO 13485 or AS9100
- Managing risk analysis (FMEA) alongside DFMA
- Justifying design simplification in audit contexts
- Documentation standards for design rationale
- Working with contract manufacturers under regulatory oversight
- Design freeze and change control integration
- Ensuring patient or user safety during simplification
Module 13: Software and Digital Tools for DFMA - Overview of DFMA analysis software tools
- Importing CAD models for evaluation
- Automated part count and handling time estimation
- Using built-in cost databases for material and labour
- Generating comparative reports across design variants
- Exporting scorecards for team reviews
- Integrating with PLM and ERP systems
- Version control for DFMA studies
- Collaborative review features and markup tools
- Training your team on digital DFMA workflows
Module 14: Building a DFMA Culture - Developing internal DFMA guidelines and playbook
- Creating department-specific checklists
- Defining gate reviews in the product development process
- Training new engineers in DFMA principles
- Recognising and rewarding design efficiency
- Linking DFMA metrics to performance goals
- Presenting DFMA results to senior leadership
- Securing budget for DFMA software and training
- Measuring the return on DFMA initiatives
- Scaling DFMA across multiple product lines
Module 15: Project: Apply DFMA to Your Real Product - Selecting a current or past product for analysis
- Creating an as-built bill of materials
- Mapping the current assembly sequence
- Estimating current handling and insertion times
- Calculating baseline design efficiency
- Identifying opportunities for part reduction
- Proposing alternative fastening or joining methods
- Redesigning one critical subassembly
- Re-evaluating cost and assembly time post-redesign
- Documenting improvement rationale and projected savings
Module 16: Certification, Next Steps & Career Impact - Preparing your final DFMA project submission
- Review criteria for Certificate of Completion
- Presenting your analysis to stakeholders
- Adding DFMA certification to your professional profile
- Updating LinkedIn and resume with verified skills
- Leveraging certification in performance reviews
- Negotiating higher responsibility based on DFMA expertise
- Joining the global Art of Service engineer network
- Accessing exclusive job boards and mentorship
- Planning your next DFMA initiative with confidence
- Overview of the Boothroyd-Dewhurst method
- Manual handling and insertion time estimation
- Design efficiency formula and target setting
- Part count minimisation strategies
- Design for ease of orientation and insertion
- Use of symmetry to reduce assembly complexity
- Passive vs. active assembly features
- Design for self-locating and self-fixturing components
- Material selection guidelines for manufacturability
- Fastening method evaluation and substitution
Module 3: Advanced Cost Analysis Tools - Cost breakdown structure for mechanical assemblies
- Estimating labour time per part
- Automated time estimation using standard databases
- Material cost sensitivity analysis
- Tooling and fixture cost allocation
- Overhead rate integration in cost models
- Bottleneck identification in assembly lines
- Calculating total cost per assembly operation
- Cost impact of design variations
- Scenario modelling for alternative designs
Module 4: Design for Manual Assembly - Ergonomic principles in manual handling
- Graspability and pinch-point reduction
- Visual identification and part differentiation
- Minimising reorientation during assembly
- Use of chamfers, tapers, and guides
- Design for one-handed assembly operations
- Avoiding tangling, nesting, and jamming in feeds
- Reducing fine motor skill requirements
- Standardising torque and force requirements
- Designing for error-proofing in manual steps
Module 5: Design for Automated Assembly - Understanding automation constraints and capabilities
- Part feedability and bowl feeder compatibility
- Design for robotic gripper compatibility
- Minimising part flipping and orientation steps
- Tolerance stack-up in robotic assembly
- Sensor integration and feedback requirements
- Repeatability and precision in automated handling
- Avoiding features that require vision correction
- Design for high-speed pick-and-place systems
- Automated fastening compatibility (screwdrivers, crimping)
Module 6: Design for Manufacturability by Process - Injection moulding design rules (draft angles, ribs, bosses)
- Sheet metal forming: bend allowances, cutouts, flanges
- Casting design: parting lines, undercuts, cores
- Extrusion: profile symmetry, thickness consistency
- 3D printing: support structure reduction, overhangs
- Machining: tool access, feature complexity, fixturing
- Stamping: nest efficiency, scrap minimisation
- Welding: joint accessibility, fit-up requirements
- Adhesive bonding: surface preparation, gap control
- Assembly sequence compatibility with downstream processes
Module 7: Component Integration and Part Count Reduction - Functional decomposition and consolidation
- Merging parts with similar materials and processes
- Redesigning subassemblies as single components
- Using snap-fits instead of fasteners
- Designing for two-shot or overmoulded features
- Integrating bearings, seals, or gaskets into housings
- Replacing screws with press-fits or tabs
- Combining electrical and mechanical features
- Assessing trade-offs between integration and serviceability
- Using design morphology charts for innovation
Module 8: Tolerance and Fit Optimisation - Understanding clearance vs. interference fits
- Tolerance stack-up analysis in assemblies
- Statistical vs. worst-case tolerance methods
- Designing for maximum allowable variation
- Using generous tolerances without sacrificing function
- Specifying geometric dimensioning and tolerancing (GD&T)
- Selecting fit classes based on assembly method
- Minimising sensitivity to thermal expansion
- Designing for easy adjustment and shimming
- Conducting sensitivity analysis on critical dimensions
Module 9: Standardisation and Modular Design - Creating company-wide component libraries
- Standardising fasteners, bearings, and O-rings
- Developing modular architecture for product families
- Designing for platform scalability
- Using common mounting interfaces
- Reducing SKU proliferation through modularity
- Capturing reusable design patterns
- Aligning with enterprise parts databases
- Benefits of supplier rationalisation
- Change management for introducing standards
Module 10: Design for Disassembly and Serviceability - Reverse DFMA: Planning for end-of-life
- Designing for tool access in maintenance
- Use of access panels and inspection hatches
- Minimising part removal complexity
- Designing for quick-replace modules
- Labelling and colour-coding for service identification
- Designing for reusability and remanufacturing
- Service interval compatibility with disassembly effort
- Avoiding permanent bonding in serviceable areas
- Creating service procedure guidelines from design
Module 11: Cross-Functional Collaboration & Integration - Engaging manufacturing engineering early in design
- Setting up Design for Manufacturing reviews (DFM)
- Facilitating joint design-manufacturing workshops
- Using checklists for interdisciplinary alignment
- Translating manufacturing feedback into design changes
- Managing resistance to design simplification
- Building trust between design and production teams
- Documenting assumptions and trade-offs
- Creating a shared language for manufacturability
- Linking DFMA to Design for Six Sigma and Lean
Module 12: DFMA in Regulated Industries - Applying DFMA in medical device design
- Aerospace compliance and traceability requirements
- Automotive safety-critical component considerations
- Validating design changes under ISO 13485 or AS9100
- Managing risk analysis (FMEA) alongside DFMA
- Justifying design simplification in audit contexts
- Documentation standards for design rationale
- Working with contract manufacturers under regulatory oversight
- Design freeze and change control integration
- Ensuring patient or user safety during simplification
Module 13: Software and Digital Tools for DFMA - Overview of DFMA analysis software tools
- Importing CAD models for evaluation
- Automated part count and handling time estimation
- Using built-in cost databases for material and labour
- Generating comparative reports across design variants
- Exporting scorecards for team reviews
- Integrating with PLM and ERP systems
- Version control for DFMA studies
- Collaborative review features and markup tools
- Training your team on digital DFMA workflows
Module 14: Building a DFMA Culture - Developing internal DFMA guidelines and playbook
- Creating department-specific checklists
- Defining gate reviews in the product development process
- Training new engineers in DFMA principles
- Recognising and rewarding design efficiency
- Linking DFMA metrics to performance goals
- Presenting DFMA results to senior leadership
- Securing budget for DFMA software and training
- Measuring the return on DFMA initiatives
- Scaling DFMA across multiple product lines
Module 15: Project: Apply DFMA to Your Real Product - Selecting a current or past product for analysis
- Creating an as-built bill of materials
- Mapping the current assembly sequence
- Estimating current handling and insertion times
- Calculating baseline design efficiency
- Identifying opportunities for part reduction
- Proposing alternative fastening or joining methods
- Redesigning one critical subassembly
- Re-evaluating cost and assembly time post-redesign
- Documenting improvement rationale and projected savings
Module 16: Certification, Next Steps & Career Impact - Preparing your final DFMA project submission
- Review criteria for Certificate of Completion
- Presenting your analysis to stakeholders
- Adding DFMA certification to your professional profile
- Updating LinkedIn and resume with verified skills
- Leveraging certification in performance reviews
- Negotiating higher responsibility based on DFMA expertise
- Joining the global Art of Service engineer network
- Accessing exclusive job boards and mentorship
- Planning your next DFMA initiative with confidence
- Ergonomic principles in manual handling
- Graspability and pinch-point reduction
- Visual identification and part differentiation
- Minimising reorientation during assembly
- Use of chamfers, tapers, and guides
- Design for one-handed assembly operations
- Avoiding tangling, nesting, and jamming in feeds
- Reducing fine motor skill requirements
- Standardising torque and force requirements
- Designing for error-proofing in manual steps
Module 5: Design for Automated Assembly - Understanding automation constraints and capabilities
- Part feedability and bowl feeder compatibility
- Design for robotic gripper compatibility
- Minimising part flipping and orientation steps
- Tolerance stack-up in robotic assembly
- Sensor integration and feedback requirements
- Repeatability and precision in automated handling
- Avoiding features that require vision correction
- Design for high-speed pick-and-place systems
- Automated fastening compatibility (screwdrivers, crimping)
Module 6: Design for Manufacturability by Process - Injection moulding design rules (draft angles, ribs, bosses)
- Sheet metal forming: bend allowances, cutouts, flanges
- Casting design: parting lines, undercuts, cores
- Extrusion: profile symmetry, thickness consistency
- 3D printing: support structure reduction, overhangs
- Machining: tool access, feature complexity, fixturing
- Stamping: nest efficiency, scrap minimisation
- Welding: joint accessibility, fit-up requirements
- Adhesive bonding: surface preparation, gap control
- Assembly sequence compatibility with downstream processes
Module 7: Component Integration and Part Count Reduction - Functional decomposition and consolidation
- Merging parts with similar materials and processes
- Redesigning subassemblies as single components
- Using snap-fits instead of fasteners
- Designing for two-shot or overmoulded features
- Integrating bearings, seals, or gaskets into housings
- Replacing screws with press-fits or tabs
- Combining electrical and mechanical features
- Assessing trade-offs between integration and serviceability
- Using design morphology charts for innovation
Module 8: Tolerance and Fit Optimisation - Understanding clearance vs. interference fits
- Tolerance stack-up analysis in assemblies
- Statistical vs. worst-case tolerance methods
- Designing for maximum allowable variation
- Using generous tolerances without sacrificing function
- Specifying geometric dimensioning and tolerancing (GD&T)
- Selecting fit classes based on assembly method
- Minimising sensitivity to thermal expansion
- Designing for easy adjustment and shimming
- Conducting sensitivity analysis on critical dimensions
Module 9: Standardisation and Modular Design - Creating company-wide component libraries
- Standardising fasteners, bearings, and O-rings
- Developing modular architecture for product families
- Designing for platform scalability
- Using common mounting interfaces
- Reducing SKU proliferation through modularity
- Capturing reusable design patterns
- Aligning with enterprise parts databases
- Benefits of supplier rationalisation
- Change management for introducing standards
Module 10: Design for Disassembly and Serviceability - Reverse DFMA: Planning for end-of-life
- Designing for tool access in maintenance
- Use of access panels and inspection hatches
- Minimising part removal complexity
- Designing for quick-replace modules
- Labelling and colour-coding for service identification
- Designing for reusability and remanufacturing
- Service interval compatibility with disassembly effort
- Avoiding permanent bonding in serviceable areas
- Creating service procedure guidelines from design
Module 11: Cross-Functional Collaboration & Integration - Engaging manufacturing engineering early in design
- Setting up Design for Manufacturing reviews (DFM)
- Facilitating joint design-manufacturing workshops
- Using checklists for interdisciplinary alignment
- Translating manufacturing feedback into design changes
- Managing resistance to design simplification
- Building trust between design and production teams
- Documenting assumptions and trade-offs
- Creating a shared language for manufacturability
- Linking DFMA to Design for Six Sigma and Lean
Module 12: DFMA in Regulated Industries - Applying DFMA in medical device design
- Aerospace compliance and traceability requirements
- Automotive safety-critical component considerations
- Validating design changes under ISO 13485 or AS9100
- Managing risk analysis (FMEA) alongside DFMA
- Justifying design simplification in audit contexts
- Documentation standards for design rationale
- Working with contract manufacturers under regulatory oversight
- Design freeze and change control integration
- Ensuring patient or user safety during simplification
Module 13: Software and Digital Tools for DFMA - Overview of DFMA analysis software tools
- Importing CAD models for evaluation
- Automated part count and handling time estimation
- Using built-in cost databases for material and labour
- Generating comparative reports across design variants
- Exporting scorecards for team reviews
- Integrating with PLM and ERP systems
- Version control for DFMA studies
- Collaborative review features and markup tools
- Training your team on digital DFMA workflows
Module 14: Building a DFMA Culture - Developing internal DFMA guidelines and playbook
- Creating department-specific checklists
- Defining gate reviews in the product development process
- Training new engineers in DFMA principles
- Recognising and rewarding design efficiency
- Linking DFMA metrics to performance goals
- Presenting DFMA results to senior leadership
- Securing budget for DFMA software and training
- Measuring the return on DFMA initiatives
- Scaling DFMA across multiple product lines
Module 15: Project: Apply DFMA to Your Real Product - Selecting a current or past product for analysis
- Creating an as-built bill of materials
- Mapping the current assembly sequence
- Estimating current handling and insertion times
- Calculating baseline design efficiency
- Identifying opportunities for part reduction
- Proposing alternative fastening or joining methods
- Redesigning one critical subassembly
- Re-evaluating cost and assembly time post-redesign
- Documenting improvement rationale and projected savings
Module 16: Certification, Next Steps & Career Impact - Preparing your final DFMA project submission
- Review criteria for Certificate of Completion
- Presenting your analysis to stakeholders
- Adding DFMA certification to your professional profile
- Updating LinkedIn and resume with verified skills
- Leveraging certification in performance reviews
- Negotiating higher responsibility based on DFMA expertise
- Joining the global Art of Service engineer network
- Accessing exclusive job boards and mentorship
- Planning your next DFMA initiative with confidence
- Injection moulding design rules (draft angles, ribs, bosses)
- Sheet metal forming: bend allowances, cutouts, flanges
- Casting design: parting lines, undercuts, cores
- Extrusion: profile symmetry, thickness consistency
- 3D printing: support structure reduction, overhangs
- Machining: tool access, feature complexity, fixturing
- Stamping: nest efficiency, scrap minimisation
- Welding: joint accessibility, fit-up requirements
- Adhesive bonding: surface preparation, gap control
- Assembly sequence compatibility with downstream processes
Module 7: Component Integration and Part Count Reduction - Functional decomposition and consolidation
- Merging parts with similar materials and processes
- Redesigning subassemblies as single components
- Using snap-fits instead of fasteners
- Designing for two-shot or overmoulded features
- Integrating bearings, seals, or gaskets into housings
- Replacing screws with press-fits or tabs
- Combining electrical and mechanical features
- Assessing trade-offs between integration and serviceability
- Using design morphology charts for innovation
Module 8: Tolerance and Fit Optimisation - Understanding clearance vs. interference fits
- Tolerance stack-up analysis in assemblies
- Statistical vs. worst-case tolerance methods
- Designing for maximum allowable variation
- Using generous tolerances without sacrificing function
- Specifying geometric dimensioning and tolerancing (GD&T)
- Selecting fit classes based on assembly method
- Minimising sensitivity to thermal expansion
- Designing for easy adjustment and shimming
- Conducting sensitivity analysis on critical dimensions
Module 9: Standardisation and Modular Design - Creating company-wide component libraries
- Standardising fasteners, bearings, and O-rings
- Developing modular architecture for product families
- Designing for platform scalability
- Using common mounting interfaces
- Reducing SKU proliferation through modularity
- Capturing reusable design patterns
- Aligning with enterprise parts databases
- Benefits of supplier rationalisation
- Change management for introducing standards
Module 10: Design for Disassembly and Serviceability - Reverse DFMA: Planning for end-of-life
- Designing for tool access in maintenance
- Use of access panels and inspection hatches
- Minimising part removal complexity
- Designing for quick-replace modules
- Labelling and colour-coding for service identification
- Designing for reusability and remanufacturing
- Service interval compatibility with disassembly effort
- Avoiding permanent bonding in serviceable areas
- Creating service procedure guidelines from design
Module 11: Cross-Functional Collaboration & Integration - Engaging manufacturing engineering early in design
- Setting up Design for Manufacturing reviews (DFM)
- Facilitating joint design-manufacturing workshops
- Using checklists for interdisciplinary alignment
- Translating manufacturing feedback into design changes
- Managing resistance to design simplification
- Building trust between design and production teams
- Documenting assumptions and trade-offs
- Creating a shared language for manufacturability
- Linking DFMA to Design for Six Sigma and Lean
Module 12: DFMA in Regulated Industries - Applying DFMA in medical device design
- Aerospace compliance and traceability requirements
- Automotive safety-critical component considerations
- Validating design changes under ISO 13485 or AS9100
- Managing risk analysis (FMEA) alongside DFMA
- Justifying design simplification in audit contexts
- Documentation standards for design rationale
- Working with contract manufacturers under regulatory oversight
- Design freeze and change control integration
- Ensuring patient or user safety during simplification
Module 13: Software and Digital Tools for DFMA - Overview of DFMA analysis software tools
- Importing CAD models for evaluation
- Automated part count and handling time estimation
- Using built-in cost databases for material and labour
- Generating comparative reports across design variants
- Exporting scorecards for team reviews
- Integrating with PLM and ERP systems
- Version control for DFMA studies
- Collaborative review features and markup tools
- Training your team on digital DFMA workflows
Module 14: Building a DFMA Culture - Developing internal DFMA guidelines and playbook
- Creating department-specific checklists
- Defining gate reviews in the product development process
- Training new engineers in DFMA principles
- Recognising and rewarding design efficiency
- Linking DFMA metrics to performance goals
- Presenting DFMA results to senior leadership
- Securing budget for DFMA software and training
- Measuring the return on DFMA initiatives
- Scaling DFMA across multiple product lines
Module 15: Project: Apply DFMA to Your Real Product - Selecting a current or past product for analysis
- Creating an as-built bill of materials
- Mapping the current assembly sequence
- Estimating current handling and insertion times
- Calculating baseline design efficiency
- Identifying opportunities for part reduction
- Proposing alternative fastening or joining methods
- Redesigning one critical subassembly
- Re-evaluating cost and assembly time post-redesign
- Documenting improvement rationale and projected savings
Module 16: Certification, Next Steps & Career Impact - Preparing your final DFMA project submission
- Review criteria for Certificate of Completion
- Presenting your analysis to stakeholders
- Adding DFMA certification to your professional profile
- Updating LinkedIn and resume with verified skills
- Leveraging certification in performance reviews
- Negotiating higher responsibility based on DFMA expertise
- Joining the global Art of Service engineer network
- Accessing exclusive job boards and mentorship
- Planning your next DFMA initiative with confidence
- Understanding clearance vs. interference fits
- Tolerance stack-up analysis in assemblies
- Statistical vs. worst-case tolerance methods
- Designing for maximum allowable variation
- Using generous tolerances without sacrificing function
- Specifying geometric dimensioning and tolerancing (GD&T)
- Selecting fit classes based on assembly method
- Minimising sensitivity to thermal expansion
- Designing for easy adjustment and shimming
- Conducting sensitivity analysis on critical dimensions
Module 9: Standardisation and Modular Design - Creating company-wide component libraries
- Standardising fasteners, bearings, and O-rings
- Developing modular architecture for product families
- Designing for platform scalability
- Using common mounting interfaces
- Reducing SKU proliferation through modularity
- Capturing reusable design patterns
- Aligning with enterprise parts databases
- Benefits of supplier rationalisation
- Change management for introducing standards
Module 10: Design for Disassembly and Serviceability - Reverse DFMA: Planning for end-of-life
- Designing for tool access in maintenance
- Use of access panels and inspection hatches
- Minimising part removal complexity
- Designing for quick-replace modules
- Labelling and colour-coding for service identification
- Designing for reusability and remanufacturing
- Service interval compatibility with disassembly effort
- Avoiding permanent bonding in serviceable areas
- Creating service procedure guidelines from design
Module 11: Cross-Functional Collaboration & Integration - Engaging manufacturing engineering early in design
- Setting up Design for Manufacturing reviews (DFM)
- Facilitating joint design-manufacturing workshops
- Using checklists for interdisciplinary alignment
- Translating manufacturing feedback into design changes
- Managing resistance to design simplification
- Building trust between design and production teams
- Documenting assumptions and trade-offs
- Creating a shared language for manufacturability
- Linking DFMA to Design for Six Sigma and Lean
Module 12: DFMA in Regulated Industries - Applying DFMA in medical device design
- Aerospace compliance and traceability requirements
- Automotive safety-critical component considerations
- Validating design changes under ISO 13485 or AS9100
- Managing risk analysis (FMEA) alongside DFMA
- Justifying design simplification in audit contexts
- Documentation standards for design rationale
- Working with contract manufacturers under regulatory oversight
- Design freeze and change control integration
- Ensuring patient or user safety during simplification
Module 13: Software and Digital Tools for DFMA - Overview of DFMA analysis software tools
- Importing CAD models for evaluation
- Automated part count and handling time estimation
- Using built-in cost databases for material and labour
- Generating comparative reports across design variants
- Exporting scorecards for team reviews
- Integrating with PLM and ERP systems
- Version control for DFMA studies
- Collaborative review features and markup tools
- Training your team on digital DFMA workflows
Module 14: Building a DFMA Culture - Developing internal DFMA guidelines and playbook
- Creating department-specific checklists
- Defining gate reviews in the product development process
- Training new engineers in DFMA principles
- Recognising and rewarding design efficiency
- Linking DFMA metrics to performance goals
- Presenting DFMA results to senior leadership
- Securing budget for DFMA software and training
- Measuring the return on DFMA initiatives
- Scaling DFMA across multiple product lines
Module 15: Project: Apply DFMA to Your Real Product - Selecting a current or past product for analysis
- Creating an as-built bill of materials
- Mapping the current assembly sequence
- Estimating current handling and insertion times
- Calculating baseline design efficiency
- Identifying opportunities for part reduction
- Proposing alternative fastening or joining methods
- Redesigning one critical subassembly
- Re-evaluating cost and assembly time post-redesign
- Documenting improvement rationale and projected savings
Module 16: Certification, Next Steps & Career Impact - Preparing your final DFMA project submission
- Review criteria for Certificate of Completion
- Presenting your analysis to stakeholders
- Adding DFMA certification to your professional profile
- Updating LinkedIn and resume with verified skills
- Leveraging certification in performance reviews
- Negotiating higher responsibility based on DFMA expertise
- Joining the global Art of Service engineer network
- Accessing exclusive job boards and mentorship
- Planning your next DFMA initiative with confidence
- Reverse DFMA: Planning for end-of-life
- Designing for tool access in maintenance
- Use of access panels and inspection hatches
- Minimising part removal complexity
- Designing for quick-replace modules
- Labelling and colour-coding for service identification
- Designing for reusability and remanufacturing
- Service interval compatibility with disassembly effort
- Avoiding permanent bonding in serviceable areas
- Creating service procedure guidelines from design
Module 11: Cross-Functional Collaboration & Integration - Engaging manufacturing engineering early in design
- Setting up Design for Manufacturing reviews (DFM)
- Facilitating joint design-manufacturing workshops
- Using checklists for interdisciplinary alignment
- Translating manufacturing feedback into design changes
- Managing resistance to design simplification
- Building trust between design and production teams
- Documenting assumptions and trade-offs
- Creating a shared language for manufacturability
- Linking DFMA to Design for Six Sigma and Lean
Module 12: DFMA in Regulated Industries - Applying DFMA in medical device design
- Aerospace compliance and traceability requirements
- Automotive safety-critical component considerations
- Validating design changes under ISO 13485 or AS9100
- Managing risk analysis (FMEA) alongside DFMA
- Justifying design simplification in audit contexts
- Documentation standards for design rationale
- Working with contract manufacturers under regulatory oversight
- Design freeze and change control integration
- Ensuring patient or user safety during simplification
Module 13: Software and Digital Tools for DFMA - Overview of DFMA analysis software tools
- Importing CAD models for evaluation
- Automated part count and handling time estimation
- Using built-in cost databases for material and labour
- Generating comparative reports across design variants
- Exporting scorecards for team reviews
- Integrating with PLM and ERP systems
- Version control for DFMA studies
- Collaborative review features and markup tools
- Training your team on digital DFMA workflows
Module 14: Building a DFMA Culture - Developing internal DFMA guidelines and playbook
- Creating department-specific checklists
- Defining gate reviews in the product development process
- Training new engineers in DFMA principles
- Recognising and rewarding design efficiency
- Linking DFMA metrics to performance goals
- Presenting DFMA results to senior leadership
- Securing budget for DFMA software and training
- Measuring the return on DFMA initiatives
- Scaling DFMA across multiple product lines
Module 15: Project: Apply DFMA to Your Real Product - Selecting a current or past product for analysis
- Creating an as-built bill of materials
- Mapping the current assembly sequence
- Estimating current handling and insertion times
- Calculating baseline design efficiency
- Identifying opportunities for part reduction
- Proposing alternative fastening or joining methods
- Redesigning one critical subassembly
- Re-evaluating cost and assembly time post-redesign
- Documenting improvement rationale and projected savings
Module 16: Certification, Next Steps & Career Impact - Preparing your final DFMA project submission
- Review criteria for Certificate of Completion
- Presenting your analysis to stakeholders
- Adding DFMA certification to your professional profile
- Updating LinkedIn and resume with verified skills
- Leveraging certification in performance reviews
- Negotiating higher responsibility based on DFMA expertise
- Joining the global Art of Service engineer network
- Accessing exclusive job boards and mentorship
- Planning your next DFMA initiative with confidence
- Applying DFMA in medical device design
- Aerospace compliance and traceability requirements
- Automotive safety-critical component considerations
- Validating design changes under ISO 13485 or AS9100
- Managing risk analysis (FMEA) alongside DFMA
- Justifying design simplification in audit contexts
- Documentation standards for design rationale
- Working with contract manufacturers under regulatory oversight
- Design freeze and change control integration
- Ensuring patient or user safety during simplification
Module 13: Software and Digital Tools for DFMA - Overview of DFMA analysis software tools
- Importing CAD models for evaluation
- Automated part count and handling time estimation
- Using built-in cost databases for material and labour
- Generating comparative reports across design variants
- Exporting scorecards for team reviews
- Integrating with PLM and ERP systems
- Version control for DFMA studies
- Collaborative review features and markup tools
- Training your team on digital DFMA workflows
Module 14: Building a DFMA Culture - Developing internal DFMA guidelines and playbook
- Creating department-specific checklists
- Defining gate reviews in the product development process
- Training new engineers in DFMA principles
- Recognising and rewarding design efficiency
- Linking DFMA metrics to performance goals
- Presenting DFMA results to senior leadership
- Securing budget for DFMA software and training
- Measuring the return on DFMA initiatives
- Scaling DFMA across multiple product lines
Module 15: Project: Apply DFMA to Your Real Product - Selecting a current or past product for analysis
- Creating an as-built bill of materials
- Mapping the current assembly sequence
- Estimating current handling and insertion times
- Calculating baseline design efficiency
- Identifying opportunities for part reduction
- Proposing alternative fastening or joining methods
- Redesigning one critical subassembly
- Re-evaluating cost and assembly time post-redesign
- Documenting improvement rationale and projected savings
Module 16: Certification, Next Steps & Career Impact - Preparing your final DFMA project submission
- Review criteria for Certificate of Completion
- Presenting your analysis to stakeholders
- Adding DFMA certification to your professional profile
- Updating LinkedIn and resume with verified skills
- Leveraging certification in performance reviews
- Negotiating higher responsibility based on DFMA expertise
- Joining the global Art of Service engineer network
- Accessing exclusive job boards and mentorship
- Planning your next DFMA initiative with confidence
- Developing internal DFMA guidelines and playbook
- Creating department-specific checklists
- Defining gate reviews in the product development process
- Training new engineers in DFMA principles
- Recognising and rewarding design efficiency
- Linking DFMA metrics to performance goals
- Presenting DFMA results to senior leadership
- Securing budget for DFMA software and training
- Measuring the return on DFMA initiatives
- Scaling DFMA across multiple product lines
Module 15: Project: Apply DFMA to Your Real Product - Selecting a current or past product for analysis
- Creating an as-built bill of materials
- Mapping the current assembly sequence
- Estimating current handling and insertion times
- Calculating baseline design efficiency
- Identifying opportunities for part reduction
- Proposing alternative fastening or joining methods
- Redesigning one critical subassembly
- Re-evaluating cost and assembly time post-redesign
- Documenting improvement rationale and projected savings
Module 16: Certification, Next Steps & Career Impact - Preparing your final DFMA project submission
- Review criteria for Certificate of Completion
- Presenting your analysis to stakeholders
- Adding DFMA certification to your professional profile
- Updating LinkedIn and resume with verified skills
- Leveraging certification in performance reviews
- Negotiating higher responsibility based on DFMA expertise
- Joining the global Art of Service engineer network
- Accessing exclusive job boards and mentorship
- Planning your next DFMA initiative with confidence
- Preparing your final DFMA project submission
- Review criteria for Certificate of Completion
- Presenting your analysis to stakeholders
- Adding DFMA certification to your professional profile
- Updating LinkedIn and resume with verified skills
- Leveraging certification in performance reviews
- Negotiating higher responsibility based on DFMA expertise
- Joining the global Art of Service engineer network
- Accessing exclusive job boards and mentorship
- Planning your next DFMA initiative with confidence