Today’s manufacturing and supply chain landscapes are unpredictable. Geopolitical issues are difficult to anticipate and even harder to react to. However, design — which makes up most production, operating and maintenance costs — is within companies’ control. Design for manufacturing and assembly (DfMA) is an emerging intervention for resilience.
Developing a Resilience-By-Design Approach
From the COVID-19 pandemic to the China-United States trade war, disruptive geopolitical events seem to be the new normal. Inflation volatility, trade disputes, ongoing conflicts and erratic tariff policies are evolving faster than industry professionals can keep up. While they may feel at the mercy of geopolitics, supply chain resilience is within reach.
In the traditional industry standard model, development, fabrication, assembly and logistics are separate. However, siloing is not strategic. In today’s volatile environment, companies need DfMA to bridge the gaps. This engineering tactic prioritizes easier manufacturing and assembly during the early development stages. The goal is to reduce production costs and shorten time-to-market, consequently improving supply chain resilience.
This approach has potential. While design accounts for just //medium.com/@drdolas2002/design-for-manufacturing-and-assembly-dfma-acff30da0e14">5% of an item’s total cost, it determines 70% of manufacturing expenses. Considering the product life cycle and every design decision’s implications early on could guarantee a sizable return.
A conventional design, production, assembly and packaging method can take months or years. The typical DfMA process takes around two weeks in comparison. It can vary depending on part requirements, operation complexity and manufacturing method utilization. However, it still shortens time-to-market significantly.
The Benefits of DfMA for Manufacturing and Logistics
DfMA shortens production and assembly times by optimizing component count. A simple layout has less room for error, reducing defect frequency. Manufacturers lower variable costs by mitigating waste and streamlining production. In uncertain times like these, saving money wherever possible is important.
These benefits aren’t hypothetical. Research shows that a DfMA-oriented approach can optimize computer part development, decreasing design costs by 80% and component tooling expenses by 75 percent. Decision-makers could redirect such savings toward reshoring efforts or supplier diversification to mitigate the effects of geopolitical factors like tariffs.
Collectively, these improvements lead to larger profit margins and greater logistics flexibility. The beauty of this strategy is that it works regardless of facility location. Leaders can improve offshore or domestic assembly lines, regardless of whether they produce foods, textiles or toiletries.
DfMA Strategies for Supply Chain-Friendly Products
Industry professionals don’t know how tariffs will impact material prices or whether economic sanctions will affect supplier availability. They should prioritize minimizing part count while maximizing functionality — without inadvertently creating a single point of failure — to combat geopolitical effects.
Symmetrical Layouts
Symmetrical design shortens assembly time because workers don’t have to keep track of which side they’re working on. Robots can also machine parts simultaneously. Symmetrical layouts even enhance logistics because they make stacking items easier. Since this approach simplifies production, it may reduce defects. As a result, companies avoid delays and returns.
Modular Design
Manufacturers can achieve resilience by design with multifunctional parts and flexible tooling strategies. This way, there is no single point of failure. A cross-functional approach could help streamline processes. Collaboration between individuals from various disciplines — like fabrication, marketing and quality assurance — would ensure diverse perspectives and ideas.
Reduced Part Count
Minimizing component count simplifies every stage in the product life cycle. It shortens time-to-market, improves ease of handling and decreases production expenses.
GE’s production process for commercial engine fuel nozzles is an excellent example. Using three-dimensional printing, it reduced the number of parts from 20 to one, decreasing its reliance on overseas vendors. Moreover, the final product was five times more durable and 25% lighter. Lowering component count without compromising performance is possible.
Self-Aligning Components
Self-aligning parts mitigate delays and defects, streamlining assembly. For example, a company can design a component so a spring falls into place instead of getting caught on the rim when placed by hand. Time is of the essence when inflation, trade wars and tariffs are at play, so this strategy is practical.
Leveraging DfMA for a Resilient Supply Chain
The possibility of a cost overrun starts at the beginning of development. Once design decisions are made, manufacturing expenses are locked in. This is why DfMA is important. Industry professionals should consider implementing these strategies to remain resilient in the face of tariffs, trade wars, inflation and other geopolitical uncertainties.
