Product Design for Manufacturing & Assembly Innovations
Product Design for Manufacturing & Assembly Innovations

Dec 22, 2020

An important methodology for virtually all companies that create products is design for manufacturing and assembly (DFMA). This practice improves the design of components, so production costs are as little as possible. As DFMA has taken shape over the years, the focus has expanded on the delicate balance between serviceability and reliability. Sometimes, optimizing one component of a product can result in another component being degraded. Software, electronics, and sensors are making their way into the world of product design. New composites, plastics, and alloys are replacing traditional metals.

Designs are even reducing the carbon footprint of manufacturers, and more products can be recycled when they reach the end of their use. Some breakthroughs have been software-intensive, reducing reliance on outside DFMA consultants. Some techniques apply to product redesign and the creation of new eco-friendly products. Many markets are being disrupted because they move away from traditional models toward those that achieve innovation at a lower cost since experimentation is becoming more popular.

Digital imaging plays a larger role, as 3-D visual models can easily be transformed into physical products. Creating a digital image that can generate an accurate prototype and tighten measurements is also more affordable. Another area of innovation is looking for solutions that work well in developing and economically developing countries, then adding certain capacities that allow companies to move products into the more established economies. Those products tend to target the poorer people living in first-world economies. This strategy plays an important role in DFMA in the most affordable way possible. In other words, the people at the bottom are being targeted instead of more affluent consumers.

The latest DFMA advancements revolve around the following key areas:

  • Disruption
  • Emerging technology
  • Digital innovation
  • Moving away from traditional innovation
  • Human-centered thinking
  • Sustainability
  • Embracing the tension between old and new

Product Design Breakthroughs

The Harvard Business Review suggested in the June 2008 issue that thinking processes should literally start with a blank sheet of paper before deciding the direction a product should take. Everything from human behavior to innovation should be factored into this from the scratch development process. Human-centered thinking will help realize those specific insights that help produce innovation that focuses more on consumer demand. An example of focusing on consumer demand is delivering better sustainability. [1]

Clients expect green design to make more environmentally friendly materials that don’t sacrifice quality or usability. 12 S&P Global 100 companies experienced a 91% increase in revenues after using more green product options. Overall, breakthroughs will continue to disrupt many markets, which will impact DFMA practices for years to come. Some of these advances will increase the need for DFMA expertise while, in other ways, they’ll actually decrease that need. Sustainability, in particular, will result in design optimization for improved recyclability and environmental impact. [1]

Backed by 40 Years of Expertise

We contribute our 40 years of design and manufacturing expertise spanning multiple diverse markets. We look forward to discussing how we can deliver world-class products for OEMs across the globe. We understand our home Indian market, familiar with its vast regulatory and selling environments. We foster growth opportunities within India through our strong technology incubation ecosystem. We also assist global OEMs in entering the Indian market by leveraging the local supply chain and favorable operating environments for cost reductions.

Our flagship Chennai location opened in 2006 and lies within a Special Economic Zone (SEZ) for electronics manufacturing, offering economic incentives for imports and exports. This primary facility is within 90 minutes of the Chennai seaport and 20 minutes to the international airport. Additional road and rail connectivity links to the rest of India and beyond and infrastructure advantages with faster import and export clearances. We also have labor force flexibility, both technical and manual, to scale to demand rapidly.

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