Table Of ContentTOOL AND MANUFACTURING
ENGINEERS HANDBOOK
VOLUME VI
DESIGN FOR MANUFACTURABILITY
SOCIETY OF MANUFACTURING ENGINEERS
OFFICERS AND DIRECTORS, 1992
President Ronald P. Harrelson, CMfgE
Douglas E. Booth, CMfgE, PE Caterpillar Institute
Bond Robotics, Inc.
Rita M. Hiiyer, CMfgT
President-Elect Veeder-Root Co .
Frank H. McCarthy, CMfgE, PE
Jim C. Hoover
Raytheon Company (retired)
Northrop Corporation
Second Vice President
Elvin W. Keith, Jr., CMfgE, PE
Charles A. Templeton, CMfgE, PE
E. W. Keith & Associates
Charles A. Templeton Machine
Ken K. Koch, CMfgE, PE
Third Vice President
Parker Hannifin Corp.
Gustav J. Oiling, PhD, CMfgE, PE
Chrysler Corporation Homer P. Lane, CMfgE, PE
Engineering Consultant
Secretary/Treasurer
Clinton 0. Larson, CMfgE, PE James F. Lardner
Honeywell, Inc . Deere & Co. (retired)
James K. Long
AMP Inc.
James F. Barcus, Jr.
Black & Decker Corp. (retired) Alan T. Male, PhD, PE
Consultant
Russ G. Biekert, PhD, CMfgE
Allied-Signal Aerospace Co. Paul A. Misegades, CMfgE
General Electric Company
Joseph E. Brown
(Retired) Louis M. Papp, CMfgE, PE
Windsor-Essex County Dev. Comm.
Gary L. Cline, CMfgE
Brunswick Corp. John T. Parsons
Jack L. Ferrell JuTohrr T. PmmsC ompany
TRW Inc. (retired) Michael Reggia, CMfgE, PE
Thiokol
Leon W. Fortin, PE
L. W. Fortin Consultants Gerald Reynolds
Perkin-Elmer Corporation
Donald G. Foster, CMfgE, PE
Consultant Vern L. Stumpenhorst
Ford New Holland Inc.
Keith M. Gardiner, PhD, PE
Lehigh University Ronald H. Vander Weerd, CMfgE
Pella-Rolscreen Company
James M. Hardy
Hardy Associates
TOOL AND MANUFACTURING
ENGINEERS HANDBOOK
FOURTH EDITION
VOLUME VI
D ES IG N FO R MANU FACTU RAB IL ITY
A reference book for manufacturing engineers, managers, and technicians
Ramon Bakerjian, CMfgE
Handbook Editor
Philip Mitchell
Staff Editor
Produced under the supervision of
the SM E Reference Publications
Committee in cooperation with the
SME Technical Divisions
Society of Manufacturing Engineers
One SME Drive
Dearborn, Michigan
ISBN NO. 0-87263-402-7
Library of Congress Catalog No. 91-060347
Society of Manufacturing Engineers (SME)
Copyright 01992, 1976, 1959, 1949 by Society of Manufacturing Engineers,
One SME Drive, P.O. Box 930, Dearborn, Michigan 48121
All rights reserved, including those of translation. This book, or parts thereof, may not be
reproduced in any form without written permission of the copyright owner. The Society
does not, by publication of data in this book, ensure to anyone the use of such data
against liability of any kind, including infringement of any patent. Publication of any data
in this book does not constitute a recommendation of any patent or proprietary right that
may be involved. The Society of Manufacturing Engineers, as well as all contributors and
reviewers of information in this volume, disclaim any and all responsibility for use of the
information contained herein by readers and users of this Handbook.
First edition published 1949 by McGraw-Hill Book Co. in cooperation with SME under
earlier Society name, American Society of Tool Engineers (ASTE), and under title Tool
Engineers Handbook. Second edition published 1959 by McGraw-Hill Book Co. in coop-
eration with SME under earlier society name, American Society of Tool and Manufactur-
ing Engineers (ASTME), and under title Tool Engineers Handbook. Third edition pub-
lished 1976 by McGraw-Hill Book Co. in cooperation with SME under current Society
name and under title Tool and Manufacturing Engineers Handbook.
Printed in the United States of America.
PREFACE
The first edition, published as the Tool Engineers Handbook in 1949, established a
useful and authoritative editorial format that was successfully expanded and improved
in the publication of highly acclaimed subsequent editions published in 1959 and 1976.
Now, with continuing dramatic advances in manufacturing technology, increasing
competitive pressure both in the United States and abroad, and a significant diversi-
fication of the information needs of the modern manufacturing engineer, comes the
need for further expansion of the Handbook. As succinctly stated by Editor Frank W.
Wilson in the preface to the second edition: “...no ‘bible’ of the industry can
indefinitely survive the impact of new and changed technology.
”
Although greatly expanded and updated to reflect the latest in manufacturing
technology, the nature of coverage in this edition is deeply rooted in the heritage of
previous editions , constituting a unique compilation of practical data detailing the
specification and use of modern manufacturing equipment and processes. Other
volumes in this Handbook series include: Volume I, Machining, published in March
1983; Volume 11, Forming, in April 1984; Volume 111, Materials, Finishing and
Coating, in July 1985; Volume IV, Quality Control and Assembly, in January 1987;
and Volume V, Manufacturing Management, in April 1989.
The scope of this edition is multifaceted, offering a ready reference source of
authoritative manufacturing information for daily use by engineers, managers , and
technicians, yet providing significant coverage of the fundamentals of manufacturing
processes, equipment, and tooling for study by the novice engineer or student.
Uniquely, this blend of coverage has characterized the proven usefulness and reputation
of SME Handbooks in previous editions and continues in this edition to provide the
basis for acceptance across all segments of manufacturing. In this, and other TMEH
volumes, in-depth, coverage of all subjects is presented in an easy-to-read format. A
comprehensive index cross-references all subjects , facilitating quick access to infor-
mation. The liberal use of drawings, graphs, and tables also speeds information
gathering and problem solving.
This volume of the Tool and Manufacturing Engineers Handbook (TMEH) series has
two audiences; the manufacturing engineer or manager and the product designer. Both
should find all of the chapters beneficial.
The first half of the book-chapters 1 through 8 -addresses background information
and topics of Design for Manufacturability (DFM): an introduction to DFM, how it
relates to Concurrent Engineering (CE) , management issues, getting started in DFM,
how to justify using DFM, applying quality tools to DFM, and how DFM is affecting
computer technology (and vice versa).
Chapters 9 and 10 cover topics starting with the creative thinking process to
combining DFM with geometrical dimensioning and tolerancing (GDT) . Figure 9-2
(while rather lighthearted for Handbook-style material) sums up the situation found in
manufacturing that DFM will overcome, knocking down the walls between depart-
ments.
Chapters 11 through 16 cover product design information that TMEH contributors
felt was important for the designer to know when committing pen to paper or mouse to
pad. This is meant to be non-process related material. There are no detailed
descriptions of processes, drawings of typical machines, or tables of feeds and speeds,
that material can be found in the first four volumes of this edition. The designer should
V
know when the job begins what are allowable tolerances, surface finishes, geometries,
and so on, for a particular process or material that is being used.
Finally, two appendices are included to help the reader get further along in DFM.
Appendix A shows how large and small companies are applying DFM to their products
and organizations. Some of these case studies are familiar and others border on being
proprietary. Appendix B lists various DFM products and services. Neither appendix is
an exhaustive listing of successes or services.
The reference material contained in this volume is the product of incalculable hours
of unselfish contribution by hundreds of individuals and organizations, as listed at the
beginning of each chapter. No written words of appreciation can sufficiently express
the special thanks due these many forward-thinking professionals. Their work is deeply
appreciated by the Society; but more important, their contributions will undoubtedly
serve to advance the understanding of manufacturing management throughout industry
and will certainly help to spur major productivity gains in the years ahead. Industry as
a whole will be the beneficiary of their dedication.
Further recognition is due the members of the SME Reference Publication Commit-
tee for their expert guidance and support as well as the many members of the SME
Technical Activities Board.
The Editors
SME staff who participated in the editorial development and production of this volume
include :
EDITORIAL TYPESETTING GRAPHICS
Thomas J. Drozda Shari L. Smith Judy Munro
Director of Publications Supervisor Art Director
Robert E. King Kathy Allison
Typesetter
Publications Manager
Marcia Theisen
Ramon Bakerjian
Typesetter
Handbook Editor
Philip Mitchell
Staff Editor
Suzanne Kosacheff
Technical Copy Editor
Frances Kania Gregory J. Ross
Editorial Secretary Ross Services
Dorothy Wylo Donna Hicks
Editorial Secretary Adcomp Services
vi
SME
The Society of Manufacturing Engineers is a professional society dedicated to
advancing manufacturing through the continuing education of manufacturing manag-
ers, engineers, technicians, and other manufacturing professionals. The specific goal of
the Society is to advance scientific knowledge in the field of manufacturing and to
apply its resources to research, writing, publishing, and disseminating information.
“The purpose of SME is to serve the professional needs of the many types of
practitioners that make up the manufacturing community.. .The collective goal of the
membership is the sharing and advancement of knowledge in the field of manufacturing
for the good of humanity. ’ ’
The Society was founded in 1932 as the American Society of Tool Engineers
(ASTE). From 1960 to 1969 it was known as the American Society of Tool and
Manufacturing Engineers (ASTME), and in January 1970 it became the Society of
Manufacturing Engineers. The changes in name reflect the evolution of the manufac-
turing engineering profession and the growth and increasing sophistication of a
technical society that has gained an international reputation for being the most
knowledgeable and progressive voice in the field.
Associations of SME- The Society provides complete technical services and
membership benefits through a number of associations. Each serves a special interest
area. Members may join these associations in addition to SME. The associations are:
Association for Finishing Processes of SME (AFP/SME)
Computer and Automated Systems Association of SME (CASA/SME)
Machine Vision Association of SME (MVA/SME)
~
North American Manufacturing Research Institute of SME
(NAMRUSME)
Robotics International of SME (RVSME)
Composites Manufacturing Association of SME (CMA/SME)
Association for Electronics Manufacturing of SME (EM/SME)
Machining Technology Association of SME (MTA/SME)
Networking and Communications in Manufacturing Group of SME
Members and Chapters-The Society and its associations have 80,000 member in 73
countries, most of whom are affiliated with SME’s 300-plus senior chapters. The
Society also has some 8000 student members and more than 150 student chapters at
colleges and universities.
Publications -T he Society is involved in various publication activities encompass-
ing handbooks, textbooks, videotapes, and magazines. Current periodicals include:
Manufacturing Engineering
Manufacturing Insights (a video magazine)
SME Technical Digest
SME News
Journal of Manufacturing Systems
vii
Certification -T his SME program formally recognizes manufacturing managers,
engineers , and technologists based on experience and knowledge. The key certification
requirement is successful completion of a two-part written examination covering (1)
engineering fundamentals and (2) an area of manufacturing specialization.
Educational Programs -T he Society sponsors a wide range of educational activi-
ties, including conferences, clinics, in-plant courses, expositions, publications and
other educationah-aining media, professional certification, and the SME Manufactur-
ing Engineering Education Foundation.
viii
CONTENTS
VOLUME VI-DESIGN FOR MANUFACTURABILITY
Symbols and Abbreviations ....................................................... xi
Design for Manufacturability ..................................................... 1. 1
Concurrent Engineering ......................................................... 2-1
Management Involvement in DFM ................................................ 3-1
Team Building and Training ..................................................... 4-1
Justification of DFM ........................................................... 5-1
Quality Tools in DFM .......................................................... 6-1
Computer-aided Technologies .................................................... 7-1
Design for Assembly .......................................................... 8-1
:
Preliminary Design Issues ....................................................... 9-1
General Product Design ........................................................ 10-1
Machining ................................................................... 11-1
Forming ..................................................................... 12-1
Finishing and Coating ......................................................... 13-1
Fastening and Joining .......................................................... 14-1
Materials .................................................................... 15-1
Design for Electronics Assembly ................................................. 16-1
Appendix A-DF'M Case Studies ................................................ A-1
Appendix B-DFM Products and Services ......................................... B-1
Index ....................................................................... 1-1
ix
SYMBOLS AND
ABBREVIATIONS
The following is alist of symbols and abbreviations in general use throughout this volume. Supplementary ancUorderived units, symbols,
and abbreviations that are peculiar to specific subject matter are listed within chapters.
CIM-11 Computer-integrative management (of the
A-B
manufacturing enterprise)
CL fdes Cutter location files
ABC Activity-based costing
CMI Continuous measurable improvement
AI Artificial intelligence
CMM Coordinate measuring machine
AIS Automated infrastructure support
CMPP Computer managed process planning
AMA American Management Association
CNC Computer numerical control
ANOVA Analysis of variation
COB Chip on board
ANSI American National Standards Institute
COQ Cost of quality
APICS American Production and Inventory Control
CQI Continuous quality improvement
Society
CRP Cost reduction potential
AQS Advanced quality system
CSG Constructive solids geometry
ASIC Application-specific integrated circuits
CSM Continuous strand mat
ASM American Society for Metals
CTS Carpal tunnel syndrome
ASME American Society of Mechanical Engineers
DFA Design for assembly
ASQ Assured quality level
DFD Design for disassembly
ASQC American Society for Quality Control
DFM Design for manufacturability (manufacture,
ASTD American Society for Training and
manufacturing)
Development
DFM/A Design for manufacttrrability/assembleability
ASTM American Society for Testing and Materials
DFQ Design for quality
ATE Automatic test equipment
DFP Direct fiber placement
ATG Automated-test generation
DFR Design for reliability
ATPG Automated-test pattern generation
DFT Design for test
AVA Added-value analysis
DFS Design for serviceability
BIST Built-in self test
DFX Design for X (anything)
BOM Bill of materials
DIP Dual in-line package
BON Bed-of-nails fixture
DNC Direct numerical control
BP Best practices
DOD Department of Defense
BPM Ballistic particle manufacturing
DOE Design of experiments
B-rep Boundary-representation
DOM Drawn over mandrel
BTAP Board-1evel test access port
DPI Design producibility index
Bump Inner-1ead bondhtg
DRF Datum reference frame
ECM Electrochemical machining
C-D-E ECO Engineering change order
EDI Electronic data interchange
CA Cyanoacrylates EDM Electrical discharge machining
CAD/CAM Computer-aided design/computer-aided EM Electrochemical metallizing
manufacturing en Enable
CAE Computer-aided engineering EPS Expanded polystyrene foam
CAM Computer-aided manufacturing Eq. Equation
CAPP Computer-aided process planning ES Expert systems
CAT Computer-aided test
CBT Computer-based training
F-G-H-l-J-K
CCB Change Control Board
CE Concurrent engineering
FAST Function analysis system technique
CFC Chlorofluorocarbon
FDM Fused deposition modeling
CIB Computer-integrated business
FEA Failure effect analysis (also, Finite element
CIE Computer-integrated enterprise
analysis)
CIM Computer-integrated manufacturing
FF Flip-flop
CIME Computer-integrated manufacturing enterprise
FGI Finished goods inventory
CIM-I Computer-interfaced manufacturing
FIA Forging Industry Association
