P08205: RP 1 Motor Module First Generation
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Detail Design

Table of Contents

Design For Manufacturing and Assembly

Step 1. Estimate the Manufacturing Costs

Fixed Costs vs. Variable Costs

The Bill of Materials

Estimating the Costs of Standard Components

Estimating the Costs of Custom Components

Estimating the Cost of Assembly

Estimating the Overhead Costs

Step 2. Reduce the Cost of Components

Understand the Process Constraints and Cost Drivers

Redesign Components to Eliminate Processing Steps

Choose the Appropriate Economic Scale for the Part Process

Standardize Components and Processes

Adhere to Black Box Component Procurement

Step 3. Reduce the Costs of Assembly

Keeping Score

Integrate Parts

Maximize Ease of Assembly

Consider Customer Assembly

Step 4. Reduce the Costs of Supporting Production

Minimize System Complexity

Error Proofing

Step 5. Consider the Impact of DFM Decisions on Other Factors

... On Development Time

... On Development Cost

... On Product Quality

... On External Factors

Robust Design

Step 1. Identify Control Factors, Noise Factors, and Performance Metrics

Step 2. Formulate an Objective Function

Step 3. Develop the Experimental Plan

Experimental Design

Testing Noise Factors

Step 4. Run the Experiment

Step 5. Conduct the Analysis

Compute the Objective Function

Computing Factor Effects by Analysis of Means

Step 6. Select and Confirm Factor Setpoints

Step 7. Reflect and Repeat

Design for the Environment and Sustainability

Design for Reliability

Design for Safety

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Planning Mission Statement -- Staffing Requirements -- Intellectual Property Considerations -- Preliminary Work Breakdown Structure -- Team Values and Norms -- Grading and Assessment Scheme -- Required Resources
Concept Development Identify Customer Needs -- Establish Target Specifications -- Generate Product Concepts -- Select Product Concept(s) -- Test Product Concept(s) -- Set Final Specifications
System Level Design Product Architecture
Detail Design Design for Manufacturing and Assembly -- Robust Design -- Design for the Environment and Sustainability -- Design for Reliability -- Design for Safety
Testing and Refinement Prototyping