Dfm Process.docx

OVERVIEW THE DFM PROCESS

Compiled by: Gracia Sembiring Sarah Panjaitan Maria Sibuea Daniel Sianturi Loly Silaban

CONTENTS Cover ................................................................................................................................... Contents ............................................................................................................................ 1 BAB 1 : Estimate the manufacturing costs ....................................................................... 2 BAB 2 : Reduce the costs of components ...................................................................... 3-4 BAB 3 : Reduce the costs of assembly .......................................................................... 5-6 BAB 4 : Reduce the costs of supporting reproduction ..................................................... 7 BAB 5 : Consider the costs of supporting production ...................................................... 8 BAB 6 : The manufacturing costs after all the reduce process…………………………..9

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BAB I Manufacturing Cost Estimation

A. Component Cost This table will show all material for making travel pillow and additional. Price is by wholesaler or if buy it from factory. So it can be cheaper than in market. No 1 2 3 6 4 5

Material Velvet fabric Thread Pin Volcro Button Memory foam

Dimension 1m x 1,2m 1 roll 1 pack 50 cm 3 1

Price Rp 45.000,00 Rp 3.000.00 Rp 2.000,00 Rp 5.000,00 Rp 2.000,00 Rp 100.000,00

B. The Bill of Materials The BOM is a list of each individual component in the product. BOM will show total cost for making each travel pillow. Based on table, we can see that for making a travel pillow the cost is Rp 227.000 cost is including for material, labor, machine and overhead.

Component

Purchased Materials

Travel pillow Cover Rp 25.000 Memory Rp 60.000 foam Additional Travel Pillow Cover Rp 15.000 Memory Rp 40.000 foam Button Rp 2.000 Bag Velvet fabric Rp 10.000 Total direct Rp 152,000 cost Overhead charges Total cost

Processing and Assembly( Machine + Labor)

Assem Total Unit Tooling and bly Varible Other NRE (Labor Cost )

Tooling Total Total cost Lifetim Unit e, M Fixed units Cost

Rp 30.000

Rp 55.000 Rp 60.000

Rp 55.000 Rp 60.000

Rp 20.000

Rp 35.000 Rp 40.000

Rp 35.000 Rp 40.000

Rp 2.000

Rp 2.000

Rp 35.000 Rp227.000

Rp 35.000 Rp 227.000

Rp 25.000 Rp 75.000

Rp 227.000

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C. Cost estimation for making each Travel Pillow Variable cost Material

Velvet pabric Memory foam Thread Pin Volcro Button

1,2 at Rp 45.000/1.2m2 1 sheet at Rp 100.000/sheet 1 roll 1 pack 50 cm 3

Processing (Sewing) Fixed cost Total Direct Cost Overhead charge Total Unit Cost

Rp 45,000 Rp 100,000 Rp 3.000 Rp 2.000 Rp 5.000 Rp 2.000 Rp 75.000 0 Rp 232.000 0 Rp 232.000

For making our working prototype, every cost is for standard components. We don’t have custom components. All of material is standard and we can find it in market. But we do some improvement for our material to make best working prototype.

BAB II Reduce the costs of components

BAB III Reduce the costs of assembly

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BAB IV Reduce the costs of supporting production 4.1 Minimize Systemic Complexity Score card of manufacturing complexity Drivers of Complexity

Rev. 1 Rev. 2 Number of new parts introduced to the manufacturing system Number of new vendors introduced to the manufacturing system Number of custom parts introduced to the manufacturing system Number of new “major tools” (e.g., molds and dies) introduced to the manufacturing system Number of new production processes introduced to the manufacturing system

1 2 0 0 2

1 2 1 0 0

Total

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Note: There is a difference between rev.1 and rev.2. In Rev.1 we don’t use custom parts so we need more production processes to make the travel pillow, but in Rev.2 we use custom parts to reduce production processes in manufacturing system. There is no a difference about new parts, new vendors, new major tools between both.

4.2 Error Proofing

The left and the right versions of travel pillow, that there is some difference between both. In the left version is showed that the size of travel pillow is bigger than the right 4

version. We have a purpose to make customer more comfortable if they use that travel pillow, so there is reduced the size of travel pillow. And in the right version there is an additional bag to make travel pillow more portable.

BAB V Consider the impact of DFM decisions on other factors

5 Consider the Impact of DFM (Design for Manufacturing) Decisions on Other Factors 5.1 The Impact of DFM on Development Time As we make this neck travel pillow estimated no longer time to get finish on this product. Because of the time development this neck travel pillow only need 3 month start from november until January.The process of making pillows start from Provide materials and tools,Print pillow patterns,Start cutting patterns and putting them together,Then sewing with a needle or sewing machine but the fabric is not fully sutured,Give memory foam as a stuffing pillow,Then sew back the cushions perfectly. As the materials and tools that we need is easy to get and to produce and the way to making the neck travel pillow, we spend 2-3 hours per day to make neck travel pillow.

5.2 the impact of DFM on development cost On this product development there is two factors that related each other there are time and cost.the more time we need to make this product the lower cost we spent.as we estimated and run this product in this three month we make a working team from the tailor whose like to help us to create the design of our product. For making this project we need Rp 390.000,00. From making alpha prototype until making working prototype, our cost is Rp 390.000,00. That cost including for buying material, tailor and transportation. We need buying material like fabric, cotton, memory foam, etc. We need pay for tailor to sewing our travel pillow. We use tailor to get a good needlework. Also, we have transportation cost. 5.3 the impact of DFM on product quality 5

5.4 the impact of DFM on external factors Components reuse: as we make this product we can create a low cost components of this part, by the three additional side of the neck travel pillow its also taking cost to make it more higher of the cost.by the implementation of the neck travel pillow we can make it into reusable product. Life cycle costs

:by this product we also create and indicate the product how it should be

opened and make acces points obvious,maintain stability and part of this neck travel pillow,not only how we can indicate them but this neck travel pillow also like to minimize the number and variety of joining all of the elements.

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