Design for Manufacturing: Reducing Part Count

Reducing part count in product design simplifies manufacturing, saves costs, and improves reliability. By focusing on fewer components, companies can cut assembly time, reduce labor costs, and minimize potential failure points. Key strategies include combining functions into single parts, designing multi-functional components, and standardizing materials. Tools like DFMA software and early collaboration with machine shops help refine designs and identify opportunities for consolidation. For example, companies have reduced assembly costs by up to 60% and achieved faster production timelines by applying these principles. Simplifying designs isn't just about saving money - it also ensures products are efficient to produce and maintain.

DFM: Design for Manufacturing

Strategies for Reducing Part Count

Simplifying designs by reducing the number of parts is a challenge that pushes engineers to think creatively. The idea is simple: combine functions where possible. This approach not only streamlines production but also aligns with Design for Manufacturing (DFM) principles, ensuring that every component serves a clear purpose while potentially taking on multiple roles.

Combining Parts with Similar Functions

When different components serve related or complementary purposes, it often makes sense to merge them into one. Take, for example, brackets and mounting hardware - if they share structural roles, why not combine them into a single machined piece? Similarly, housings and covers can often be unified into a single enclosure if their protective requirements overlap. By merging parts made from the same materials or requiring similar treatments, designers can simplify production and reduce complexity. This approach naturally leads to parts that fulfill multiple roles in a single design.

Designing Multi-Functional Parts

Creating parts that handle multiple tasks is another key strategy for cutting down on part count.

"By designing multi-functional parts, you eliminate the need to design and manufacture product-specific parts. Common parts also provide increased flexibility in manufacturing and assembly, boosting throughput." - Pro-Cise

A great example of this is Apple’s MacBook Pro, which uses a unibody aluminum chassis. This design not only enhances durability but also slashes assembly time. Tesla applies a similar idea by using a standardized battery cell design across its vehicle lineup. Smartphones, too, have embraced this principle, with multi-functional motherboards that integrate processing, memory, and connectivity functions into a single component. The result? Faster production and cost savings during manufacturing.

Standardizing Components

Once similar and multifunctional parts are merged, the next step is standardization. By reducing the number of custom variations, companies can further simplify production. For example, sticking to a limited set of fastener types - rather than a mix of custom screws and bolts - can significantly cut down on inventory complexity and reduce assembly errors.

Logitech demonstrates this approach by designing mouse casings as single molded pieces instead of assembling multiple components. The benefits are clear: standardization can lead to a 20% drop in costs per assembled part and a 30% reduction in assembly time when DFM principles are applied. It also makes supplier management and inventory control much easier, while ensuring smoother collaboration with machine shops experienced in manufacturing standardized parts.

Tools and Methods for Part Count Reduction

Streamlining part count is a cornerstone of efficient manufacturing, and the right tools and methods make it achievable. By combining advanced software with time-tested strategies, engineers can uncover opportunities for improvement that might otherwise slip through the cracks. The goal? Simplify designs, cut costs, and boost efficiency - all while maintaining top-notch quality.

Using DFA/DFM Software

DFMA (Design for Manufacture and Assembly) software has become a must-have for companies aiming to simplify their designs. These tools thoroughly analyze products, spotting areas for improvement that even the sharpest human eye might miss. Businesses leveraging DFMA software have reported substantial reductions in part count, with measurable savings in cost and time.

DFMA tools are typically divided into two categories:

• DFA (Design for Assembly) software: Focuses on simplifying product structures, minimizing part counts, and reducing assembly steps.
• DFM (Design for Manufacturing) software: Helps estimate manufacturing costs and evaluate supplier quotes.

When used together, these tools deliver impressive results. Companies have seen up to a 42% drop in labor costs, a 60% reduction in assembly time, a 45% cut in product development time, and a 50% decrease in total product cost.

CAD-integrated tools like HCL DFMPro enhance this process by working seamlessly with platforms like Creo Parametric, SOLIDWORKS, NX, and CATIA V5. Organizations using DFMPro have reported a 20% reduction in rework, a 12% decrease in manufacturing costs, a 10% faster time to market, and a 10% boost in engineering productivity.

"With DFMPro, we reduced the scrap, identified issues for improvement and also adopted these design guidelines in the DFx group."
– Hugo Cisneros, GOS DF_x, JABIL

Real-world examples highlight these benefits. A leading electronics manufacturer achieved a 30% reduction in PCB design time, a 25% cut in production costs, and a 15% improvement in product quality using CAD-integrated DFM tools. Similarly, an aerospace and defense contractor reported a 20% drop in design time, a 15% reduction in production costs, and a 10% boost in product quality. A medical device manufacturer experienced similar success, with a 25% faster design process, a 20% decrease in production costs, and a 12% improvement in product quality.

Iterative Design Process

An iterative design process, bolstered by rapid prototyping and real-time feedback, helps fine-tune designs while minimizing errors. Modern digital tools accelerate this process, allowing teams to test and refine designs quickly to meet both functional needs and manufacturing constraints.

For instance, Apple employs iterative design for its smartphones, frequently updating designs based on feedback and internal goals. In practice, this involves creating flexible plans with regular feedback loops. Engineers brainstorm, sketch initial concepts, and build prototypes for real-world testing. Feedback from users and stakeholders is then used to make adjustments. If the prototype works, the team moves forward with a minimum viable product; if not, they revisit earlier stages.

While digital tools make this process faster, success relies on organizational commitment. As Bill Gundrey, executive director for digital engineering and operations at Raytheon Missiles & Defense, puts it:

"Digital transformation requires a jump on the technology side, but it requires a leap on the people side."

Evaluating Part Necessity

Evaluating each component's necessity is another key step. Designers should analyze assemblies part by part, starting with the theoretical minimum number of parts required. This involves assessing whether parts can be combined based on material compatibility and functionality. However, it’s also essential to consider how combining parts might impact disassembly and manufacturability.

The evaluation process should challenge every level of the design - from individual components to the system as a whole. Teams should question original drawings, compare competitive products, and ensure every part contributes meaningfully to the product’s function, durability, and performance.

Collaboration is crucial here. Design reviews involving process engineering, quality control, and fabrication teams often reveal opportunities to improve machine utilization or eliminate the need for specialized tools. Standardizing materials and removing unnecessary features can also simplify production.

"It is an easy-to-use tool which significantly helped us to reduce our part checking time by almost 60% while ensuring robust quality of design."
– Randy Scherger, Senior Tool Designer, Rockwell Automation

When working with machine shops, understanding their equipment’s capabilities becomes especially important. Avoiding unnecessarily tight tolerances and leveraging the expertise of skilled machinists can prevent costly mistakes. Platforms like the Machine Shop Directory, which connects users to over 200 top-rated machine shops, make it easier to find partners well-versed in DFM principles.

Best Practices for CNC Machining and Custom Fabrication

Reducing part counts in CNC machining and custom fabrication requires a mix of timing, teamwork, and adherence to design principles like Design for Manufacturability (DFM).

Early Integration of DFM Principles

The design phase is where the biggest cost-saving opportunities lie, as over 70% of a product’s final cost is determined during this stage. Once production kicks off, making changes becomes far more expensive. That’s why integrating DFM principles early is critical for reducing part counts effectively.

Manufacturers who involve engineers during the early design discussions, rather than waiting until later, can identify opportunities to consolidate parts before designs are finalized. For instance, a smartphone manufacturer cut assembly time by 30% by applying DFM principles from the start.

For CNC machining, early design considerations might include ensuring proper tool access, optimizing material removal rates, and addressing fixturing needs. Similarly, custom fabrication projects benefit from upfront planning around welding sequences, material handling, and assembly limitations. Establishing clear DFM guidelines tailored to your product and industry early on makes collaboration with machine shops much smoother.

Working with Machine Shops

Machine shops are often an untapped goldmine of expertise when it comes to reducing part counts. Partnering with machinists early in the design process can reveal cost-saving opportunities that align with your design goals.

Experienced machinists, who know their tools and processes inside out, can suggest tweaks to designs that simplify machining and reduce costs. This is where Early Supplier Involvement (ESI) comes into play. Instead of finalizing designs and then seeking quotes, companies can engage fabricators during the design phase. This allows machine shops to provide valuable input on material choices, design adjustments, and production efficiencies.

Transparency is key. When project managers share workflow challenges with their manufacturing partners, machine shops can propose alternative methods that combine steps or eliminate unnecessary ones. For example, using the Machine Shop Directory can help you connect with top-rated shops that specialize in DFM-driven CNC machining and fabrication, ensuring they understand part consolidation strategies and can contribute to optimizing your designs.

Setting Standards and Training

To make part count reduction a lasting success, organizations need structured standards and ongoing training. The best results come when these practices begin at the design stage, using a concurrent engineering approach to simplify both component counts and manufacturing costs.

Training programs should focus on identifying critical components while eliminating unnecessary ones. For example, teams should challenge assumptions about assembly methods - like questioning whether a fastener is essential in a given design.

Key principles to include in training:

• Use the largest tolerances possible to cut costs.
• Design parts with symmetry across multiple axes to simplify assembly.
• Favor top-down assembly methods to avoid reorienting parts during production.
• Incorporate error-proofing techniques to prevent misaligned or omitted parts.

Another often-overlooked standard is the use of catalog parts. As the University of Florida advises:

"Never design a part you can buy out of a catalog unless you can clearly justify the choice (e.g., to save weight, reduce size, or use an alternate material)."

Training should also encourage designing product families that share similar components. This approach reduces the need for specialized tooling and allows machine shops to streamline their processes for a standard set of components.

Finally, regular reviews of design changes are essential to ensure that part count reduction efforts deliver real benefits. Teams should evaluate whether changes genuinely improve manufacturability or simply shift complexity to another part of the production process.

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Examples and Industry Trends

Reducing part counts offers major cost savings and boosts efficiency across various industries. At the same time, modular design and standardized components are redefining how products are made in the U.S. These concepts are backed by real-world examples that highlight their impact.

Case Studies in Part Count Reduction

Real-world examples show how simplifying designs can transform production. Take Honda's original Civic, for instance. It featured a streamlined unibody design with stamped steel panels and interchangeable engines and transmissions. This approach not only cut costs but also helped Honda carve out a significant share of the market.

OXO’s Good Grips tools are another example. Their teardrop-shaped handles, made with Santoprene rubber, reduce material use while maintaining comfort and functionality. Insulet’s OmniPod insulin pump takes it a step further with a tubing-free, pod-based design that reduces manufacturing costs and improves usability.

Similarly, iRobot’s Roomba uses off-the-shelf components and interchangeable modules, which simplifies production and lowers inventory expenses. Caterpillar’s 320 Next Generation excavator showcases how redesigning systems with interchangeable components can reduce costs without sacrificing durability.

Trends in Modular and Standardized Designs

Building on these success stories, the trend toward modular and standardized designs continues to gain momentum. U.S. manufacturers are increasingly adopting modular systems with interchangeable parts to improve efficiency and scalability.

In the automotive world, modular platforms allow companies to produce multiple car models using shared components. This not only reduces production costs but also enables greater customization. Electronics manufacturers are also embracing modularity, making it easier to upgrade or repair devices while cutting down on electronic waste.

Advances in digital technology and AI are further accelerating this shift. These tools streamline the design, testing, and assembly of modular components, which reduces labor costs and speeds up production. Modular designs also support mass customization, letting companies offer a variety of product configurations without driving up costs. Plus, they align with the circular economy by limiting waste through standardized components.

Using Machine Shop Directory

To take advantage of these trends, working with skilled machine shops is crucial. The Machine Shop Directory is a valuable resource, featuring over 200 precision CNC machining and custom fabrication experts. These shops often have deep expertise in Design for Manufacturability (DFM), helping manufacturers refine designs to simplify machining processes.

The directory makes it easy to find the right partner by offering capability-based matching and categorizing shops by industry experience and certifications. This ensures manufacturers can connect with experts who can support efficient part consolidation and streamlined production strategies.

Conclusion

Applying Design for Manufacturing (DFM) principles to reduce part count can lead to significant cost savings - up to 50% - by simplifying products.

With fewer parts, manufacturers benefit from quicker assembly times, reduced maintenance complexity, and better reliability, all of which help lower overall product costs. Additionally, this approach supports environmentally conscious practices by cutting down on material consumption, transportation needs, and machine hours.

Real-world examples highlight the impact of these strategies. NASA, for instance, slashed the number of components in a rocket engine from 80 to just three, while GE streamlined their Catalyst turboprop engine by replacing 800 parts with only 12 3D-printed components.

To achieve these results, early collaboration among design, manufacturing, and assembly teams is critical. Success also depends on proper training and clearly defined Design for Assembly (DFA) processes. Continuous monitoring and refinement of these processes ensure products maintain their functionality and quality.

For manufacturers looking to adopt these strategies, working with skilled machine shops is essential. The Machine Shop Directory offers access to over 200 CNC machining and custom fabrication experts who specialize in DFM, helping streamline designs and drive manufacturing success.

FAQs

Why does reducing the number of parts in a product improve its reliability?

Reducing the number of parts in a product can significantly improve its reliability by cutting down on potential failure points. With fewer components, there's less that can go wrong, making the design simpler and easing both assembly and maintenance.

A more streamlined design not only boosts durability but also ensures more consistent performance over time. Fewer parts mean manufacturers can focus on tighter quality control, minimizing production errors and creating a product that's more dependable in the long run.

What are some real-world examples of products that successfully reduced their part count through design strategies?

Reducing the number of parts in a product is a cornerstone of Design for Manufacturing (DFM), and plenty of companies have leveraged this approach to make production smoother and more efficient. Take LEGO, for instance - they optimized their manufacturing by cutting down the variety of color options, which made their production process run more seamlessly. Another great example is Whirlpool Sweden, which embraced Design for Assembly (DFA) principles. By rethinking their product designs, they managed to slash part counts by 29% and reduce assembly time by 26%. These examples show how strategic design tweaks can simplify assembly, trim costs, and boost manufacturing efficiency.

How does working with machine shops early in the design process help reduce part count in manufacturing?

Why Early Collaboration with Machine Shops Matters

Getting machine shops involved early in the design process can make a world of difference when it comes to simplifying part designs and improving how easily they can be manufactured. When designers team up with skilled machinists from the beginning, they can tap into expert advice on combining or refining parts to make production more efficient. This not only cuts down on assembly complexity but also reduces the chances of errors along the way.

Starting this collaboration early also means that tools, materials, and processes are aligned with the design right from the start. This alignment can save both time and money during production. For example, machine shops can suggest tweaks to designs that make parts easier to machine, speeding up production cycles and improving the final product's quality. By building these partnerships upfront, the entire manufacturing process becomes smoother, resulting in better products with fewer components.