The intent of a Producibility Engineering Review is to
focus on manufacturability and not on the product's functionality. The goal is
to identify manufacturing and assembly difficulties and potential problem areas.
New process capabilities can then be traded off if the requirements exceed
As part of the Producibility Engineering Review, detailed
attributes of the product under design are compared with documented process
capabilities. This review is used as a checking mechanism to ensure that the
product, as designed, can be produced with available manufacturing capabilities.
This systematic, thorough evaluation is a necessary step in achieving enhanced
producibility. The review can be conducted at one time or it can be done either
continually or at pre-defined points in the design process.
The producibility engineering review is conducted in
addition to normal and necessary design reviews. These latter reviews are
conducted by the IPT throughout the design process and should be used to assess
progress against the goals and metrics for the product. Since it is imperative
that the IPT maintain a focus on producibility, the regular design reviews
address many producibility issues. However, they are typically focused on
individual processes and components and normally include tool, production, and
facilities planning for those processes.
In contrast, the focus of the producibility engineering
review expands to an evaluation of whether the entire product can be
manufactured in the intended facility within the given schedule and budget.
Internal experts who are not part of the product IPT nor involved in the product
development are normally brought in to conduct this review.
Two examples of the application of producibility
reviews are presented in Appendix
D, Case Studies 37 and
. An industry example of a checklist and sequence of reviews used for
assessing producibility during design is presented in Appendix
The Producibility Engineering Review can ensure that the
product can be manufactured effectively and affordably within the allowable time
Staff: Experts from
manufacturing engineering, design engineering, and materials engineering;
production and quality personnel; and key suppliers are necessary to conduct
Tools and Techniques: Design for Manufacture / Assembly (DFMA) and Tolerance
Analysis are two of the tools that can assist the review team in compiling and
analyzing producibility engineering information. Descriptions of these tools
are presented in Appendix F.1.5 and F.1.23
Training: It may be
necessary to introduce team members to DFMA concepts and Tolerance Analysis
methods for evaluating designs.
As in many of the previous elements, the IPT is the
essential mechanism for ensuring that the producibility engineering review is
conducted. It is preferable that a separate review team be established to
conduct the review. This team should be composed of staff members of both the
enterprise and its suppliers who are not on the product IPT and who are not
directly involved with the development of the product. As with the product
IPT, this team should be structured as an IPT and should include
representatives of all the key areas (see 1.2) as well as experts
in manufacturing and design. Knowledge of the process capabilities should be
available from the process capability guidelines (see 2.1)
and also may be garnered from internal or external experts. As noted
previously, this review can be conducted all at once or at various times
during the design process. However, it should be conducted together with the
activities described in the following two elements (see 4.2 and 4.3
) due to the interdependence of these activities.
The basic steps for the producibility engineering review
- Identify the individual product attributes.
- Identify the materials used in the design and any special manufacturing
- Determine if the design can be produced using existing process
- Assess the ability of manufacturing to produce the product during the
- Review the impact of the design with regard to the tooling plan.
- Determine if conflicting requirements can be resolved by either an
enhancement of internal/external capabilities or product
After the review is completed and the other two
elements of this step are conducted (4.2 and 4.3
), the IPT should:
- Update the manufacturing plan.
- Complete the Engineering Release Package for the product.