Producibility Elements Highlighted:
Perform Trade Studies on Alternative Product and Process
Recognize the Need for Management Commitment
Lockheed Martin has identified and effected an important methodology to successfully implement the principles of concurrent engineering. This Design for Manufacture/Assembly (DFMA) approach ensures the proper balance
between design goals and ease of manufacture and assembly. The net result is a robust design that is more cost-effective to manufacture.
The company previously applied the concurrent engineering philosophy using a traditional design review process. It determined that a formal event called a DFMA workshop was needed to ensure that design-for-manufacture, design-for-assembly, and design-for-producibility considerations were addressed. After careful analysis, Lockheed Martin selected the Boothroyd Dewhurst, Inc. software to help achieve this objective. To demonstrate commitment, Lockheed Martin established a policy that DFMA be included in all programs.
Lockheed Martin embarked on a training program that taught the principles of DFMA and the specifics of the Boothroyd Dewhurst, Inc. tools to the product teams. The various disciplines represented on the team were taught the methodology, and the teams were required to use this approach in a real-world application. The teams first established the as-is baseline model of their products and then brainstormed and iterated solutions to simplify the assembly. Finally, at the end of the training, each team presented its analysis to management.
The ingredients critical to the success of this Lockheed Martin approach include mandating the requirement to utilize the DFMA approach, training personnel, providing each team a real-world case study, and involving management. The resulting synergy of this approach has helped the company achieve the desired goals of simplifying both the design and the processes necessary to manufacture and assemble the components of the design. Lockheed
Martin has been able to significantly reduce the Bills of Material required to manufacture components, and, over the life-cycle of the many systems it produces, these component-level savings are significant.