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Consulting Partners

Chris Tsai Boothroyd Dewhurst, Inc.

Chris Tsai is the Director of DFMA Implementation Services at Boothroyd Dewhurst. He has over 25 years of engineering, change management, and leadership experience with the Eastman Kodak Company and the Rochester Institute of Technology (RIT). Most of that time was spent in the equipment product design and manufacturing portion of Kodak’s operations (i.e. digital cameras, scanners, printers, medical imaging devices, etc.). He has held positions in product & tooling design engineering, manufacturing engineering, project management, quality management, and globalization. Early in his career, he established himself as a corporate subject matter expert in Value Analysis/Value Engineering (VA/VE) and Design for Manufacture & Assembly (DFMA) and later expanded that expertise to Lean Six Sigma being certified as a Black Belt and becoming a corporate Lean Six Sigma instructor and mentor. He has developed and delivered corporate training and certification around the world and is a SAVE International certified Associate Value Specialist (AVS).

As Quality & Process Improvement Manager in Kodak’s Health Imaging Group, he led the establishment of a new Supplier Quality function driving an order of magnitude reduction in defects and scrap material costs in less than three years. As Globalization Manager, he led the Lean Six Sigma Manufacturing initiatives transforming Kodak Health Imaging’s Minnesota and Shanghai, China hardware manufacturing operations. As a DFMA sensei, he has helped teams identify over $100M in potential cost savings and avoidance.

Chris has a Bachelor’s Degree in Mechanical Engineering from Purdue University and a Master’s Degree in Manufacturing Engineering from the Rochester Institute of Technology.

Contact Chris at: ctsai@dfma.com or 1-585-348-8115

Areas of Expertise
  • DMAIC Lean Six Sigma
  • Design for Six Sigma (DFSS)
  • Root Cause Analysis / Analytical Problem Solving / CAPA
  • Design for Manufacture & Assembly (DFMA)
  • Value Analysis / Value Engineering (VA/VE)
  • Team Leadership and Change Management Skills
  • Operations Management incorporating Lean Manufacturing and Six Sigma methodologies
  • Supplier Quality Management
Robert Williams Creative Design Solutions
Founder & President of Creative Design Solutions, a comprehensive product development consulting firm. Bob was with HP and Agilent Technologies for 27 years and has been a Boothroyd Dewhurst Workshop Instructor for over 18 years where he has trained over 2,500 engineers in DFMA and Creative Design. His 21 years of manufacturing experience includes extensive instrumentation product development and PCA/SMT process engineering and 6 years of R&D Design experience in both high volume products and specials. Bob is the published author in DFA for 2 university textbooks and is a past president of the Rocky Mountain Council for Competitive Products.
Areas of Expertise
  • Able to lead & inspire groups to achieve breakthrough results. 18 years experience in training over 2,500 engineers in DFMA and Creative Design
  • ‘Hands on’ Manufacturing Experience. 21 years of personal manufacturing experience including extensive instrumentation product development, as well as PCA/SMT process engineering
  • ‘Hands on’ R&D Experience. 6 years R&D design experience in both high volume products and specials
Bill Devenish The Devenish Group, Inc.
The Devenish Group, Inc., specializes in product development strategy, management and design, with emphasis on cost reduction and accelerated time-to-market. President and founder, Bill Devenish, a long-time DFMA advocate, has over 23 years experience in technology product development. As Director of Engineering for QSI Corporation, he institutionalized the use of DFMA, achieving 50% reduction in product costs. As manager of the MAD (Mechanical Advanced Development) Group at Harris RF Communications, Bill championed the use of DFMA by a team of design, manufacturing and sourcing engineers, who identified over $3 million in savings for one currently-shipping product in their first training session. As R&D Manager at Nokia, he led the team that developed the first smart phone released in North America in 1998, and has held senior management and engineering positions at AirNet Communications, NEC and Motorola. Bill earned a B.S. in Design Engineering from Brigham Young University, an M.S. in Management of Science and Technology from Oregon Graduate Institute and a graduate certificate in Systems Engineering from Florida Institute of Technology. He has been awarded ten patents and has authored several papers on DFMA, embedded passives, implementing SolidWorks, and Design for Six Sigma (DFSS).
Areas of Expertise
  • Extensive experience in electronic product development for the consumer, industrial and defense markets, including strategic planning, product and program management, product design/engineering, process implementation and technical staff development.
  • Guidance for companies of all sizes on implementing DFMA to enhance competitive position and achieve profitable growth.
  • Institutionalization of DFMA through integration with the overall design process.
  • Optimization of new product designs through early DFMA assessment and reduction of existing product costs through DFMA redesign.
  • Process improvement to foster effective project and program management, concurrent engineering, robust innovative design and effective design reviews for accelerated market introduction with improved quality and reduced cost.
  • DFMA analysis of competitor products for benchmarking and optimal market positioning.
  • Hands-on, personalized DFMA training for technical staff.
  • Design services, including SolidWorks 3D CAD modeling, 2D to 3D conversion, mechanical design of electronics packaging, rapid prototyping and product documentation.
Frank Long Independent Contractor
Frank Long is a mechanical engineer with thirty years experience in manufacturing engineering for Kulicke & Soffa Ind., Inc. (K&S), a semiconductor assembly equipment manufacturer. While at K&S, he held the role as an advanced manufacturing engineer, production manufacturing engineer, process analyst, manufacturing engineering team lead, supplier process engineer, program development manager, and DFMA facilitator. Although Frank has been performing analysis work and training for Boothroyd Dewhurst since 2007, he has twenty years of experience analyzing designs using, and as training instructor on the usage of, the BDI DFMA software. Product types include semiconductor assembly equipment, aircraft engines, marine vessel stabilizers, proprietary marine vessel components, mass spectrum analyzer, consumer appliances, pneumatic tourniquet system, and compact track loader components.
Areas of Expertise
  • In his DFMA facilitator role at K&S, he:
    • Trained all company personnel (US, Chinese, Israeli, Singaporean, and Swiss) on the concepts, tools, usage and interpretation of the Boothroyd Dewhurst DFMA software.
    • Maintained DFMA software program libraries, created company standards for commonality and documented ‘how to’ guidelines for operations (i.e. castings, & sheet metal).
    • Created and maintained an inter-company DFMA ‘Wiki’ web page that included shared information like user guides, common values, operation interpretation, training information, international material, machine & operator costs, and metric standards.
    • Developed and documented a Supplier Interface Process for DFMA analyses.
  • Presented a paper on the subject of "The Role of DFMA Software and International Suppliers", at the 2008 International Forum on Design for Manufacture and Assembly.
  • Facilitated global manufacturing engineering teams in the US, Singapore, and Switzerland.
  • Trained ISO 9001 Auditor, which included auditing internal operations and external suppliers.
  • Analyzed business practices and developed operating procedures to reduce the cycle time of a concurrent engineering team for company Product Development Process (PDP).
  • Developed manufacturing processes from concept to production, coordinated fabrication of prototypes, and documented policies, processes, and procedures.
  • Performed supplier surveys to assess supplier quality systems, capacity planning, supply chain management, and production manufacturing and quality process control, in order to deliver reliable and quality products.

Software Partners

Convergence Data Services  

Convergence Data Services provides component and supplier management software solutions to the discrete manufacturing industry.  Convergence offers a solution which enables the extension of DFMA cost modeling to the enterprise for increased accuracy, efficiency and effectiveness.  This integrated toolset manages and validates DFMA inputs against company standards and rules and then publishes the models, outputs and other related files to a centralized database for easy access.  Automated refresh capabilities are provided which allow for the automated update of cost analyses against the most up-to-date cost inputs (i.e. material, machine and operation libraries).  Convergence also provides an easy to use search, query and reporting tool which provides cost rollups and competitive cost comparisons.

For more information visit the company’s Web site (www.convergencedata.com) or call 1-203-364-8600.


SolidWorks Corporation, a Dassault Systèmes S.A. (Nasdaq: DASTY, Euronext Paris: #13065, DSY.PA) company, develops and markets mechanical design software solutions. Founded in 1993, SolidWorks’ mission is to unleash the power of 3D for everyone in product development. Only SolidWorks is 100% focused on product design, providing software and services that help manufacturers get new products to market faster. Innovative, yet proven, SolidWorks software is the standard in 3D. In seven years of delivering product, SolidWorks has shipped over 250,000 total seats of software worldwide. SolidWorks has offices around the globe and sells, distributes, and supports its products through a worldwide network of resellers. For the latest news, information, or a live online demonstration, visit the company’s Web site (www.solidworks.com) or call 1-800-693-9000 (outside of North America, call +1-978-371-5000).

Solid Concepts  

SolidView/Pro is a low-cost, easy to use, program for viewing and measuring a variety of 3D CAD data formats. With the SolidView family of products, anyone with a Windows PC can view, measure, and mark up CAD data. Instead of working with confusing paper drawings, you can now have a real-time shaded view of your CAD designs, without the need for expensive CAD hardware or software, and without extensive training.

SolidView/Pro is from Solid Concepts Inc., a privately held corporation headquarted in Valencia, California. Additional information on SolidView and Solid Concepts can be obtained from www.solidview.com. SolidView is a registered trademark of Solid Concepts Inc.

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