DFMA Case Study: Redesigned POS Terminal

DFMA Case Study: Redesigned POS Terminal

You may have heard about the benefits of DFMA (design for manufacture and assembly) software before. But there’s a significant difference between hearing about what DFMA does and seeing real numbers demonstrating how it saves companies millions of dollars.

Below is a breakdown of the impressive results NCR Voyix achieved when it implemented DFMA to streamline manufacturing processes.

NCR Voyix’s Objective

NCR Voyix needed to redesign its point-of-sale (POS) terminal to overcome some implementation issues, improve manufacturing outcomes, and reduce costs. DFMA software was an integral part of the redesign process, guiding engineers toward optimal manufacturing processes and part selections.

Results

When engineers use DFMA software, they can see the “should cost” value for each part alongside the actual quote from the source. This comparison can help them choose more efficient processes and materials and opt for the most efficient price models for processes such as machining, injection molding, and die casting, among others. This type of strategic decision-making led NCR Voyix to significant savings on assembly time, labor, and parts costs.

A key part of the process was quantifying costs and results. By assigning concrete numbers to various design choices, NCR Voyix could directly compare, discuss, evaluate, and refine various manufacturing alternatives.

• NCR Voyix slashed its POS terminal assembly time.
  Using DFMA techniques, NCR Voyix reduced the assembly time by 75%, which was a 23% improvement over initial projected estimates.
• Labor costs also fell significantly.
  NCR Voyix saw a 44% improvement on labor costs in comparison to the original product, for a savings of $1.1 million.
• Fewer suppliers were needed to make components.
  NCR Voyix reduced suppliers by 65%, greatly simplifying its supply network.
• DFMA software reduced the number of parts needed to build NCR Voyix’s POS terminal.
  NCR Voyix was able to redesign its POS terminal using 85% fewer parts than the original model. This was a significant improvement from the initial estimates that showed a 66% reduction was possible using DFMA during development.
• Interestingly, NCR Voyix eliminated screws completely from its design.
  Eliminating just one screw would have saved $12,500 over the lifetime of production, but NCR Voyix was able to get rid of all of them. The reduction in parts was dramatic: the final product required 55% fewer parts than the original terminal had in screws alone!
• Even more impressive, NCR Voyix completely eliminated the need for assembly tools.
• Once production was finished, NCR Voyix found that removing some of the cables and harnesses improved the reliability and quality of the terminal.
  The finished piece was so simple with its screwless, snap-fit assembly that NCR Voyix hosted a demonstration proving that all 15 pieces could be assembled in less than two minutes, even while blindfolded.

NCR Voyix’s redesigned 2760 terminal reduced manufacturing labor costs by $1.1 million compared to the original model. Actual cost savings are immeasurable.

In addition to the already significant labor cost savings, NCR Voyix saved countless millions on material costs, reduced overhead, fewer vendors, and fewer parts.

What could you accomplish if you implemented DFMA software in your manufacturing?

Ready to get started with DFMA software? Contact BDI and start saving today.