DFMA Case Study: Military Tank Electronic Box Redesign

DFMA Case Study: Military Tank Electronic Box Redesign

DFMA software gives companies a way to evaluate current and future products to make sure every part is necessary, each assembly process is optimized, and the overall design of the product is as simple, easy to service, and durable as possible.

These principles are helpful no matter what the industry. Using DFMA to keep costs low and product efficacy high is crucial for defense companies. These companies build and deploy the equipment used in global battles. With lives on the line, every part in the finished product must serve a purpose and survive all sorts of potential working conditions.

Here is how one company used DFMA software for early-stage design cost optimization of its military tank electronic box and the results they achieved.

DFMA Methods

Concurrent Engineering

Instead of tackling conceptualization, design, engineering, and manufacturing as separate and sequential processes, as many companies do, this client employed concurrent engineering methods to handle them simultaneously. Done right, concurrent engineering can lower part counts, reduce defect rates, allow for simpler assembly processes, ensure better product reliability, and minimize total production costs.

Design for Assembly (DFA)

From the very beginning, the team asked questions that helped them identify unnecessary parts and inefficient assembly processes. Each part’s contribution to the overall design was weighed against its value. After each part was accounted for, the finished product was as simple and streamlined as possible.

Design for Manufacturing (DFM)

Next, designers and engineers evaluated the materials used for each part and the manufacturing processes that would be necessary to build the product. The team estimated the costs associated with each manufacturing process and once again asked purposeful questions to find out which areas need the most improvement.

Results

The company used the above DFMA principles to streamline its parts and design choices in the redesign of the electronic box. By applying DFMA to every step of the process, the company achieved:

• 49% fewer steps in the assembly process
• A 58% reduction in the number of parts needed for the finished product
• A 50% reduction in overall costs

These improvements delivered immediate savings and facilitated future upgrades and maintenance. A simpler design led to faster production cycles, fewer opportunities for defects to arise, and better durability in the field.

What could a DFMA redesign do for your products?

Saving half the cost of just one product saves some companies millions of dollars year after year. Those cost savings are worthwhile on their own. But imagine redesigning an inefficient product or assembly process and never having to worry about assembly bottlenecks, fragile parts, or time-consuming repairs again. With DFMA, your team could use this same clear, structured approach to build simpler, stronger, and more usable products that customers know they can rely on.

Do you want to save money on your parts design? Contact us!