DFMA Case Study: Computer Mouse Redesign

DFMA Case Study: Computer Mouse Redesign

It’s amazing what a business can accomplish with DFMA (design for manufacturing and assembly) software. Here is a case study showing how a client of Boothroyd Dewhurst, Inc. achieved incredible results with a simple product redesign.

The Process

A computer equipment manufacturer used DFMA software to redesign a computer mouse. The goal was to improve assembly efficiency, reduce the number of parts used, and ultimately save money on future production of the mouse.

The primary aspects and goals of the project included optimizing the tooling and fixture requirements and planning the assembly sequence early during the redesign process. Prioritizing these outcomes brought about remarkable results.

The Results

• This client was able to cut the number of unique mechanical parts almost in half.

  The original mouse required 31 unique parts to function. The redesigned version needed only 16. This means for every mouse the company produced, they needed 48% fewer parts.

• They also reduced the number of electrical parts in the new product version.

  The original mouse used 30 electrical parts. The redesigned mouse used 28 electrical parts. This is a more modest result than the overall parts reduction discussed above, but the complexity and expense of electrical parts meant the company achieved significant savings with fewer electrical components.

• Assembly time requirements improved significantly after the redesign.

  Assembly time fell an impressive 65%, from 17 minutes to just six minutes per unit. This was partially driven by the reduced number of parts, but an important goal of the redesign was to improve assembly efficiency by streamlining the sequence and the ease of putting each part together. These combined approaches helped the company drastically lower the total assembly time.

  A “stackable” assembly process also made manual assembly more efficient and created the potential to automate the process.

  Ultimately, the total number of assembly operations fell to 56, down from 83 for the original mouse.

• Adjustments were eliminated.

  The original product required ten to eleven adjustments, while the redesigned version required none at all.

• Screws were also eliminated.

  Ten screws were required for the original mouse design, whereas the new design needed no screws at all. This change is part of what made the assembly process easier and faster than that of the original. Additionally, since the company no longer needed to order screws, the cost of the computer mouse was reduced.

• Material cost savings were impressive.

  Due to the redesign, the company saved 40% on the material costs for each mouse produced.

• Service and repairs became much faster and more convenient.

  Since the redesigned mouse featured fewer parts and an easy, screwless assembly, repairs on the new product took less time and were far simpler to conduct. This also saved the company both time and money over the life of the product.

Interested in harnessing the power of DFMA software for your business? Contact Boothroyd Dewhurst online or call (401) 783-5840 to get started today.