DFMA: SHOULD COSTING
DFMA: PRODUCT SIMPLIFICATION
GHSP’s DFMA Transformation
Enterprise journey to embed DFMA—governance, rollout tactics, and the impact on innovation, lead time, and quality.
BOOTHROYD DEWHURST, Inc.
DFMA Case Studies
Enterprise Deployment & Change Management
Endress+Hauser: Next Steps Toward Excellence
How a center-led model matures DFMA practice after initial wins—embedding methods across functions and products.
Concurrent Engineering & DFMA: Path to Innovation
Five cross-functional teams used DFMA to accelerate decisions and simplify designs—showing how concurrent engineering pairs naturally with DFMA practice.
Deploying Enterprise DFMA at Dell EMC
From pilot to program—how a global tech organization scaled DFMA across teams, with measurable effects on time and cost.
Should-Costing & Supplier Economics (DFM)
Using DFM to Understand PCB Assembly Costs
Breaking down PCB assembly cost drivers to improve supplier negotiations and design choices.
ROI for DFMA in the Low-Volume, High-Mix Shop
Real-world ROI patterns for DFMA in LV/HV environments and supplier negotiations—what to track and how to act.
Supplier Costing in a Low-Volume Med-Device Environment
Practical approaches to supplier costing when volumes are low and mix is high—tying DFMA to sourcing and negotiations.
ITT Valve: 76.6% Total Cost Reduction
Systematic DFMA analysis cut material and assembly costs while improving throughput and DFA Index.
Southco Medical Hinge: 53% Cost Reduction
DFMA enabled custom, high-mix product teams to cut parts and assembly effort while meeting cost targets.
Automotive & Off-Highway
Tractor Cooling Package: –58 parts • –18% assembly minutes
Concept-phase DFMA work on a new cooling package reduced parts from 352→294 and improved DFA Index—demonstrating measurable assembly-time and cost benefits early in design.
Re-Design of Vehicle Front Support Structure
At BAIC, a cost- and quality-risk bumper assembly was re-engineered with DFMA ahead of a model refresh, addressing fasteners, interfaces, and manufacturability.
John Deere: Harvesting Savings with DFMA
A new Tier 3 engine prompted cost-effective redesign choices guided by DFMA.
Automotive Seating: Continuous VA/VE with DFA
Baseline DFA analyses and on-site workshops helped a seating group iteratively remove assembly inefficiencies under tight timelines.
Truck Instrument Panel: Assembly & Environmental Savings
Replacing a complex steel assembly with two structural moldings cut assembly operations and part count, while simplifying end-of-life recycling.
Raymond: Forklift Hydraulic Cylinders
Significant part-count reductions while maintaining quality and reliability across the 7400 Reach-Fork® family.
Medical & Life Sciences
Zimmer Biomet: Navigating a Cost Reduction of Design
Lessons from a major medical OEM on structuring DFMA for cost reduction—cross-functional execution, change management, and measurable design simplification.
Blood-Gas Analyzer: DFMA for the Next Generation
Self-aligning features, material reviews, and fewer components—kicked off by a benchmark DFA—drove cost and quality improvements.
IDEXX: Simplifying a Veterinary Device
With early cost/assembly data, engineers avoided “BOM reuse by default” and made profit-driven decisions earlier.
MDS SCIEX: Design for Opportunity with DFA
DFMA enabled a hybrid mass spectrometer to hit a narrow market window with simpler assemblies and faster builds.
Electronics & Industrial Tech
Motorola DS9208 Scanner: DFA-Driven Cost Savings
Applying DFMA at concept helped the team meet cost targets and deliver on time and on budget.
Motorola Solutions: DFA Benchmarking Across a Portfolio
Handheld readers, mobile radios, kiosks, and more are benchmarked with DFA to cut parts and assembly time in redesign cycles.
Symbol Technologies: Putting It All Together Faster
DFMA helped reduce assembly costs and times across mobile/fixed data-capture devices.
Nortel: Dramatically Lower Product Costs
DFMA-led redesigns delivered ~$700,800 annual savings on an OC-3 shelf and ~$3.45M on a redesigned filler pack.
Consumer Appliances & Packaging
Whirlpool Sweden: 29% Fewer Parts, 26% Faster Assembly
Cross-functional teams trained in DFA delivered immediate returns via hands-on analyses.
Electrolux “Chameleon”: Cool, Stylish, and Green
Using DFE (with Boothroyd Dewhurst) to simulate end-of-life disassembly and environmental impact informed a greener cooling display design.
Access Business Group: Water Filters & Coffee Maker
DFMA improved designs for water filtration and a coffee maker—cutting parts and assembly time.
Aerospace & Defense
Product Affordability via Enterprise DFMA
Tying DFMA into lean, TCO, VAVE, and supply chain to meet affordability goals on major programs.
Helicopter Crew Station: Up to 74% Cost Reduction
DFA analysis of several areas in a helicopter crew station yielded large reductions in part count, install time, weight, and overall cost.
Strategy & Sourcing
There and Back Again—China
Hard-won insights on moving work to China and back—cost, risk, and capability lessons that inform DFMA trade-offs.
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