Browse Learn 92047

Design for Manufacturing & Assembly (DFM/DFA) 92047

Discounted pricing is in effect during the COVID-19 pandemic. Registration fees of $1355 applies to the special live, online August 3, 2020 offering.

Design for Manufacturing and Assembly (DFM+A), pioneered by Boothroyd and Dewhurst, has been used by many companies around the world to develop creative product designs that use optimal manufacturing and assembly processes. Correctly applied, DFM+A analysis leads to significant reductions in production cost, without compromising product time-to-market goals, functionality, quality, serviceability, or other attributes. In this two-day seminar, you will not only learn the Boothroyd Dewhurst Method, you will actually apply it to your own product design!

This seminar will include information on how DFM+A fits in with QFD, concurrent engineering, robust engineering, and other disciplines. In addition, there will be a brief demonstration of computer software tools, which simplify the DFM+A analysis.

Each participant will receive and use the hard-bound authoritative reference textbook, Product Design for Manufacture and Assembly, written by Geoffrey Boothroyd, Peter Dewhurst and Winston Knight.

Learning Objectives
By attending this seminar, you will be able to:
  • Perform Design for Assembly (DFA) Analysis using the BDI Manual (Worksheet) Method
  • Perform DFM Analysis (manufacturing cost estimation)
  • Apply Design for Service (DFS) Principles
  • Reduce your company's production costs by analyzing and eliminating the factors that greatly affect the time, cost, and quality of manufacturing, assembly and service processes
  • Utilize effective analysis, brainstorming, and trade-off techniques for redesigning assemblies and subassemblies

    Who Should Attend

    Product designers, product engineers, or manufacturing engineers will benefit by attending this seminar. Individuals involved in a new or ongoing product development process will also benefit by learning how to help synchronize and optimize fabrication and assembly activities. This course is most effective when attended by product development team members; however, this is not a requirement for attendance.

    NOTE: You are strongly encouraged to bring a sample or drawing of one of your own designs to analyze during the workshop on Day Two. You are also asked to bring a calculator capable of making simple calculations.

    An engineering undergraduate degree in any discipline would be beneficial.
    • What is DFM+A
      • The history of DFM+A
      • The various "Design fors"
      • Why companies are using DFM+A
      • DFM+A success stories
      • DFM+A benefits
      • Key factors in ensuring DFM+A success
    • DFA Good Design Principles
      • The Boothroyd Dewhurst Design for Manual Assembly Method
      • Using the manual handling and insertion tables
      • Determining theoretical minimum part count
      • Filling in the BDI DFA worksheet
      • Computing the DFA Index
    • DFA Baseline Analysis Exercise (Pneumatic Piston)
    • Redesign Project (Pneumatic Piston Assembly)
      • Developing design concepts
      • Identifying conservative and "stretch" designs
      • Selecting the best DFA concept
      • Analysis of redesign
      • Presentation of team results
    • General Approach to Manufacturing Cost Estimation
      • Manufacturing cost drivers
      • Estimating piece cost
      • Cost calculation exercise
    • BDI Design for Manufacture (DFM) Cost Estimation
      • Injection molding cost algorithms
      • Sample calculation
      • Exercise (analyzing part from pneumatic piston)
    • BDI DFM Cost Estimation (continued)
      • Review of die casting and/or sheet metal stamping cost algorithms
    • Design for Service (DFS) Assessment
      • Two main approaches
      • Life cycle considerations
      • DFS exercise
    • BDI DFM/A Software Toolkit Demonstration
      • DFA module
      • Injection molding or other module
    • DFM+A Workshop Checklist
    • Brainstorming Guidelines
    • DFM+A Workshop Project (approximately 4 hours)
      • Project selection (from those brought to class)
      • Team identification
      • Baseline analysis
      • Redesign development
      • Development of project reports (illustrations, action plan, possible roadblocks, etc.)
      • Presentations of team results
    • Institutionalizing DFM+A in Your Organization
      • How DFM+A fits in with other strategies
      • Lessons learned from other companies
      • Ideal workplace implementation plan
    • Video Presentation on Goal Setting (time permitting)
    • Wrap Up
    • Course Evaluation

    Registration for the web seminar (live, online) is available on a per-person basis, similar to purchasing a seat in a classroom. The fee includes one connection to WebEx training center, using a PC with internet access and VoIP or a telephone,* and access to a secure course in the SAE Learning Center for presentations, supplemental materials, assignments, and learning assessment. To enjoy a more personalized experience, use of a webcam is encouraged.

    *Global toll-free telephone numbers are provided for many countries outside the U.S., but are limited to those on the WebEx call-in toll-free number list. Check here to see if your country has a global call-in toll free telephone number for this web seminar. If your country is not listed, you may still connect using the US/Canada Call-in toll number or VoIP. 

    Although WebEx will automatically launch when you join the web seminar, you are encouraged to test your setup in advance of the course start date. Click here, then follow the onscreen instructions.

    Kevin Zielinski

    Kevin Zielinski Kevin Zielinski currently owns and operates Red Cedar Media LLC, a training and corporate communications consulting, design, development and delivery company based in Michigan. Previously, Kevin was Senior Applications Specialist for EDS (including General Motors/EDS and Hewlett Packard/EDS) specializing in technical training delivery, training consulting, courseware design and development, and e-Learning. He has designed, developed and delivered over 40 lecture- and web-based courses attended by General Motors and EDS employees worldwide. Mr. Zielinski has also served as Adjunct Professor for the Wayne State University College of Engineering and WSU/Focus:Hope for many years. His areas of expertise include: e-Learning design and development, Quality Tools and Methods (Design of Six Sigma, Robust Engineering, Design of Experiments (DOE), Statistical Tolerancing and GD&T); Design for Manufacturing and Assembly (DFMA); Engineering Economics; and Plant Floor Throughput Improvement. He has been an instructor for SAE Professional Development since 1990, and is a recipient of SAE's Forest R. McFarland Award (April 2005). He holds a bachelor's and master's degree in engineering from Wayne State University.

    Fees: $1595.00
    SAE Members: $1436.00 - $1436.00

    1.3 CEUs
    You must complete all course contact hours and successfully pass the learning assessment to obtain CEUs.


    "I think the seminar is a great way to help engineers to consider manufacturing during initial design concepts."
    Cinthia Becks
    Sensor Development Engineer
    ITT Automotive

    "Very helpful in establishing guidelines for evaluating product improvement in a simple and effective manner."
    Ralph Colborn
    Product Engineer
    Ark-Les Corporation

    "This course delivers what it says and keeps you engaged with hands-on exercises. I strongly recommend this course to any engineer; this will definitely broaden their scope and insight at work. Thank you SAE."
    Praneeth Gandi
    Sr. R&D Design Engineer


    If paying by a credit card, click the Register button above. If paying by any other method or for general inquiries, please contact SAE Customer Service 1-877-606-7323 (724-776-4970 outside the U.S. and Canada) or at

    Duration: 13 Hours
    August 3-6, 2020 (4 Sessions) - Live Online
  • Session 1 - August 3 (11:30 a.m. - 3:30 p.m. ET)
  • Session 2 - August 4 (11:30 a.m. - 3:30 p.m. ET)
  • Session 3 - August 5 (11:30 a.m. - 3:30 p.m. ET)
  • Session 4 - August 6 (11:30 a.m. - 3:30 p.m. ET)
  • November 11-12, 2020 (8:30 a.m. - 4:30 p.m.) - Troy, Michigan
    A discounted fee of $1355 applies only to the special live, online August 3, 2020 date. An additional SAE Member discount will be applied for SAE Professional Members at the time of registration. Note: A Multiple Seat Discount is also available for groups of 5 or more wishing to participate online. Contact the Corporate Learning Sales Team at for more information or to register.

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