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Zero-defect a Myth or a reality – Design For Manufacturability


Design for manufacturability is a must to achieve a zero-defect product where the principle in DFM must be followed. Some of the major DFM principles are:-

  1. Design with least part to reduce supplier chain and manufacturing process complexity
  2. Design product which is simple to make
  3. Consider the availability of raw materials which use design for manufacturability strategy.




The world is haunted by poor design product especially in some traditional industry where the product life cycle is more than 30 years such as industrial equipment and aerospace where those products are designed without design for manufacturability principle. Unfortunately, most of these companies esp. those big multinational companies choose not to acknowledge the poor design of their product. 

The main reason could be political where a large investment had to make and could cause the shareholder to be unhappy with huge investment make to redesign the product.  

To work towards zero defect, there must be rigour and quality awareness throughout the supply chain from the transformation of raw material to piece part, subassembly and final product.   This includes the followings:

  1. Product design for manufacturability
  2. Product design for simplicity
  3. A systematic approach to supplier quality management through 7 essential areas (http://www.7esupplierquality.com/)
  4. Control of process input according to what had been discussed in this website
  5. Accurate data analysis to understand what contributed to the defect
  6. Understand the variation throughout the supply chain

I am sure if all the 6 steps are following through, working towards a zero-defect should become a reality.


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