DFM/DFT and Manufacturing Process Design

Stage: Design and Verification

Definition

Activities before PDR include:

Perform preliminary DFM/DFT reviews (Technical reviews and BOMs / documentation)
Review available BOMs (lead-time, content, critical components)
Decide on Contract Manufacturing to grant project
Prepare test vehicle plan (for advanced technologies)

Activities before CDR include:

Develop detailed manufacturing plan (Gantt Chart)
·Prepare manufacturing process draft
Get commercial and legal contracts signed with CM and other sub-contractors
Perform detailed DFM/DFT reviews for bare PCB and Assembly
Decide on supplier strategy for Mechanical parts and PCBs for prototypes and production quantities (with purchasing)
Initiate design of fixtures, tools and equipment
Initiate packaging design and testing
Develop preliminary tooling plans (Set-ups, jigs and testers)
Implement test vehicle plan

Activities after CDR include:

Support pre-production build plans
Prepare MRP database
Schedule build quantities (table of quantities, customers for each build, synchronizes with the Gantt chart dates)
Finalize manufacturing process
Finalize tooling plans and start ordering tooling
Manage ECO’s receive change requests in, approve by PMT (or not), change revision (if needed), update production file, implement and test
Conduct MRR (Manufacturing Readiness Review)

Dependencies
This step is done during all the design and verification stage

Input
Preliminary Manufacturing Plan
Preliminary cost estimates
List of selected sub-contractors and vendors

Deliverables

For PDR:

Flow chart of Manufacturing processes
New technologies & trade-offs
Complexity and volume analysis
Project basics (updated)

For CDR:

Test Vehicle results and required action items
Progress report on DFX activities (completed and remaining)
Manufacturing costs, NREs and GM analysis
Material Flow
Updated Manufacturing Plan (Gantt chart)

For Alpha Readiness Review:

Product Manufacturing Process Plan
Production File (Structured BOM, routing files)
Manufacturing readiness review material is ready before pilot build

Responsibility
Manufacturing representative in project team (MPE)

Resources

Workload

Competencies
1 MPE (full time), 1 test engineer (at 50%)
Requires support from component engineer, configuration controller, quality engineer, manufacturing planner and commodity analyst

Lead-times
6-18 months depending on project complexity (Design and verification stage duration)

Metrics
New Product Introduction Readiness Metrics
Updated NRE forecast table
Updated GM and Cost analysis model
New Product Introduction project Gantt chart template (as a basis for project time table)
Project basics
Updated Project objectives (one page summary)

Guidelines
DFM/DFT guide for PCB assembly and testing (subcontractor’s guide)
New product introduction guide (NPI)
Test vehicles’ plans and reports from past projects as basis for the new Test Vehicle
Change Request template (to be developed)
Production file content summary table

Definition	Activities before PDR include: Perform preliminary DFM/DFT reviews (Technical reviews and BOMs / documentation) Review available BOMs (lead-time, content, critical components) Decide on Contract Manufacturing to grant project Prepare test vehicle plan (for advanced technologies) Activities before CDR include: Develop detailed manufacturing plan (Gantt Chart) ·Prepare manufacturing process draft Get commercial and legal contracts signed with CM and other sub-contractors Perform detailed DFM/DFT reviews for bare PCB and Assembly Decide on supplier strategy for Mechanical parts and PCBs for prototypes and production quantities (with purchasing) Initiate design of fixtures, tools and equipment Initiate packaging design and testing Develop preliminary tooling plans (Set-ups, jigs and testers) Implement test vehicle plan Activities after CDR include: Support pre-production build plans Prepare MRP database Schedule build quantities (table of quantities, customers for each build, synchronizes with the Gantt chart dates) Finalize manufacturing process Finalize tooling plans and start ordering tooling Manage ECO’s receive change requests in, approve by PMT (or not), change revision (if needed), update production file, implement and test Conduct MRR (Manufacturing Readiness Review)
Dependencies	This step is done during all the design and verification stage
Input	Preliminary Manufacturing Plan Preliminary cost estimates List of selected sub-contractors and vendors
Deliverables	For PDR: Flow chart of Manufacturing processes New technologies & trade-offs Complexity and volume analysis Project basics (updated) For CDR: Test Vehicle results and required action items Progress report on DFX activities (completed and remaining) Manufacturing costs, NREs and GM analysis Material Flow Updated Manufacturing Plan (Gantt chart) For Alpha Readiness Review: Product Manufacturing Process Plan Production File (Structured BOM, routing files) Manufacturing readiness review material is ready before pilot build
Responsibility	Manufacturing representative in project team (MPE)
Resources Workload Competencies	1 MPE (full time), 1 test engineer (at 50%) Requires support from component engineer, configuration controller, quality engineer, manufacturing planner and commodity analyst
Lead-times	6-18 months depending on project complexity (Design and verification stage duration)
Metrics	New Product Introduction Readiness Metrics Updated NRE forecast table Updated GM and Cost analysis model New Product Introduction project Gantt chart template (as a basis for project time table) Project basics Updated Project objectives (one page summary)
Guidelines	DFM/DFT guide for PCB assembly and testing (subcontractor’s guide) New product introduction guide (NPI) Test vehicles’ plans and reports from past projects as basis for the new Test Vehicle Change Request template (to be developed) Production file content summary table