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Staff member
Mar 22, 2024
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The earlier two components have centered on minimizing product manufacturing and guarantee prices via manufacturing course of choice, half design, and testing. In Half 1, we coated defining volumes, course of, and DFX. In Half 2 we coated enhancing reliability. With excessive quantity product manufacturing the amount of supplies, period of the venture and variety of individuals concerned have implications past that of low quantity and small prototype builds. Now, we should additionally contemplate reliability and stability of the product provide chain, minimizing adjustments as adapting to alter could also be tough, the protection and well being of these concerned, and the environmental influence. Listed below are a few of the key elements to contemplate.

Vendor Choice​

A dependable provide of high quality components is a key factor to the success of high volume product manufacturing. Listed below are some questions to contemplate when deciding on manufacturing distributors.


  • Part Price – is the seller aggressive with different distributors?
  • Tooling Price – how does the tooling price evaluate with options? What’s the anticipated lifetime of the tooling?
  • NRE Prices – will the seller do any engineering on the half or sub-assembly?
  • Guarantee Prices – will the seller cowl prices associated to faulty components?


  • What’s the improvement time from begin to first articles?
  • What’s the anticipated response time to design adjustments that have an effect on tooling or restore or alternative of tooling?
CMM inspection

CMM inspection



  • Competency – has the seller demonstrated the processes on related merchandise?
  • Capability – is the seller able to attaining manufacturing charges and adapting to charge adjustments?


  • Does manufacturing contain poisonous supplies? If that’s the case, can one deal with and eliminate supplies correctly?
  • Does manufacturing create pollution? What are the methods to handle pollution?
  • Are the waste supplies recyclable?
  • Is there a plan to recycle the manufactured items at finish of life?

Well being and Security

  • Are supplies transported and dealt with safely?
  • If hazardous supplies are concerned are workers utilizing PPE? Are workers skilled for hazardous spill administration? Is there a security crew?

High quality

  • If exams or measurements are concerned is the seller skilled and geared up? Have they got programs in place to trace handle the info?
  • ISO certification – is the seller licensed demonstrating capabilities in useful resource administration, measurement, evaluation and steady enchancment?

In-flexibility for change​

Excessive quantity manufacturing might be rigid to design adjustments. Adjustments to components and assemblies might have re-qualification. Tooling adjustments might be costly. Disposition of present manufacturing components and assemblies might be costly. A software launch guidelines will help reduce preliminary adjustments. Here’s a partial listing.

  • Design: drawings full, crucial to perform options recognized with dimensions and tolerances, processes evaluated for functionality in opposition to the tolerances, measurement programs documented certified and evaluated on prototype components
  • Price: BOM full, design price and manufacturing price hole is suitable, tooling price reviewed
  • Tooling: prototype components have accomplished purposeful analysis, variations between prototype and manufacturing components recognized and reviewed (supplies, gating, draft, and so forth.)
  • Instrument design, timeline, and life reviewed
  • Provider: qualification plan prepared, materials obtainable and at price goal, capability reviewed, course of functionality reviewed
Tooling for Carton Sealing

Tooling for carton sealing
Progressive die tooling

Progressive die tooling

Product materials life cycle​

Excessive quantity manufacturing can contain the big portions of supplies. Within the context of this dialogue have been are involved with the life cycle of these supplies and the way the administration of them impacts elements resembling environmental influence and sustainability. Listed below are some elements to contemplate:

plastic waste

Plastic waste
plastic pellets

Plastic pellets for injection molding
  • Uncooked materials: availability, provide stability, environmental influence of extraction
  • Manufacturing and distribution: power use (carbon foot print), proximity to make use of and transportation prices
  • Use and upkeep of the meeting or element
  • Finish of life: disposal or recyclability


Manufacturing quantity strongly influences many features of product design. Excessive quantity manufacturing strategies typically have excessive tooling prices and lengthy lead instances. Nonetheless, the ensuing decrease half price yields an financial benefit that pays for added and obligatory design effort. Additional financial good points are achievable by designing components and assemblies for manufacturing, meeting and repair. Doing so improves effectivity and reduces manufacturing time and meeting errors. Competitors and publicity to guarantee prices can drive reliability targets. There are a lot of design and check strategies that one can apply for reliability enchancment. Lastly, excessive quantity manufacturing can imply giant volumes of supplies used. Consider the life cycle of the supplies for manufacturing stability and environmental influence.


Bearing races
apple labeler machine production

Machine manufacturing


Concerning the Writer: Mike is a Techniques Engineer at SIGMADESIGN with a background in controls design and system integration. He’s a licensed “Black Belt” in “Design for Lean Six Sigma”. He enjoys the artistic part of the design course of and dealing cross-functionally with the groups to realize buyer targets.
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